134th Airfield Slab Replacement_Specifications_04.04.24.pdf

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4/5/2024 FIELD MOLDED SEALANT FOR SEALING JOINTS 32 01 19-1

IN RIGID PAVEMENTS

SECTION 32 01 19

FIELD MOLDED SEALANTS FOR SEALING JOINTS

IN RIGID PAVEMENTS

PART 1 - GENERAL

1.01 SYSTEM DESCRIPTION

A. Joint Cleaning Equipment

1. Tractor-Mounted Routing Tool

Provide a routing tool, used for removing old sealant from the joints, of such shape and dimensions and so mounted on the tractor that it will not damage the sides of the joints. The tool shall be designed so that it can be adjusted to remove the old material to varying depths as required. The use of V-shaped tools or rotary impact routing devices will not be permitted. Hand-operated spindle routing devices may be used to clean and enlarge random cracks.

2. Concrete Saw

Provide a self-propelled power saw, with water-cooled diamond or abrasive saw blades, for cutting joints to the depths and widths specified or for refacing joints or cleaning sawed joints where sandblasting does not provide a clean joint.

3. Sandblasting Equipment

Include with the sandblasting equipment an air compressor, hose, and long-wearing venturi-type nozzle of proper size, shape and opening. The maximum nozzle opening should not exceed ¼ inch. The air compressor shall be portable and capable of furnishing not less than 150 cfm and maintaining a line pressure of not less than 90 psi at the nozzle while in use. Demonstrate compressor capability, under job conditions, before approval. The compressor shall be equipped with traps that will maintain the compressed air free of oil and water. The nozzle shall have an adjustable guide that will hold the nozzle aligned with the joint approximately 1 inch above the pavement surface. Adjust the height, angle of inclination and the size of the nozzle as necessary to secure satisfactory results.

4. Waterblasting Equipment

Include with the waterblasting equipment a trailer-mounted water tank, pumps, high-pressured hose, wand with safety release cutoff control, nozzle, and auxiliary water resupply equipment of sufficient capacity to permit continuous operations.

The nozzle shall have an adjustable guide that will hold the nozzle aligned with the joint approximately 1 inch above the pavement surface. Adjust the height, angle of inclination and the size of the nozzle as necessary to obtain satisfactory results.

A pressure gauge mounted at the pump shall show at all times the pressure in psi at which the equipment is operating.

5. Hand Tools

Hand tools may be used, when approved, for removing defective sealant from a crack and repairing or cleaning the crack faces.

4/5/2024 FIELD MOLDED SEALANT FOR SEALING JOINTS 32 01 19-2

IN RIGID PAVEMENTS

B. Sealing Equipment

1. Two-Component, Cold-Applied, Hand-Mix Sealing Equipment

2. Mixing equipment for FS SS-S-200 Type H sealants shall consist of a slow-speed electric drill or air-driven mixer with a stirrer in accordance with the manufacturer’s recommendations.

1.02 SUBMITTALS

A. Product Data

1. Printed copies of manufacturer’s recommendations, 30 days prior to use on the project, where installation procedures, or any part thereof, are required to be in accordance with those recommendations. Installation of the material will not be allowed until the recommendations are received. Failure to furnish these recommendations can be cause for rejection of the material.

2. Equipment – List of proposed equipment to be used in performance of construction work including descriptive data, 30 days prior to use on the project.

B. Samples

1. Samples of the materials (sealant, primer if required, and backup material), in sufficient quantity for testing and approval 30 days prior to the beginning of work.

No material will be allowed to be used until it has been approved.

1.03 QUALITY ASSURANCE

A. Test Requirements

1. Test the joint sealant and backup or separating material for conformance with the referenced applicable material specification. Perform testing of the materials in an approved independent laboratory and submit certified copies of the test reports for approval 30 days prior to the use of the materials at the job site. Samples will be retained by the Government for possible future testing should the materials appear defective during or after application. Conformance with the requirements of the laboratory tests specified will not constitute final acceptance of the materials. Final acceptance will be based on the performance of the in-place materials.

B. Trial Joint Sealant Installation

1. Prior to the cleaning and sealing of the joints for the entire project, prepare a test section at least 200 feet long using the specified materials and approved equipment, so as to demonstrate the proposed joint preparation and sealing of all types of joints in the project. Following the completion of the test section and before any other joint is sealed, inspect the test section to determine that the materials and installation meet the requirements specified. If it is determined that the materials or installation do not meet the requirements, remove the materials, and reclean and reseal the joints at no cost to the Government. When the test section meets the requirements, it may be incorporated into the permanent work.

Prepare and seal all other joints in the manner approved for sealing the test section.

4/5/2024 FIELD MOLDED SEALANT FOR SEALING JOINTS 32 01 19-3

1.04 DELIVERY, STORAGE, AND HANDLING

Inspect materials delivered to the job site for defects, unload, and store them with a minimum of handling to avoid damage. Provide storage facilities at the job site for maintaining materials at the temperatures and conditions recommended by the manufacturer.

1.05 ENVIRONMENTAL REQUIREMENTS

The ambient air temperature and the pavement temperature within the joint wall shall be a minimum of 50 degrees F and rising at the time of application of the materials. Do not apply sealant if moisture is observed in the joint.

1.06 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM C 509 (2006) Elastomeric Cellular Preformed Gasket and Sealing Material

ASTM D 789 (2007) Determination of Relative Viscosity and Moisture Content of

Polyamide (PA)

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS SS-S-200 (Rev E; Am 2) Sealant, Joint, Two-Component, Jet-Blast-Resistant, Cold-Applied, for Portland Cement Concrete Pavement

PART 2 - PRODUCTS

2.01 SEALANTS

A. Materials for sealing cracks in the various paved areas indicated on the drawings shall meet all the requirements of FS SS-S-200 Type H.

2.02 PRIMERS

A. When primers are recommended by the manufacturer of the sealant, use them in accordance with the recommendation of the manufacturer.

2.03 BACKUP MATERIALS

A. Provide backup material that is a compressible, nonshrinking, nonstaining, nonabsorbing material, nonreactive with the joint sealant. The material shall have a melting point at least 5 degrees F greater than the pouring temperature of the sealant being used when tested in accordance with ASTM D 789. The material shall have water absorption of not more than 5 percent of the sample weight when tested in accordance with ASTM C 509. The backup material shall be 25 plus or minus 5 percent larger in diameter than the nominal width of the crack.

4/5/2024 FIELD MOLDED SEALANT FOR SEALING JOINTS 32 01 19-4

2.04 BOND BREAKING TAPES

A. Provide a bond breaking tape or separating material that is a flexible, nonshrinkable, nonabsorbing, nonstaining, and nonreacting adhesive-backed tape. The material shall have a melting point at least 5 degrees F greater than the pouring temperature of the sealant being used when tested in accordance with ASTM D 789. The bond breaker tape shall be approximately 1/8 inch wider than the nominal width of the joint and shall not bond to the joint sealant.

PART 3 - EXECUTION

3.01 PREPARATION OF JOINTS

A. Immediately before the installation of the sealant, thoroughly clean the joints to remove all laitance, curing compound, filler, protrusions of hardened concrete, and old sealant from the sides and upper edges of the joint space to be sealed.

B. Sawing

1. Facing of Joints

Accomplish facing of joints using a concrete saw as specified in paragraph EQUIPMENT until the joint is clean and open to the full specified width and depth.

Stiffen the blade with a sufficient number of suitable dummy (used) blades or washers. Thoroughly clean, immediately following the sawing operation, the joint opening using a water jet to remove all saw cuttings and debris.

C. Sandblasting

1. The newly exposed concrete joint faces and the pavement surfaces extending a minimum of ½ inch from the joint edges shall be sandblasted clean. Use a multiple-pass technique until the surfaces are free of dust, dirt, curing compound, filler, old sealant residue, or any foreign debris that might prevent the bonding of the sealant to the concrete. After final cleaning and immediately prior to sealing, blow out the joints with compressed air and leave them completely free of debris and water.

D. Back-Up Material

1. When the joint opening is of a greater depth than indicated for the sealant depth, plug or seal off the lower portion of the joint opening using a back-up material to prevent the entrance of the sealant below the specified depth. Take care to ensure that the backup material is placed at the specified depth and is not stretched or twisted during installation.

E. Bond Breaking Tape

1. Where inserts or filler materials contain bitumen, or the depth of the joint opening does not allow for the use of a backup material, insert a bond breaker separating tape to prevent incompatibility with the filler materials and three-sided adhesion of the sealant. Securely bond the tape to the bottom of the joint opening so it will not float up into the new sealant.

4/5/2024 FIELD MOLDED SEALANT FOR SEALING JOINTS 32 01 19-5

F. Rate of Progress of Joint Preparation

1. Limit the stages of joint preparation, which include sandblasting, air pressure cleaning and placing of the back-up material to only that lineal footage that can be sealed during the same day.

3.02 PREPARATION OF SEALANT

A. Type H Sealants

1. Mix the FS SS-S-200 Type H sealant components either in the container furnished by the manufacturer or a cylindrical metal container of volume approximately 50 percent greater than the package volume. Thoroughly mix the base material in accordance with the manufacturer’s instructions. The cure component shall then be slowly added during continued mixing until a uniform consistency is obtained.

3.03 INSTALLATION OF SEALANT

A. Time of Application

1. Seal joints immediately following final cleaning of the joint walls and following the placement of the separating or backup material. Open joints, that cannot be sealed under the conditions specified, or when rain interrupts sealing operations shall be recleaned and allowed to dry prior to installing the sealant.

B. Sealing Joints

1. Immediately preceding, but not more than 50 feet ahead of the joint sealing operations, perform a final cleaning with compressed air. Fill the joints from the bottom up to 1/8 inch plus or minus 1/16 inch below the pavement surface.

Remove and discard excess or spilled sealant from the pavement by approved methods. Install the sealant in such a manner as to prevent the formation of voids and entrapped air. In no case shall gravity methods or pouring pots be used to install the sealant material. Traffic shall not be permitted over newly sealed pavement until authorized by the Contracting Officer. When a primer is recommended by the manufacturer, apply it evenly to the joint faces in accordance with the manufacturer’s instructions. Check the joints frequently to ensure that the newly installed sealant is cured to a tack-free condition within the time specified.

C. Joint Sealant

1. Inspect the joint sealant for proper rate of cure and set, bonding to the joint walls, cohesive separation within the sealant, reversion to liquid, entrapped air and voids.

Sealants exhibiting any of these deficiencies at any time prior to the final acceptance of the project shall be removed from the joint, wasted, and replaced as specified herein at no additional cost to the Government.

D. Clean-Up

1. Upon completion of the project, remove all unused materials from the site and leave the pavement in a clean condition.

END OF SECTION

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-1

SECTION 32 11 23

GRADED – CRUSHED AGGREGATE BASE COURSE

PART 1 – GENERAL

1.01 DEFINITIONS

A. Graded-Crushed Aggregate Base Course – Graded-crushed aggregate (GCA) base course is well graded, crushed, durable aggregate uniformly moistened and mechanically stabilized by compaction.

B. Degree of Compaction – Degree of compaction required, except as noted in the second sentence, is expressed as a percentage of the maximum laboratory dry density obtained by the test procedure presented in ASTM D 698 (Standard Proctor) abbreviated as a percent of laboratory maximum dry density.

A. Test Reports

1. Submit Certified copies of test results for approval not less than 30 days before material is required for the work.

1.03 SYSTEM DESCRIPTION

A. All plant, equipment, and tools used in the performance of the work will be subject to approval before the work is started and shall be maintained in satisfactory working condition at all times. Provide adequate equipment having the capability of producing the required compaction, meeting grade controls, thickness control, and smoothness requirements as set forth herein.

1.04 ENVIRONMENTAL REQUIREMENTS

A. Perform construction when the atmospheric temperature is above 35 degrees F. When the temperature falls below 35 degrees F, protect all completed areas by approved methods against detrimental effects of freezing. Correct completed areas damaged by freezing, rainfall, or other weather conditions to meet specified requirements.

1.05 REFERENCES

A. The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by basic designation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

1 AASHTO T 180 (2001; R 2004) Moisture-Density Relations of Soils

Using a 4.54-kg (10-lb) Rammer and an 457-mm (18-in) Drop

2 AASHTO T 224 (2001; R 2004) Correction for Coarse Particles in the Soil Compaction Test

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-2

3 ASTM C 117 (2004) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

4 ASTM C 127 (2007) Standard Test Method for Density, Relative

Density (Specific Gravity), and Absorption of Coarse Aggregate

5 ASTM C 128 (2007a) Standard Test Method for Density, Relative

Density (Specific Gravity), and Absorption of Fine

6 ASTM C 131 (2006) Standard Test Method for Resistance to

Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

7 ASTM C 136 (2006) Standard Test Method for Sieve Analysis of

Fine and Coarse Aggregates

8 ASTM C 29/C 29M (2007) Standard Test Method for Bulk Density (“Unit

Weight”) and Voids in Aggregate

9 ASTM C 88 (2005) Standard Test Method for Soundness of

Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

10 ASTM D 1556 (2007) Density and Unit Weight of Soil in Place by the Sand-Cone Method

11 ASTM D 1557 (2007) Standard Test Methods for Laboratory

Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3) (2700kN-m/m3)

12 ASTM D 2487 (2006) Soils for Engineering Purposes (Unified Soil

Classification System)

13 ASTM D 4318 (2005) Liquid Limit, Plastic Limit, and Plasticity

Index of Soils

14 ASTM D 75 (2003) Standard Practice for Sampling Aggregates

15 ASTM E 11 (2004) Wire Cloth and Sieves for Testing Purposes

PART 2 – PRODUCTS

2.01 AGGREGATES

A. Provide GCA consisting of clean, sound, durable particles of crushed stone, crushed gravel, angular sand, or other approved material. GCA shall be free of silt and clay as defined by ASTM D 2487, organic matter, and other objectionable materials or coatings.

The portion retained on the No. 4 sieve is known as coarse aggregate; that portion passing the No. 4 sieve is known as fine aggregate.

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-3

B. Coarse Aggregate

1. Provide coarse aggregates with angular particles of uniform density. When the coarse aggregate is supplied from more than one source, aggregate from each source shall meet the specified requirements and shall be stockpiled separately.

a. Crushed Gravel: Crushed gravel shall be manufactured by crushing gravels, and shall meet all the requirements specified below.

b. Crushed Stone: Provide crushed stone consisting of freshly mined quarry rock, meeting all the requirements specified below.

C. Graded-Crushed Aggregate Base Course

1. GCA coarse aggregate shall not show more than 40 percent loss when subjected to the Los Angeles abrasion test in accordance with ASTM C 131. GCA coarse aggregate shall not exhibit a loss greater than 18 percent weighted average, at five cycles, when tested for soundness in magnesium sulfate, or 12 percent weighted average, at five cycles, when tested in sodium sulfate in accordance with ASTM C

88. The amount of flat and elongated particles shall not exceed 20 percent for the fraction retained on the ½ inch sieve nor 20 percent for the fraction passing the ½ inch sieve. A flat particle is one having a ratio of width to thickness greater than 3;

an elongated particle is one having a ratio of length to width greater than 3. In the portion retained on each sieve specified, the crushed aggregate shall contain at least 90 percent by weight of crushed pieces having two or more freshly fractured faces with the area of each face being at least equal to 75 percent of the smallest midsectional area of the piece. When two fractures are contiguous, the angle between planes of the fractures must be at least 30 degrees in order to count as two fractured faces. Crushed gravel shall be manufactured from gravel particles 90 percent of which by weight are retained on the maximum size sieve listed in

TABLE 1.

D. Fine Aggregate

1. Fine aggregates shall be angular particles of uniform density. When the fine aggregate is supplied from more than one source, aggregate from each source shall meet the specified requirements.

2. Graded-Crushed Aggregate Base Course

a. Provide GCA fine aggregate consisting of angular particles produced by crushing stone, or gravel that meets the requirements for wear and soundness specified for GCA coarse aggregate. Fine aggregate shall be manufactured from gravel particles 95 percent of which by weight are retained on the ½ inch sieve.

E. Gradation Requirements

1. Apply the specified gradation requirements to the completed base course. The aggregates shall be continuously well graded within the limits specified in TABLE

1. Sieves shall conform to ASTM E 11.

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-4

Table 1. GRADATION OF AGGREGATES

Percentage by Weight Passing Square-Mesh Sieve

Sieve Designation

No. 2

2 inch ----- 1-1 ½ inch 100

1 inch 60-100 ½ inch 30-65

No. 4 20-50 No. 10 15-40 No. 40 5-25

No. 200 0-8

Note 1: Particles having diameters less than that needed to be retained on the No. 635 shall not be in excess of 3 percent by weight of the total sample tested.

Note 2: The values are based on aggregates of uniform specific gravity. If materials from different sources are used for the coarse and fine aggregates, they shall be tested in accordance with ASTM C 127 and ASTM C 128 to determine their specific gravities. If the specific gravities vary by more than 10 percent, the percentages passing the various sieves shall be corrected as directed by the Contracting Officer.

2.02 LIQUID LIMIT AND PLASTICITY INDEX

A. Apply liquid limit and plasticity index requirements to the completed course and to any component that is blended to meet the required gradation. The portion of any component or of the completed course passing the No. 40 sieve shall be either nonplastic or have a liquid limit not greater than 25 and a plasticity index not greater than 5.

PART 3 – EXECUTION

3.01 GENERAL REQUIREMENTS

A. When the GCA is constructed in more than one layer, clean the previously constructed layer of loose and foreign matter by sweeping with power sweepers or power brooms, except that hand brooms may be used in areas where power cleaning is not practicable.

Provide adequate drainage during the entire period of construction to prevent water from collecting or standing on the working area. Provide line and grade stakes as necessary for control.

3.02 PREPARATION OF UNDERLYING COURSE

A. Prior to constructing the base course(s), the underlying subgrade shall be cleaned of all foreign substances. At the time of construction of the base course(s), the underlying course shall contain no frozen material. The surface of the underlying subgrade shall meet specified compaction and surface tolerances. The underlying course shall conform to Section 31 00 00 EARTHWORK. Ruts or soft yielding spots in the underlying courses, areas having inadequate compaction, and deviations of the surface from the requirements set forth herein shall be corrected by loosening and removing soft or unsatisfactory material and by adding approved material, reshaping to line and grade, and recompacting to specified density requirements. The finished underlying course shall not be disturbed by traffic or other operations and shall be maintained in a satisfactory condition until the base course is placed.

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-5

3.03 INSTALLATION

A. Mixing the Material

1. Mix the coarse and fine aggregate in a stationary plant, or in a traveling plant or bucket loader on an approved paved working area. Make adjustments in mixing procedures or in equipment, as directed, to obtain true grades, to minimize segregation or degradation, to obtain the required water content, and to insure a satisfactory base course meeting all requirements of this specification.

Adjustments to the Job Mix Formula shall be limited to plus or minus 5 percent on the 1-1/2 inch and coarser sieves; plus or minus 8 percent on the 1 inch to No. 4 sieves; plus or minus 5 percent on the No. 30 sieve, and plus or minus 3 percent on the No. 200 sieve. Tolerances given above may permit the aggregate grading to be outside the limits shown in Table 1; this is acceptable.

B. Placing

1. Place the mixed material on the prepared subgrade in layers of uniform thickness with an approved spreader. When a compacted layer 6 inches or less in thickness is required, place the material in a single layer. When a compacted layer in excess of 6 inches is required, place the material in layers of equal thickness. No layer shall be thicker than 6 inches or thinner than 3 inches when compacted. The layers shall be so placed that when compacted they will be true to the grades or levels required with the least possible surface disturbance. Where the base course is placed in more than one layer, the previously constructed layers shall be cleaned of loose and foreign matter by sweeping with power sweepers, power brooms or hand brooms, as directed. Such adjustments in placing procedures or equipment shall be made as may be directed to obtain true grades, to minimize segregation and degradation, to adjust the water content, and to insure an acceptable base course.

C. Grade Control

1. The finished and completed base course shall conform to the lines, grades, and cross sections shown. Underlying material(s) shall be excavated and prepared at sufficient depth for the required base course thickness so that the finished base course and the subsequent surface course will meet the designated grades.

D. Edges of Base Course

1. For slab replacements at the edge of the concrete base course(s) shall be placed so that the completed section will be a minimum of 2 feet wider, on all sides, than the next layer that will be placed above it. Additionally, place approved fill material along the outer edges of the base course in sufficient quantities to compact to the thickness of the course being constructed, or to the thickness of each layer in a multiple layer course, allowing in each operation at least a 2 foot width of this material to be rolled and compacted simultaneously with rolling and compacting of each layer of base course. If this base course material is to be placed adjacent to another pavement section, then the layers for both of these sections shall be placed and compacted along this edge at the same time.

E. Compaction

1. Compact each layer of the base course, as specified, with approved compaction equipment. Maintain water content during the compaction procedure to within plus

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-6

or minus 2 percent of the optimum water content determined from laboratory tests as specified in paragraph SAMPLING AND TESTING. Begin rolling at the outside edge of the surface and proceed to the center, overlapping on successive trips at least one-half the width of the roller. Alternate trips of the roller shall be slightly different lengths. Speed of the roller shall be such that displacement of the aggregate does not occur. In all places not accessible to the rollers, the mixture shall be compacted with hand-operated power tampers. Continue compaction until each layer has a degree of compaction that is at least 95 percent of laboratory maximum density through the full depth of the layer. Make such adjustments in compacting or finishing procedures as may be directed to obtain true grades, to minimize segregation and degradation, to reduce or increase water content, and to ensure a satisfactory base course. Any materials that are found to be unsatisfactory shall be removed and replaced with satisfactory material or reworked, as directed, to meet the requirements of this specification.

F. Thickness

1. Construct the compacted thickness of the base course as indicated. No individual layer shall be thicker than 6 inches nor be thinner than 3 inches in compacted thickness. The total compacted thickness of the base course(s) shall be within ¼ inch of the thickness indicated. Where the measured thickness is more than ¼ inch deficient, correct such areas by scarifying, adding new material of proper gradation, reblading, and recompacting as directed. Where the measured thickness is more than ¼ inch thicker than indicated, the course shall be considered as conforming to the specified thickness requirements. Average job thickness shall be the average of all thickness measurements taken for the job, but shall be within ¼ inch of the thickness indicated on the plans. The total thickness of the base course shall be measured at intervals in such a manner as to ensure one measurement for each 500 square yards of base course. Measurements shall be made in 3 inch diameter test holes penetrating the base course.

G. Finishing

1. The surface of the top layer of base course shall be finished after final compaction by cutting any overbuild to grade and rolling with a steel-wheeled roller. Thin layers of material shall not be added to the top layer of base course to meet grade. If the elevation of the top layer of base course is ½ inch or more below grade, then the top layer should be scarified to a depth of at least 3 inches and new material shall be blended in and compacted to bring to grade. Adjustments to rolling and finishing procedures shall be made as directed to minimize segregation and degradation, obtain grades, maintain moisture content, and insure an acceptable base course.

Should the surface become rough, corrugated, uneven in texture, or traffic marked prior to completion, the unsatisfactory portion shall be scarified, reworked and recompacted or it shall be replaced as directed.

H. Smoothness

1. The surface of the top layer shall show no deviations in excess of 3/8 inch when tested with a 12 foot straightedge. Take measurements in successive positions parallel to the centerline of the area to be paved. Measurements shall also be taken perpendicular to the centerline at 50 foot intervals. Deviations exceeding this amount shall be corrected by removing material and replacing with new material, or by reworking existing material and compacting it to meet these specifications.

4/5/2024 GRADED-CRUSHED AGGREGATE BASE COURSE 321123-7

3.04 TRAFFIC

A. Do not allow traffic on the completed base course.

3.05 MAINTENANCE

A. Maintain the base course in a satisfactory condition until the full pavement section is completed and accepted. Maintenance shall include immediate repairs to any defects and shall be repeated as often as necessary to keep the area intact. Any base course that is not paved over prior to the onset of winter, shall be retested to verify that it still complies with the requirements of this specification. Any area of base course that is damaged shall be reworked or replaced as necessary to comply with this specification.

3.06 DISPOSAL OF UNSATISFACTORY MATERIALS

A. Any unsuitable materials that must be removed shall be disposed of as directed. No additional payments will be made for materials that must be replaced.

4/5/2024 PORTLAND CEMENT-STABILIZED BASE COURSE 32 11 34-1

SECTION 32 11 34

PORTLAND CEMENT – STABILIZED BASE COURSE

1.01 DEFINITION

A. Portland cement – stabilized base course, as used herein, is a mixture of Portland cement and in-place, or select borrow, material uniformly blended and thoroughly compacted to produce a pavement course which meets the criteria set forth in the drawings and specifications.

1. Mix Design: Submit proposed mix design, prior to start of stabilization work.

2. Aggregate: Submit notification of sources from which aggregates are to be obtained, within 15 days after the award of contract.

B. Test Reports

1. Submit certified copies of aggregate test results, not less than 15 days before the material is required in the work.

1.03 SYSTEM DESCRIPTION

A. Plant, equipment, machines, and tools used in the work shall be subject to approval and shall be maintained in a satisfactory working condition at all times. Provide equipment with the capability of producing the required compaction, meeting grade controls, thickness control and smoothness requirements specified. Place a test section of at least 8 by 100 feet, utilizing the equipment and procedures proposed for use by the Contractor, to demonstrate that aggregate-cement stabilization conforming to this specification can be produced.

B. Straightedge:

1. Furnish and maintain at the site, in good condition, one 12 foot straightedge for each paver, for use in the testing of the finished surface. Make straightedges available for Government use. Construct straightedges of aluminum or other light weight metal with blades of box or box-girder cross section with flat bottom reinforced to insure rigidity and accuracy. Straightedges shall have handles to facilitate movement on pavement.

1.04 ENVIRONMENTAL REQUIREMENTS

A. Do not apply cement when the atmospheric temperature is less than 40 degrees F or to soils that are frozen or contain frost, or when the underlying material is frozen. If the temperature falls below 35 degrees F, protect completed cement-treated areas against detrimental effects of freezing. Any areas of completed base that are damaged by freezing, rainfall, or other weather conditions shall be brought to a satisfactory condition in conformance with this specification without additional cost to the Government.

4/5/2024 PORTLAND CEMENT-STABILIZED BASE COURSE 32 11 34-2

1.05 REFERENCES

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)

1 AASHTO M 147 (1965; R 2004) Materials for Aggregate and Soil- Aggregate Subbase, Base and Surface Courses

2 AASHTO M 182 (2005) Standard Specification for Burlap Cloth Made fro Jute or Kenaf and Cotton Mats

3 AASHTO T 134 (2005) Moisture-Density Relations of Soil-Cement

Mixtures

ASTM INTERNATIONAL (ASTM)

4 ASTM C 136 (2006) Standard Test Method for Sieve Analysis of

Fine and Coarse Aggregates

5 ASTM C 150 (2007) Standard Specification for Portland Cement

6 ASTM C 171 (2007) Standard Specification for Sheet Materials for

Curing Concrete

7 ASTM C 595 (2008) Standard Specification for Blended Hydraulic

Cements

8 ASTM D 1241 (2007) Materials for Soil-Aggregate Subbase, Base, and Surface Courses

9 ASTM D 1250 (2007) Standard Guide for Use of the Petroleum

Measurement Tables

10 ASTM D 1556 (2007) Density and Unit Weight of Soil in Place by the

Sand-Cone Method

11 ASTM D 1557 (2007) Standard Test Methods for Laboratory

Compaction Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3) (2700 kN-m/m3)

12 ASTM D 1632 (2007) Making and Curing Soil-Cement Compression and Flexure Test Specimens in the Laboratory

13 ASTM D 1633 (2000; R 2007) Compressive Strength of Molded

Soil-Cement Cylinders

14 ASTM D 422 (1963; R 2007) Particle-Size Analysis of Soils

15 ASTM D 4318 (2005) Liquid Limit, Plastic Limit, and Plasticity Index of Soils

16 ASTM D 558 (2004) Moisture-Density (Unit Weight) Relations of

Soil-Cement Mixtures

4/5/2024 PORTLAND CEMENT-STABILIZED BASE COURSE 32 11 34-3

17 ASTM D 6938 (2007a) Standard Test Method for In-Place Density and Water Content of Soil and Soil-Aggregate by Nuclear Methods (Shallow Depth)

18 ASTM D 75 (2003) Standard Practice for Sampling Aggregates

19 ASTM E11 (2004) Wire Cloth and Sieves for Testing Purposes

2.01 MATERIALS

A. Cement

1. Provide cement conforming to ASTM C 150, Type I, IA, II, or IIA or ASTM C 595, Type IS or IS(A).

B. Material to be Stabilized

1. Stabilize material using select material conforming to AASHTO M 147, Grading C.

Remove stones retained on a 2 inch sieve and deleterious substances such as sticks, debris, and organic matter.

C. Water

1. Provide water which is clean, fresh, and free from injurious amounts of oil, acid, salt, alkali, organic matter, and other substances deleterious to the hardening of soil-cement, and subject to approval.

D. Burlap

1. Burlap shall conform to AASHTO M 182.

E. Impervious Sheeting

1. Sheeting shall conform to ASTM C 171 and shall be white waterproof paper, white opaque polyethylene film or white burlap-polyethylene sheets.

2.02 MIX DESIGN

A. Develop the mix using the aggregate to be stabilized. Mix shall have a minimum compressive strength of 750 psi, a weight loss of 14 percent or less after 12 cycles of the durability test, and “low alkali” cement for alkali reactive aggregate.

2.03 SAMPLING AND TESTING

A. Testing Facilities

1. Perform sampling and testing using an approved commercial testing laboratory or by facilities furnished by the Contractor. Work requiring testing will not be permitted until the facilities have been inspected and approved. The first inspection will be at the expense of the Government. Cost incurred for any subsequent inspection, required because of failure of the facilities to pass the first inspection, will be charged to the Contractor. Perform tests in sufficient numbers, 4/5/2024 PORTLAND CEMENT-STABILIZED BASE COURSE 32 11 34-4 and as specified, to ensure that materials and compaction meet specified requirements. Furnish copies of the test results to the Contracting Officer within 24 hours of completion of tests.

B. Test Results

1. Results shall verify that materials comply with the specification. When a material source is changed, test the new material for compliance. When deficiencies are found, the initial analysis shall be repeated and the material already placed shall be retested to determine the extent of unacceptable material. All in-place unacceptable material shall be replaced or repaired to conform to the contract requirements at no additional cost to the Government.

C. Aggregate

1. Tests for determining the suitability of aggregate shall include, but not be limited to: sieve analysis in accordance with ASTM C 136, and ASTM D 422 using sieves conforming to ASTM E 11, liquid limits and plasticity index in accordance with ASTM D 4318. Take aggregate samples for laboratory tests in accordance with ASTM D 75. Prepare specimens to be used for unconfined compression tests in accordance with ASTM D 1632 except that a 4 inch diameter by 8 inch high mold shall be used to prepare specimens when more than 35 percent of the material is retained on the No. 4 sieve.

D. Initial Sampling and Testing

1. Laboratory Density

Conduct moisture-density tests in accordance with the procedure contained in

AASHTO T 134 or ASTM D 558; however the apparatus and procedures outlined in ASTM D 1557 shall be used to compact the soil-cement mixture.

2. Unconfined Compression Testing

Conduct three unconfined compression tests, in accordance with ASTM D 1633, for each mix design tested. Cure samples at a constant moisture content and temperature for 7 days.

E. Sieve Analysis

1. A minimum of one analysis shall be performed for each 1000 tons of material to be stabilized, with a minimum of 3 analyses for each day’s run until the course is completed. When the source of materials is changed and deficiencies are found, the analysis shall be repeated and the material already placed shall be retested to determine the extent of unacceptable material. All in-place unacceptable material shall be replaced at no additional cost to the Government.

F. Liquid Limit and Plasticity Index

1. One liquid limit and plasticity index shall be performed for each sieve analysis.

Liquid limit and plasticity index shall be in accordance with ASTM D 4318.

G. Sampling and Testing During Construction

1. Perform quality control sampling and testing during construction as required in paragraph FIELD QUALITY CONTROL.

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3.01 GENERAL REQUIREMENTS

A. Do not apply cement if the soil moisture content exceeds optimum moisture content specified for the cement-treated mixture. After mixing is completed, the proportions of the mixture shall be in accordance with the approved mix design. When application of water and mixing are completed, on the basis of dry weight, moisture shall not be below the optimum moisture content of the mixture nor shall it be more than 2 percent above the optimum moisture content. When the stabilized course is constructed in more than 1 layer, clean the previously constructed layer of loose and foreign matter by sweeping with power sweepers or power brooms, except that hand brooms may be used in areas where power cleaning is not practicable. Provide adequate drainage during the entire construction period to prevent water from collecting or standing on the areas to be stabilized or on pulverized, mixed, or partially mixed material. Provide line and grade stakes as necessary for control. Place grade stakes in lines parallel to the centerline of the area under construction and suitably spaced for string lining.

3.02 STOCKPILING MATERIALS

A. Stockpile select material, in the manner and at the locations designated. Before stockpiling of material, the storage sites shall be cleared, drained, and leveled. Materials obtained from different sources shall be stockpiled separately.

3.03 PREPARATION OF AREA TO BE STABILIZED

A. Area to be stabilized shall be cleaned of debris; inspected for adequate compaction; and shall be capable of withstanding, without displacement, the compaction specified for the soil-cement mixture. Debris and removed unsatisfactory in-place material shall be disposed of as specified.

B. Select Material

1. Sufficient select material shall be utilized to provide the required thickness of the soil-cement layer after compaction and shall be processed to meet the requirements specified before cement stabilization is undertaken.

3.04 INSTALLATION

A. Edges of Stabilized Course

1. Place approved material along the edges of the stabilized course in such quantity as will compact to the thickness of the course being constructed, or to the thickness of each layer in a multiple-layer course, allowing at least a 1 foot width of the shoulder to be rolled and compacted simultaneously with the rolling and compacting of each layer of the stabilized course.

B. Central-Plant Method

1. Haul the mixture to the job in trucks equipped with protective covers. Thoroughly moisten the underlying course and deposit the material on the prepared area in a quantity that will produce a compacted base of uniform density to the required grade and cross section. Spreading or spreading-trimming equipment shall be constructed and operated to produce a layer of material which is uniform in

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thickness and surface contour and free from irregularities in density. Use spreading or spreading-trimming equipment in sufficient numbers and in staggered formation to obtain full-width spreading in 1 construction operation. Not more than 60 minutes shall elapse between the start of the moist mixing and the start of compaction of the treated layer. Not more than 30 minutes shall elapse between the placement of the cement-treated soil in adjacent lanes on 2-lane structures at any location.

C. Layer Thickness

1. Compacted thickness of the stabilized course shall be as indicated. No layer shall be in excess of 8 inches nor less than 4 inches in compacted thickness.

D. Compaction

1. Before compaction operations are started and as a continuation of the mixing operation, the mixture shall be thoroughly loosened to the full depth. At the beginning of compaction, at least 80 percent of the soil shall pass a No. 4 sieve, and 100 percent shall pass the 1 inch sieve. Start compaction immediately after mixing is completed. Density of compacted soil-cement mixture shall be at least 90 percent of the maximum density obtained from the laboratory prepared samples. Loose mixture shall be uniformly and continuously compacted until the entire depth and width of the area are compacted to the density specified. The moisture content at the surface shall be maintained near optimum at all times through the rolling, but shall be less than that quantity which will cause the soil-cement mixture to become unstable during compaction. Begin rolling at the outside edge of the surface and proceed to the center, overlapping on successive trips at least one-half the width of the roller. Alternate trips of the roller shall be slightly different lengths. Displacement of the mixture shall not occur due to the speed of the roller. Areas inaccessible to rollers shall be compacted with mechanical tampers.

3.05 FINISHING

The surface shall be moistened, if necessary, and shaped to the required lines, grades, and cross section. Lightly scarify the surface, if necessary, to eliminate any imprints made by the compacting or shaping equipment. The surface shall then be thoroughly compacted to the specified density with rubber-tired rollers and smooth-wheel tandem rollers to the extent necessary to provide a smooth, dense, uniform surface that is free of surface checking, ridges, or loose material, and that conforms to the crown, grade, and line indicated. Complete these finishing operations within 2 hours after completion of mixing operations. In places not accessible to finishing and shaping equipment, the mixtures shall be compacted with mechanical tampers to the density specified and shall be shaped and finished by hand methods. Correct, as specified below, any portion of the compacted mix that has density less than that specified, that has not properly hardened, or that is improperly finished.

3.06 CURING AND PROTECTION

A. Protect the finished surface against rapid drying for 7 days by one of the methods specified.

1. Burlap

Provide burlap covers consisting of 2 or more layers of burlap having a combined weight of 14 ounces or more per square yard in a dry condition. Burlap shall be either new or shall have been used only for curing concrete. Burlap strips shall

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have a length, after shrinkage, at least 1 foot greater than necessary to cover the entire width and edges of the finished stabilized area. Mats shall overlap each other at least 6 inches. Mats shall be thoroughly wetted before placing and shall be kept continuously wet and in contact with the surface and edges of the finished stabilized area for the entire curing period.

2. Impervious Sheeting

The surface of the finished stabilized area shall be moistened with a fine spray of water and then covered with impervious sheeting. The burlap of the polyethylene-coated burlap shall be thoroughly saturated with water before placing. Sheeting shall be placed with the light-colored side up. Sheets shall extend over the edges of the stabilized area and shall be held securely in place throughout the curing period. Edges of sheets shall overlap each other at least 12 inches and shall be securely cemented or taped to form continuous closed joints. Tears and holes in sheets shall be repaired immediately.

3.07 FIELD QUALITY CONTROL

A. Grade Control

Underlying material shall be excavated to sufficient depth for the required stabilized-course thickness. The finished stabilized course with the subsequent surface course shall meet the fixed grade. Finished and completed stabilized area shall conform to the lines, grades, cross section, and dimensions indicated.

B. Smoothness Test

The surface of a stabilized layer shall show no deviations in excess of 3/8 inch when tested with the straightedge. Deviations exceeding this amount shall be corrected by removing material and replacing new material, or by reworking existing material and compacting, as directed. Measurements for deviation from grade and cross section shown shall be taken in successive positions parallel to the apron centerline with a straightedge.

C. Thickness Control

The completed thickness of the stabilized course shall be within ½ inch of the thickness indicated. Where the measured thickness is more than ½ inch deficient, such areas shall be corrected by scarifying, adding mixture of proper gradation, reblading, and recompacting as directed. Where the measured thickness is more than ½ inch thicker than indicated, the course shall be considered as conforming with the specified thickness requirements. Average job thickness shall be the average of all thickness measurements taken for the job, but shall be within ¼ inch of the thickness indicated. The thickness of the stabilized course shall be measured at intervals which ensure one measurement for each 500 square yards of stabilized course. Measurements shall be made in 3 inch diameter test holes penetrating the stabilized course.

D. Testing

Perform field tests in sufficient numbers to assure that the specifications are being met.

Testing is to be the responsibility of the Contractor and shall be performed by an approved commercial laboratory.

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E. Field Density

Field density tests shall be performed in accordance with ASTM D 1556 or ASTM D6938.

ASTM D 6938 results in a wet unit weight of soil and ASTM D 6938 shall be used to determine the moisture content of the soil. Calibration curves furnished along with the density gauge shall be checked as described in ASTM D 6938. Calibration checks of the density gauge shall be made at the beginning of a job on each type of material encountered. If ASTM D 6938 is used, in-place densities shall be checked by ASTM D 1556 at least once per lift for each 250 square yards of stabilized material. Calibration curves and calibration test results shall be furnished within 24 hours of conclusion of the tests. At least 1 field density test shall be performed for each 250 square yards of each layer of base material.

F. Maintenance

Maintain the stabilized area in a satisfactory condition until the completed work is accepted.

Maintenance shall include immediate repairs to any defects and shall be repeated as often as necessary to keep the area intact. Defects shall be remedied as specified.

3.08 DISPOSAL OF UNSATISFACTORY MATERIALS

Removed in-place materials, that are unsuitable for stabilization, material that is removed for the required correction of defective areas, waste material, and debris shall be disposed of as directed.

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SECTION 32 13 13

AIRFIELDS AND HEAVY-DUTY CONCRETE PAVEMENT

1.01 SUBMITTALS

1. Proposed Techniques

Placing and protection methods; paving sequence; jointing pattern; data on curing equipment; demolition of existing pavements; as specified.

B. Design Data

1. Proportioning Studies

a. The results of the mixture proportioning studies must be signed and stamped by the registered professional engineer having technical responsibility for the mix design study and submitted at least 30 days prior to commencing concrete placing operations. The results must include a statement giving the maximum nominal coarse aggregate size and the weights and volumes of each ingredient proportioned on a one cubic meter yard basis. Base aggregate quantities on the mass in a saturated surface dry condition. Accompany the recommended mixture proportions by test results demonstrating that the proportions selected will produce concrete of the qualities indicated. The submittal must include:

(1) Coarse and fine aggregate gradations and plots.

(2) Combined aggregate gradation and plots.

(3) Coarse aggregate quality test results, including deleterious materials.

(4) Fine aggregate quality test results.

(5) Mill certificates for cement and pozzolan.

(6) Certified test results for air entraining, water reducing, retarding, and non-chloride accelerating admixtures.

(7) Specified flexural strength, slump, and air content.

(8) Documentation for average CQC flexural strength increase.

(9) Recommended proportions/volumes for proposed mixture and trial water-cementitious materials ratios.

(10) Individual beam and cylinder breaks.

(11) Flexural and compressive strength summaries and plots.

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(12) Correlation ratios for acceptance testing and CQC testing.

(13) Historical record of test results, documenting production standard deviation (if available).

C. Test Reports

1. Sampling and Testing

a.…