Specification 32 13 14.14 - Concrete Paving for Small Airfield Projects.pdf

FCLP Phase 9 - Wallops Flight Facility 1696789

SECTION 32 13 14.14

CONCRETE PAVING FOR SMALL AIRFIELD PROJECTS

11/17

PART 1 GENERAL

1.1 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.

AMERICAN CONCRETE INSTITUTE (ACI)

ACI 201.1R (2008) Guide for Conducting a Visual Inspection of Concrete in Service

ACI 211.1 (1991; R 2009) Standard Practice for Selecting Proportions for Normal, Heavyweight and Mass Concrete

ACI 214R (2011) Evaluation of Strength Test Results of Concrete

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306R (2016) Guide to Cold Weather Concreting

ACI 325.14R (2017) Guide for Design and Proportioning of Concrete Mixtures for Pavements

ASTM INTERNATIONAL (ASTM)

ASTM A1064/A1064M (2017) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM A1078/A1078M (2019) Standard Specification for Epoxy-Coated Steel Dowels in Concrete Pavement

ASTM A184/A184M (2017) Standard Specification for Welded Deformed Steel Bar Mats for Concrete Reinforcement

ASTM A185/A185M (2007) Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A615/A615M (2016) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A996/A996M (2016) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars

SECTION 32 13 14.14 Page 1 for Concrete Reinforcement

ASTM C1017/C1017M (2013; E 2015) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C1064/C1064M (2017) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C1077 (2017) Standard Practice for Agencies Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Testing Agency Evaluation

ASTM C117 (2017) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

ASTM C123/C123M (2014) Standard Test Method for Lightweight Particles in Aggregate

ASTM C1260 (2014) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C131/C131M (2014) Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136/C136M (2014) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C138/C138M (2017a) Standard Test Method for Density (Unit Weight), Yield, and Air Content (Gravimetric) of Concrete

ASTM C142/C142M (2017) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C143/C143M (2015) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2018) Standard Specification for Portland Cement

ASTM C1567 (2013) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C1602/C1602M (2018) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM C1646/C1646M (2016) Making and Curing Test Specimens for Evaluating Frost Resistance of Coarse Aggregate in Air-Entrained Concrete by

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Rapid Freezing and Thawing

ASTM C172/C172M (2017) Standard Practice for Sampling Freshly Mixed Concrete

ASTM C174/C174M (2017) Standard Test Method for Measuring Thickness of Concrete Elements Using Drilled Concrete Cores

ASTM C192/C192M (2018) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C231/C231M (2017a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C260/C260M (2010a; R 2016) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C294 (2012; R 2017) Standard Descriptive Nomenclature for Constituents of Concrete Aggregates

ASTM C295/C295M (2018a) Standard Guide for Petrographic Examination of Aggregates for Concrete

ASTM C31/C31M (2019) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33/C33M (2018) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2018) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C494/C494M (2017) Standard Specification for Chemical Admixtures for Concrete

ASTM C595/C595M (2018) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2019) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C666/C666M (2015) Resistance of Concrete to Rapid Freezing and Thawing

ASTM C685/C685M (2017) Standard Specification for Concrete Made by Volumetric Batching and Continuous Mixing

ASTM C88 (2018) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM C881/C881M (2015) Standard Specification for

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Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C94/C94M (2018) Standard Specification for Ready-Mixed Concrete

ASTM C989/C989M (2018a) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM D1752 (2018) Standard Specification for Preformed Sponge Rubber, Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM D2995 (1999; R 2009) Determining Application Rate of Bituminous Distributors

ASTM D3665 (2012; R 2017) Standard Practice for Random Sampling of Construction Materials

ASTM D4791 (2010) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D75/D75M (2014) Standard Practice for Sampling Aggregates

NATIONAL READY MIXED CONCRETE ASSOCIATION (NRMCA)

NRMCA QC 3 (2015) Quality Control Manual: Section 3, Plant Certifications Checklist:

Certification of Ready Mixed Concrete Production Facilities

U.S. AIR FORCE (USAF)

AF ETL 97-5 (1997) Proportioning Concrete Mixtures with Graded Aggregates for Rigid Airfield Pavements

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 300 (1990) Specifications for Membrane-Forming Compounds for Curing Concrete

COE CRD-C 521 (1981) Standard Test Method for Frequency and Amplitude of Vibrators for Concrete

COE CRD-C 662 (2009) Determining the Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials, Lithium Nitrate Admixture and Aggregate (Accelerated Mortar-Bar Method)

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00

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SUBMITTAL PROCEDURES:

SD-03 Product Data

Diamond Grinding Plan; G

Dowels; G

Dowel Bar Assemblies; G

Equipment; G

Proposed Techniques; G

SD-05 Design Data

Proportioning Studies; G

SD-06 Test Reports

Mixer Performance (Uniformity) Testing; G

Batch Tickets

Contractor Quality Control Reports

Repair Recommendations Plan; G

SD-07 Certificates

Contractor Quality Control Staff; G

Laboratory Accreditation

NRMCA Certificate of Conformance

1.3 QUALITY CONTROL

1.3.1 Contractor Quality Control Staff

Reference Section 01 45 00.00 10 QUALITY CONTROL for Contractor personnel qualification requirements. Submit the Contractor Quality Control staff for approval. Provide American Concrete Institute certificates of CQC staff in addition to the qualifications and resumes of the petrographer, surveyor, concrete batch plant operator, and CQC System Manager. All Contractor Quality Control personnel assigned to concrete construction are required to be American Concrete Institute (ACI) certified in the following grade:

a. The minimum requirements for the CQC System Manager consist of being a graduate engineer or a graduate of construction management, with a minimum of 3 years airfield construction experience and a minimum of 1 year experience as a CQC System Manager on an airfield construction project.

b. CQC staff is required to oversee all aspects of sawing operations (sawing, flushing, vacuuming, checking for random cracking, lighting).

c. Lead Foreman or Journeyman of the Concrete Placing, Finishing, and

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Curing Crews: ACI Concrete Flatwork Technician/Finisher.

d. Field Testing Technicians: ACI Concrete Field Testing Technician, Grade I.

e. Laboratory Testing Technicians: ACI Concrete Strength Testing Technician and Laboratory Testing Technician, Grade I or II.

1.3.2 Other Staff

Submit for approval, the qualifications and resumes for the following staff:

a. Petrographer: Bachelor of Science degree in geology or petrography, trained in petrographic examination of concrete aggregate according to ASTM C294 and ASTM C295/C295M and trained in identification of the specific deleterious materials and tests identified in this specification. Detail the education, training and experience related to the project-specific test methods and deleterious materials in the Resume and submit at least 20 days before petrographic and deleterious materials examination is to commence.

b. Licensed Surveyor: Perform all survey work under the supervision of a Licensed Surveyor.

c. Concrete Batch Plant Operator: National Ready Mix Concrete Association (NRMCA) Plant Manager certification.

1.3.3 Preconstruction Testing of Materials

All sampling and testing is required to be performed by an approved commercial laboratory. For cementitious materials and chemical admixtures use a laboratory maintained by the manufacturer of the material. Materials are not allowed to be used until notice of acceptance has been given.

Additional payment and extension of time is not allowed due to failure of any material to meet project requirements. Additional tests may be performed by the Government and do not relieve any of the required testing responsibilities.

1.3.3.1 Aggregates

Sample aggregates in the presence of a Government Representative. Obtain samples in accordance with ASTM D75/D75M that are representative of the materials to be used for the project. Perform all aggregate tests no earlier than 120 days prior to contract award.

1.3.3.2 Chemical Admixtures, Curing Compounds, and Epoxies

Submit certified copies of test results of admixtures, curing compounds, and epoxies that are going to be used on the project at least 30 days before the material is used. Provide test results less than 5 years old prior to use in the work.

1.3.3.3 Cementitious Materials

Cement, slag cement, and pozzolan will be accepted on the basis of manufacturer's certification of compliance, accompanied by mill test reports showing that the material in each shipment meets the requirements of the specification under which it is provided. Provide mill test reports no more than 6 months old prior to use in the work. Do not use

SECTION 32 13 14.14 Page 6 cementitious materials until notice of acceptance has been given.

Cementitious materials may be subjected to testing by the Government from samples obtained at the mill, at transfer points, or at the project site.

If tests prove that a cementitious material that has been delivered is unsatisfactory, promptly remove it from the project site.

1.4 DELIVERY, STORAGE, AND HANDLING

1.4.1 Bulk Cementitious Materials

Provide all cementitious materials in bulk at a temperature, as delivered to storage at the site, not exceeding 150 degrees F. Provide sufficient cementitious materials in storage to sustain continuous operation of the concrete mixing plant while the pavement is being placed. Provide separate facilities to prevent any intermixing during unloading, transporting, storing, and handling of each type of cementitious material.

1.4.2 Aggregate Materials

Store aggregate at the site of the batching and mixing plant avoiding breakage, segregation, intermixing or contamination by foreign materials.

Store each size of aggregate from each source separately in free-draining stockpiles. Provide a minimum 24 inch thick sacrificial layer left undisturbed for each aggregate stored on ground. Provide free-draining storage for fine aggregate and the smallest size coarse aggregate for at least 24 hours immediately prior to use. Maintain sufficient aggregate at the site at all times to permit continuous uninterrupted operation of the mixing plant at the time concrete pavement is being placed. Do not allow tracked equipment on coarse aggregate stockpiles.

1.4.3 Other Materials

Store reinforcing bars and accessories above the ground on supports. Store all materials to avoid contamination and deterioration.

1.5 ACCEPTANCE

1.5.1 Acceptability of Work

Acquire the services of an independent commercial laboratory to perform acceptance testing. Perform all required test methods by an accredited laboratory. The materials and the pavement itself will be accepted on the basis of production testing. The Government may make check tests from split samples to validate the results of the production testing. Testing performed by the Government does not reduce the required testing of the independent commercial laboratory. Split samples will be taken for Government testing to reduce the variability between the independent commercial laboratory and the Government's test results. When the difference between the independent commercial laboratory and the Government's test results for split samples exceed the acceptable range of two results for multilaboratory precision for the appropriate test method (i.e. ASTM) then at least one of the laboratories is determined to be in error. An evaluation of procedures and equipment in both laboratories will be made to determine the cause(s) for the differences. Develop steps to correct procedures and equipment to bring multilaboratory precision to within acceptable limits.

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1.5.2 Acceptance Requirements

Provide all sampling and testing required for acceptance including batch tickets. Select sample locations on a random basis in accordance with ASTM D3665. Individuals performing sampling, testing and inspection duties are required to meet the qualifications of the accredited laboratory. The Government reserves the right to direct additional samples and tests for any area which appears to deviate from the specification requirements.

Testing in these areas are additional and must meet the same requirements as random tests. Provide facilities and personnel where directed to assist in obtaining samples for any Government testing. Acceptance of work is based on compliance with the pavement characteristics discussed below.

1.5.3 Concrete Strength

Acceptance test results are the average strengths of two specimens tested at 28 days. The strength of the concrete is considered satisfactory so long as every average of three consecutive acceptance test results equal or exceeds the specified compressive strength (f'c) and no individual test result falls below f'c by more than 500 psi. Remove and replace the deficient area where any portion of the work fails to meet the acceptance criteria for concrete strength, at no additional cost to the Government.

1.5.4 Thickness

Provide the pavement thickness required. Measure pavement thickness using cores taken in accordance with ASTM C174/C174M. If the cores have a thickness deficiency of 0.75 inch or more for pavements 8 inches, remove and replace the deficient area, at no additional cost to the Government.

If the cores have a thickness deficiency of 0.50 inch or more for pavements less 8 inches, remove and replace the deficient area, at no additional cost to the Government.

1.5.5 Surface Smoothness

Provide runways and taxiways with a variation from the specified straight edge not greater than 1/8 inch in the longitudinal direction and not greater than 1/4 inch in the transverse direction. Provide all other airfield areas with a variation from a straight edge not greater than 1/4 inch in either the longitudinal or transverse direction. Smoothness requirements do not apply over crowns, drainage structures, or similar penetration. Remove and replace the deficient area when more than 20.0 percent of the measurements exceed the tolerance, at no additional cost to the Government.

1.5.6 Bumps

Reduce any bumps by diamond grinding areas exceeding the tolerances shown by the straightedge method. Continue diamond grinding until the tolerances for the straightedge test are met. Taper such diamond grinding in all directions to provide smooth transitions to areas not requiring diamond grinding. Perform additional straightedge testing in all areas corrected by diamond grinding.

1.5.7 Grade

Provide finished surfaces of all airfield pavements that vary less than 1/2 inch above or below the plan grade line or elevation indicated. The above deviations from the approved grade line and elevation are not permitted in

SECTION 32 13 14.14 Page 8 areas where closer conformance with the planned grade and elevation is required for the proper functioning of appurtenance structures. Provide finished surfaces of new abutting pavements that coincide at their juncture. Provide horizontal control of the finished surfaces of all airfield pavements that vary not more than 1/2 inch from the plan alignment indicated. Remove and replace the deficient area where the deviation from grade exceeds the specified tolerances by 50 percent or more, at no additional cost to the Government.

1.5.8 Diamond Grinding

The maximum depth of diamond grinding is 1/4 inch. Remove and replace all pavement areas requiring plan grade or surface smoothness corrections in excess of the maximum diamond grinding depth permitted, at no additional cost to the Government. The maximum area corrected by diamond grinding the surface of the hardened concrete is 5 percent of the individual repair area area.

1.5.9 Deficient Areas

The size of a deficient area is measured as one or more failing tests or measurements that are in between two passing tests. Deficient areas may be reduced in size by performing additional tests or measurements to show areas that meet the requirements for acceptance.

1.5.10 Laboratory Accreditation

Submit laboratory accreditation for approval. Provide independent commercial laboratories for aggregate testing, mixture proportioning studies, acceptance testing, and Contractor Quality Control. Submit accreditation of the commercial laboratory by an independent evaluation authority indicating conformance to ASTM C1077 including ASTM C39/C39M, ASTM C1260, and all applicable test procedures. Provide accreditation that is current and listed on the accrediting authority’s website with the required and optional test methods specified. Maintain this accreditation for the duration of the project. Schedule and provide payment for laboratory inspections. Additional payment or a time extension due to failure to acquire the required laboratory accreditation is not allowed.

PART 2 PRODUCTS

2.1 SYSTEM DESCRIPTION

This section is intended to stand alone for construction of concrete airfield pavement. However, where the construction covered herein interfaces with other sections, construct each interface to conform to the requirements of both this section and the other section including tolerances for both.

2.2 CEMENTITIOUS MATERIALS

Provide cementitious materials consisting of blended cement or portland cement in combination with supplementary cementitious materials (SCM), that conform to appropriate specifications listed below. New submittals are required when the cementitious materials sources or types change.

2.2.1 Portland Cement

Provide portland cement conforming to ASTM C150/C150M, Type II, including

SECTION 32 13 14.14 Page 9 false set requirements.

2.2.2 Blended Cements

Provide blended cement conforming to ASTM C595/C595M, Type IL, IP, or IS including the optional requirement for sulfate resistance. Provide pozzolan added to the Type IP blend consisting of ASTM C618 Class F or Class N and that is interground with the cement clinker. Include in written statement from the manufacturer that the amount of pozzolan in the finished cement does not vary more than plus or minus 5 mass percent of the finished cement. The percentage and type of mineral admixture used in the blend are not allowed to change from that submitted for the aggregate evaluation and mixture proportioning. The requirements of Table 2 in paragraph SUPPLEMENTARY CEMENTITIOUS MATERIALS (SCM) CONTENT do not apply to the SCM content of blended cement.

2.2.3 Pozzolan

2.2.3.1 Fly Ash

Provide fly ash conforming to ASTM C618, Class F including the optional requirement for uniformity and a loss on ignition not exceeding 3 percent.

Provide Class F fly ash for use in mitigating Alkali-Silica Reactivity with a total equivalent alkali content less than 3 percent.

2.2.3.2 Raw or Calcined Natural Pozzolan

Provide natural pozzolan that is raw or calcined and conforms to ASTM C618, Class N, including the optional requirements for uniformity and a loss on ignition not exceeding 3 percent. Provide Class N pozzolan for use in mitigating Alkali-Silica Reactivity with a total equivalent alkali content less than 3 percent.

2.2.3.3 Ultra Fine Fly Ash and Ultra Fine Pozzolan

Provide Ultra Fine Fly Ash (UFFA) and Ultra Fine Pozzolan (UFP) conforming to ASTM C618, Class F or N, and the following additional requirements:

a. The strength activity index at 28 days of age of at least 95 percent of the control specimens.

b. The average particle size not exceeding 6 microns.

2.2.4 Slag Cement

Provide slag cement (ground-granulated blast-furnace slag) that conforms to ASTM C989/C989M, Grade 100 or Grade 120.

2.2.5 Supplementary Cementitious Materials (SCM) Content

Provide a concrete mix that contains one of the SCMs in Table 2 within the ranges specified therein.

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TABLE 2

SUPPLEMENTARY CEMENTITIOUS MATERIALS CONTENT

Supplementary Cementitious Material Minimum Content (percent)

Maximum Content (percent)

Class N Pozzolan and Class F Fly Ash

SiO2 + Al2O3 + Fe2O3 > 70 percent 25 35

SiO2 + A12O3 + Fe2O3 > 80 percent 20 35

SiO2 + A12O3 + Fe2O3 > 90 percent 15 35

UFFA and UFP 7 16

Slag Cement 40 50

2.3 AGGREGATES

2.3.1 Aggregate Sources

2.3.1.1 Durability of Coarse Aggregate

Provide durable aggregate that meets one of the following requirements:

a. Provide aggregate with a satisfactory service record in freezing and thawing of at least 5 years successful service in three concrete paving projects. Include a condition survey of the existing concrete and a review of the concrete-making materials, including coarse aggregates, cement, and mineral admixtures in the service record. Consider the previous aggregate source and test results, cement mill certificate data, mineral admixture chemical and physical composition, and the mix design (cement factor and water-cementitious material ratio) in the review. Provide service record performed by an independent third party professional engineer, petrographer, or concrete materials engineer along with their resume. Include photographs and a written report addressing D-cracks and popouts in accordance with ACI 201.1R in the service record.

b. Provide coarse aggregate with a durability factor of 80 or more when subjected to freezing and thawing of specimens prepared in accordance with ASTM C1646/C1646M and tested in accordance with ASTM C666/C666M, Procedure A. Test all coarse aggregate size groups and sources proposed for use individually. Historical data that is representative of material on the project may be provided if the testing is within 1 year of when production paving will begin.

2.3.1.2 Alkali-Silica Reactivity

Evaluate and test fine and coarse aggregates to be used in all concrete for alkali-aggregate reactivity. Test all size groups and sources proposed for use.

a. Evaluate the fine and coarse aggregates separately using ASTM C1260.

Reject individual aggregates with test results that indicate an expansion of greater than 0.08 percent after 28 days of immersion in 1N NaOH solution, or perform additional testing as follows: utilize the proposed low alkali portland cement, blended cement, and SCM, or

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Lithium Nitrate in combination with each individual aggregate. If only SCMs are being evaluated, test in accordance with ASTM C1567. If Lithium Nitrate is being evaluated, with or without SCMs, test in accordance with COE CRD-C 662. Determine the quantity that meets all the requirements of these specifications and that lowers the expansion equal to or less than 0.08 percent after 28 days of immersion in a 1N NaOH solution. Base the mixture proportioning on the highest percentage of SCM required to mitigate ASR-reactivity.

b. If any of the above options does not lower the expansion to less than

0.08 percent after 28 days of immersion in a 1N NaOH solution, reject the aggregate(s) and submit new aggregate sources for retesting.

Submit the results of testing for evaluation and acceptance.

2.3.1.3 Combined Aggregate Gradation

In addition to the grading requirements specified for coarse aggregate and for fine aggregate, provide the combined aggregate grading meeting the following requirements:

a. Provide materials selected and the proportions used such that when the Coarseness Factor (CF) and the Workability Factor (WF) are plotted on a diagram as described in d. below, the point and its associated production tolerance thus determined falls within the parallelogram described therein. Refer to AF ETL 97-5 for combined aggregate plot area recommendations for the intended placement technique(s).

b. Determine the Coarseness Factor (CF) from the following equation:

CF = (cumulative percent retained on the 3/8 inch sieve)(100) (cumulative percent retained on the No. 8 sieve)

c. The Workability Factor (WF) is defined as the percent passing the No. 8 sieve based on the combined aggregate gradation. Adjust the WF, prorated upwards only, by 2.5 percentage points for each 94 pounds per cubic yard of cementitious material greater than 564 pounds per cubic yard.

d. Plot a diagram using a rectangular scale with WF on the Y-axis with units from 20 (bottom) to 45 (top), and with CF on the X-axis with units from 80 (left side) to 30 (right side). On this diagram, plot a parallelogram with corners at the following coordinates (CF-75, WF-28), (CF-75, WF-40), (CF-45, WF-32.5), and (CF-45, WF-44.5). If the point determined by the intersection of the computed CF and WF does not fall within the above parallelogram, revise the grading of each size of aggregate used and the proportions selected as necessary.

e. Plot the associated production tolerance limits, identified in Table 6, around the CF and adjusted WF point.

2.3.2 Coarse Aggregate

2.3.2.1 Material Composition

Provide coarse aggregate consisting of crushed or uncrushed gravel, crushed stone, or a combination thereof. Provide aggregates, as delivered to the mixers, consisting of clean, hard, uncoated particles meeting the requirements of ASTM C33/C33M except as specified herein. Provide coarse aggregate that has been washed sufficient to remove dust and other coatings.

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Provide coarse aggregate with no more than 40 percent loss when subjected to the Los Angeles abrasion test in accordance with ASTM C131/C131M. Provide coarse aggregates with a maximum sodium sulfate soundness loss of 12 percent, or with a magnesium sulfate soundness loss of 18 percent after five cycles when tested in accordance with ASTM C88.

2.3.2.2 Particle Shape Characteristics

Provide particles of the coarse aggregate that are generally spherical or cubical in shape. The quantity of flat particles and elongated particles in any size group coarser than the 3/8 inch sieve are not allowed to exceed 20 percent by weight as determined by the Flat Particle Test and the Elongated Particle Test of ASTM D4791. A flat particle is defined as 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.

2.3.2.3 Size and Grading

Provide coarse aggregate with a nominal maximum size of 1.0 inches. Grade and provide the individual aggregates in two size groups meeting the individual grading requirements of ASTM C33/C33M, Size No. 4 and Size No. 57 to meet the coarseness and workability factor criteria for the proposed combined gradation. A third aggregate size group may be required to meet the above mentioned coarseness and workability criteria of paragraph

COMBINED AGGREGATE GRADATION.

2.3.2.4 Deleterious Materials - Airfield Pavements

The amount of deleterious material in each size group of coarse aggregate is not allowed to exceed the limits shown in Table 5 below, determined in accordance with the test methods shown.

TABLE 5

LIMITS OF DELETERIOUS MATERIALS IN COARSE AGGREGATE FOR AIRFIELD

Materials (h) Percentage by Mass

Clay lumps and friable particles

(ASTM C142/C142M)

1.0

Material finer than No. 200 sieve (a) (ASTM C117) 1.0

Lightweight particles (b)

(ASTM C123/C123M)

0.5

Chert, cherty stone, and other aggregates (less than

2.40 Sp. Gr.) (c)

(ASTM C123/C123M and ASTM C295/C295M)

1.0

(a) Limit for material finer than No. 200 sieve is allowed to be increased to 1.5 percent for crushed aggregates if the fine material consists of crusher dust that is essentially free from clay or shale. Use XRD or other appropriate techniques as determined by petrographer to quantify amount and justify increase.

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TABLE 5

LIMITS OF DELETERIOUS MATERIALS IN COARSE AGGREGATE FOR AIRFIELD

Materials (h) Percentage by Mass

(b) Test with a separation medium with a density of Sp. Gr. of

2.0. This limit does not apply to coarse aggregate manufactured from blast-furnace slag unless contamination is evident.

(c) Chert is defined as a rock composed of quartz, chalcedony or opal, or any mixture of these forms of silica. It is variable in color. The texture is so fine that the individual mineral grains are too small to be distinguished by the unaided eye. Its hardness is such that it scratches glass but is not scratched by a knife blade. It may contain impurities such as clay, carbonates, iron oxides, and other minerals. Cherty stone is defined as any type of rock (generally limestone) that contains chert as lenses and nodules, or irregular masses partially or completely replacing the original stone. Other aggregates consist of obsidian, ash tuff, and palygorskite.

(d) Perform testing in accordance with the referenced test methods, except use the minimum sample size specified below.

2.3.2.5 Testing Sequence for Deleterious Materials in Coarse Aggregate - Airfields Only

No extension of time or additional payment due to any delays caused by the testing, evaluation, or personnel requirements is allowed. The minimum test sample size of the coarse aggregate is 200 pounds for the 3/4 inch and larger maximum size and 25 pounds for the No. 4 to 3/4 inch coarse aggregate. Provide facilities for the ready procurement of representative test samples.

2.3.3 Fine Aggregate

2.3.3.1 Composition

Provide fine aggregate consisting of natural sand, manufactured sand, or a combination of the two, and composed of clean, hard, durable particles meeting the requirements of ASTM C33/C33M. Stockpile and batch each type of fine aggregate separately. Provide fine aggregate with particles that are generally spherical or cubical in shape.

2.3.3.2 Grading

Provide fine aggregate, as delivered to the mixer, with a grading that conforms to the requirements of ASTM C33/C33M and having a fineness modulus of not less than 2.50 nor more than 3.40.

2.3.3.3 Deleterious Material

The minimum test sample size for fine aggregate proposed for use in airfield paving is 10 pounds. The amount of deleterious material in the fine aggregate is not to exceed the following limits by mass when performed on the full sample:

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Material Percentage by Mass

Clay lumps and friable particles ASTM C142/C142M 1.0

Material finer than No. 200 sieve ASTM C117 3.0

Lightweight particles ASTM C123/C123M using a medium with a density of Sp. Gr. of 2.0

0.5

Total of all above 3.0

2.4 CHEMICAL ADMIXTURES

2.4.1 General Requirements

Chemical admixtures may only be used when the specific admixture type and manufacturer is the same material used in the mixture proportioning studies. Provide air-entraining admixture conforming to ASTM C260/C260M.

An accelerating admixture conforming to ASTM C494/C494M, Type C or E, may be used only when specified in paragraph MIXTURE PROPORTIONS below provided it is not used to reduce the amount of cementitious material. Calcium chloride and admixtures containing calcium chloride are not allowed.

Provide retarding or water-reducing admixture that meet the requirements of ASTM C494/C494M, Type A, B, or D, except that the 6-month and 1-year compressive strength tests are waived. Type S specific performance admixtures are not allowed. ASTM C1017/C1017M flowable admixtures are not allowed.

2.4.2 Lithium Nitrate

Provide lithium admixture that consists of a nominal 30 percent aqueous solution of Lithium Nitrate, with a density of 10 pounds per gallon, with the approximate chemical form as shown below:

Constituent Limit (Percent by Mass)

LiNo3 (Lithium Nitrate) 30 plus or minus 0.5

SO4

-2 (Sulfate Ion) 0.1 (max)

Cl- (Chloride Ion) 0.2 (max)

Na+ (Sodium Ion) 0.1 (max)

K+ (Potassium Ion) 0.1 (max)

Provide the manufacturer'sapproval in dispensing, mixing, proportioning, placement procedures and curing of concrete containing lithium nitrate..

[2.4.3 High Range Water Reducing Admixture (HRWRA)

ASTM C494/C494M, Type F and G high range water reducing admixtures are not allowed.

2.5 MEMBRANE FORMING CURING COMPOUND

Provide membrane forming curing compound that conforms to COE CRD-C 300 and

SECTION 32 13 14.14 Page 15 is white pigmented.

2.6 WATER

Provide water for mixing and curing that is fresh, clean, potable, and free of injurious amounts of oil, acid, salt, or alkali, except that non-potable water, or water from concrete production operations, may be used if it meets the requirements of ASTM C1602/C1602M.

2.7 JOINT MATERIALS

2.7.1 Expansion Joint Material

Provide preformed expansion joint filler material conforming to ASTM D1752 Type II. Provide expansion joint filler that is 3/4 inch thick, unless otherwise indicated, and provided in a single full depth piece.

2.7.2 Slip Joint Material

Provide slip joint material that is 1/4 inch thick expansion joint filler, unless otherwise indicated, conforming to paragraph EXPANSION JOINT

MATERIAL.

2.8 REINFORCING

Provide reinforcement that is free from loose, flaky rust, loose scale, oil, grease, mud, or other coatings that might reduce the bond with concrete. Removal of thin powdery rust and tight rust is not required.

However, reinforcing steel which is rusted to the extent that it does not conform to the required dimensions or mechanical properties is not allowed to be used.

2.8.1 Reinforcing Bars and Bar Mats

Provide deformed reinforcing bars conforming to ASTM A615/A615M, Grade 60.

Provide bar mats conforming to ASTM A184/A184M.

2.8.2 Welded Wire Reinforcement

Provide welded wire reinforcement that is deformed or smooth, conforming to ASTM A1064/A1064M or ASTM A185/A185M, and is provided in flat sheets.

2.9 DOWELS

2.9.1 Dowels

Provide dowels in single piece bars fabricated or cut to length at the shop or mill before delivery to the site. Dowels are to be free of loose, flaky rust and loose scale and be clean and straight. Dowels may be sheared to length provided that the deformation from true shape caused by shearing does not exceed 0.04 inch on the diameter of the dowel and does not extend more than 0.04 inch from the end of the dowel. Dowels are required to be plain (non-deformed) steel bars conforming to ASTM A615/A615M, Grade 40 or 60; ASTM A996/A996M, Grade 50 or 60. Dowel bars are required to be epoxy coated in conformance with Type 1 coating requirements of ASTM A1078/A1078M, to include the ends. Provide grout retention rings that are fully circular metal or plastic devices capable of supporting the dowel until the epoxy hardens. Dowel sleeves or inserts are not permitted.

SECTION 32 13 14.14 Page 16

2.9.2 Dowel Bar Assemblies

Provide dowel bar assemblies that consist of a framework of metal bars or wires arranged to provide rigid support for the dowels throughout the paving operation, with a minimum of four continuous bars or wires extending along the joint line. Provide dowels that are welded to the assembly or held firmly by mechanical locking arrangements that prevent them from rising, sliding out, or becoming distorted during paving operations.

2.10 EPOXY RESIN

Provide epoxy-resin materials that consist of two-component materials conforming to the requirements of ASTM C881/C881M, Class as appropriate for each application temperature to be encountered, except that in addition, the materials meet the following requirements:

a. Material for use for embedding dowels and anchor bolts be Type IV, Grade 3.

b. Material for use as patching materials for complete filling of spalls and other voids and for use in preparing epoxy resin mortar be Type III, Grade as approved.

c. Material for use for injecting cracks be Type IV, Grade 1.

d. Material for bonding freshly mixed portland cement concrete or mortar or freshly mixed epoxy resin concrete or mortar to hardened concrete be Type V, Grade as approved.

2.11 EQUIPMENT

All plant, equipment, tools, and machines used in the work are required to be maintained in satisfactory working conditions at all times. Submit the following:

a. Details and data on the batching and mixing plant prior to plant assembly including manufacturer's literature showing that the equipment meets all requirements specified herein.

b. Obtain National Ready Mixed Concrete Association (NRMCA) certification of the concrete plant, at no expense to the Government. Provide inspection report of the concrete plant by an engineer approved by the NRMCA. A list of NRMCA approved engineers is available on the NRMCA website at http://www.nrmca.org. Submit a copy of the NRMCA QC Manual Section 3 Concrete Plant Certification Checklist, NRMCA Certificate of Conformance, and Calibration documentation on all measuring and weighing devices prior to uniformity testing.

c. A description of the equipment proposed for transporting concrete mixture from the central mixing plant to the paving equipment.

d. A description of the equipment proposed for the machine and hand placing, consolidating and curing of the concrete mixture.

Manufacturer's literature on the paver and finisher, together with the manufacturer's written instructions on adjustments and operating procedures necessary to assure a tight, smooth surface on the concrete pavement. The literature is required to show that the equipment meets all details of these specifications.

SECTION 32 13 14.14 Page 17

2.11.1 Batching and Mixing Plant

2.11.1.1 Location

Locate the batching and mixing plant off Government premises no more than 45 minutes haul time from the placing site. Provide operable telephonic or radio communication between the plant and the placing site at all times concreting is taking place.

2.11.1.2 Type and Capacity

Provide a batching and mixing plant consisting of a stationary-type central mix plant, including permanent installations and portable plants installed on stable foundations. Provide a plant designed and operated to produce concrete within the specified tolerances, with a minimum capacity of 250 cubic yards per hour, that conforms to the requirements of NRMCA QC 3 including provisions addressing:

1. Material Storage and Handling

2. Batching Equipment

3. Central Mixer

4. Ticketing System

5. Delivery System

2.11.1.3 Ready-Mixed Concrete

Provide ready-mixed concrete in accordance with ASTM C94/C94M.

2.11.1.4 Concrete Made by Volumetric Batching and Continuous Mixing

Provide concrete made by volumetric batching and continuous mixing in accordance with ASTM C685/C685M.

2.11.1.5 Concrete Uniformity Requirements

Provide concrete meeting the uniformity requirements of ASTM C94/C94M or ASTM C685/C685M. Perform uniformity testing no earlier than 6 months before contract award using the approved mixture proportions for the project. Submit mixer performance (uniformity) testing showing concrete is within the limits of ASTM C94/C94M or ASTM C685/C685M.

2.11.2 Transporting Equipment

Deliver concrete to the paving site in accordance with ASTM C94/C94M or ASTM C685/C685M. Do not use non-agitating equipment.

2.11.3 Paver-Finisher

2.11.3.1 General

Use a heavy duty vibratory truss screed or triple roller tube paver for concrete placement.

2.11.3.2 Heavy Duty Vibratory Truss Screed

Provide a heavy duty vibratory truss screed designed specifically for paving and finishing low slump concrete with an engine having a minimum of 9 horsepower. The truss screed is required to be easily adjustable and capable of spanning the lane being paved with a minimum weight of 18 pounds

SECTION 32 13 14.14 Page 18 per foot of lane width. Operate the truss screed to spread, consolidate, and shape the plastic concrete to the desired cross section in one pass so that the end result is a dense and homogeneous pavement which is achieved with a minimum of hand finishing.

2.11.3.2.1 Screed

Equip the heavy duty vibratory truss with a transversely oscillating screed. Operate the screed to shape, compact, and smooth the surface and finish the surface so that no significant amount of hand finishing except use of cutting straightedges is required. Provide adjustment for variation in lane width or thickness and to prevent more than 8 inches of the screed extending over previously placed or existing concrete. Repair or replace machines that cause displacement of properly installed forms or cause ruts or indentations in the prepared underlying materials and machines that cause frequent delays due to mechanical failures as directed.

2.11.3.3 Triple Roller Tube Paver

Provide a triple roller tube paver with an engine having a minimum of 74 horsepower. The paver is required to be easily adjustable and capable of spanning the lane being paved with a minimum weight of 480 pounds per foot of lane width. Operate the paver to spread, consolidate, and shape the plastic concrete to the desired cross section in two passes so that the end result is a dense and homogeneous pavement which is achieved with a minimum of hand finishing.

2.11.3.4 Vibrators

Provide full-depth consolidation using immersion vibrators from a work bridge. Provide vibrators that can be operated at any desired depth within the slab and can be completely withdrawn from the concrete as required.

Equip vibrators with controls to immediately stop vibration as forward motion of the work ceases. Space immersion vibrators across the paving lane as necessary to properly consolidate the concrete with a maximum clear distance between vibrators of 30 inches. Place outside vibrators within 12 inches from the lane edge. Measure the vibrator frequency and amplitude in accordance with COE CRD-C 521.

2.11.3.5 Other Types of Finishing Equipment

Grate tampers (jitterbugs), clary screeds, laser screeds, other rotating tube floats, or bridge deck finishers are not allowed.

2.11.3.5.1 Strike-off and Tamping Templates

Provide a strike-off and tamping templates for areas where hand finishing concrete is permitted. Provide a template at least 1 foot longer than the width of pavement being finished with an approved design that is sufficiently rigid to retain its shape using metal or other suitable material shod with metal. Grate tampers (jitterbugs) are not allowed.

2.11.3.5.2 Longitudinal Float

Provide a longitudinal float at least 10 feet long with an approved design that is rigid, substantially braced, and maintains a plane surface on the bottom. Only use in areas where hand finishing concrete is permitted.

SECTION 32 13 14.14 Page 19

2.11.4 Curing Equipment

Provide equipment for applying membrane-forming curing compound mounted on a self-propelled frame that spans the paving lane. Constantly agitate the curing compound reservoir mechanically (not air) during operation and provide a means for completely draining the reservoir. Provide a spraying system that consists of a mechanically powered pump which maintains constant pressure during operation, an operable pressure gauge, and either a series of spray nozzles evenly spaced across the lane to provide uniformly overlapping coverage or a single spray nozzle which is mounted on a carriage which automatically traverses the lane width at a speed correlated with the forward movement of the overall frame. Protect all spray nozzles with wind screens. Calibrate the spraying system in accordance with ASTM D2995, Method A, for the rate of application required in paragraph MEMBRANE CURING. Provide hand-operated sprayers allowed by that paragraph with compressed air supplied by a mechanical air compressor. Immediately replace curing equipment if it fails to apply an even coating of compound at the specified rate.

2.11.5 Texturing Equipment

Provide texturing equipment as specified below. Before use, demonstrate the texturing equipment on a test section, and modify the equipment as necessary to produce the texture directed.

2.11.5.1 Broom

Apply surface texture using an approved mechanical stiff bristle broom drag of a type that provides a uniformly scored surface transverse to the pavement center line. Provide broom capable of traversing the full width of the pavement at a uniform speed and with a uniform pressure that results in scores uniform in appearance and approximately 1/16 inch in depth but not more than 1/8 inch in depth.

2.11.6 Sawing Equipment

Provide saws capable of sawing to the full depth required.

2.11.6.1 Diamond Saw

Provide equipment for sawing joints and for other similar sawing of concrete consisting of standard diamond-type concrete saws mounted on a wheeled chassis which can be easily guided to follow the required alignment. Provide diamond tipped blades. If demonstrated to operate properly, abrasive blades may be used. Provide spares as required to maintain the required sawing rate. Early-entry saws may be used subject to demonstration and approval. No change to the initial sawcut depth is permitted.

2.11.6.2 Wheel Saw

Provide wheel saws used in the removal of concrete with large diameter tungsten carbide tipped blades mounted on a heavy-duty chassis which produce a saw kerf at least 1-1/2 inches wide.

2.11.7 Straightedge

Provide and maintain at the job site, in good condition, a minimum 12 foot straightedge for each paving train for testing the hardened portland cement

SECTION 32 13 14.14 Page 20 concrete surfaces. Provide straightedges constructed of aluminum or magnesium alloy and blades of box or box-girder cross section with flat bottom, adequately reinforced to insure rigidity and accuracy. Provide straightedges with handles for operation on the pavement.

2.11.8 Work Bridge

Provide a self-propelled working bridge capable of spanning the required paving lane width where workmen can efficiently and adequately reach the pavement surface.

2.11.9 Diamond Grinding of PCC Surfaces

Submit a Diamond Grinding Plan for review and approval prior to diamond grinding. At a minimum, include the daily reports for the deficient areas, the location and extent of deficiencies, corrective actions, and equipment. Those performing diamond grinding are required to have a minimum of three years experience in diamond grinding of airfield pavements. In areas not meeting the specified limits for surface smoothness and plan grade, reduce high areas to attain the required smoothness and grade, except as depth is limited below. Reduce high areas by diamond grinding the hardened concrete with an approved equipment after the concrete is at a minimum age of 14 days. Perform diamond grinding by sawing with an industrial diamond abrasive which is impregnated in the saw blades. Assemble the saw blades in a cutting head mounted on a machine designed specifically for diamond grinding that produces the required texture and smoothness level without damage to the concrete pavement or joint faces. Provide diamond grinding equipment with saw blades that are 1/8-inch wide, a minimum of 55 to 60 blades per 12 inches of cutting head width, and capable of cutting a path a minimum of 3 ft wide. Diamond grinding equipment that causes ravels, aggregate fractures, spalls or disturbance to the joints is not permitted. Provide diamond grinding machine equipped to flush and vacuum the pavement surface. Dispose of all debris from diamond grinding operations off Government property. Remove and replace all pavement areas requiring plan grade or surface smoothness corrections in excess of the limits specified above in conformance with paragraph REPAIR, REMOVAL AND REPLACEMENT OF NEWLY CONSTRUCTED SLABS. All areas in which diamond grinding has been performed are subject to the thickness tolerances specified in paragraph THICKNESS, above.

Prior to production diamond grinding operations, perform a test section at the approved location. Perform a test section that consists of a minimum of two adjacent passes with a minimum length of 40 feet to allow evaluation of the finish, transition between adjacent passes, and the results of crossing a transverse joint. Production diamond grinding operations are not to be performed prior to approval.

2.12 SPECIFIED CONCRETE STRENGTH AND OTHER PROPERTIES

2.12.1 Specified Compressive Strength

Specified compressive strength, f'c, for concrete is 5,000 psi at 28 days of age as determined by test specimens fabricated in accordance with ASTM C192/C192M and tested in accordance with ASTM C39/C39M.

2.12.2 Water-Cementitious Materials Ratio

Maximum allowable water-cementitious material ratio is 0.45. The water-cementitious material ratio is the equivalent water-cement ratio as

SECTION 32 13 14.14 Page 21 determined by conversion from the weight ratio of water to cement plus SCM by the mass equivalency method described in ACI 211.1.

2.12.3 Air Content

Provide concrete that is air-entrained with a total air content of 6.5 plus or minus 1.5 percentage points, at the point of placement. Determine air content in accordance with ASTM C231/C231M.

2.12.4 Slump

The maximum allowable slump of the concrete at the point of placement is 3 inches for pavement constructed with fixed forms.

2.12.5 Concrete Temperature

The temperature of the concrete as delivered is…