EXHIBIT_3_-_SPECIFICATIONS.pdf

STANDARD SPECIFICATIONS FOR CONSTRUCTION OF ROADS AND BRIDGES ON FEDERAY

HIGHWAY PROJECTS (FP‐14 U.S. CUSTOMARY UNITS)

The STANDARD SPECIFICATIONS FOR CONSTRUCTION OF ROADS AND BRIDGES ON FEDERAL HIGHWAYS (FP‐14 U.S. Customary Units), 2014, are included by reference. The requirements contained in these specifications are hereby made a part of this solicitation and any resultant contract.

The 700‐page book entitled “Standard Specifications for Construction of Roads and Bridges on Federal Highway Projects (FP‐14 U.S. Customary Units), is available from:

Headquarters

Washington DC

David K. Green

Construction Standards Engineer

Internet: David.Green@fhwa.dot.gob

Mail: Federal Highway Administration

HFPD‐3

400 Seventh Street, SW

Washington, DC 20590

Website: http://flh.fhwa.dot.gov/resources/pse/specs/

Applicable sections include Sections designated in the following list and others referenced therein.

1) Section 501. – RIGID PAVEMENT

2) Section 502. – RIGID PAVEMENT RESTORATION

The following link has the full manual, as sections refer to other sections that are not specifically listed above: http://flh.fhwa.dot.gov/resources/pse/specs/fp-14/fp14.pdf

DIVISION 500

RIGID PAVEMENTS

Section 501

Section 501. — MINOR CONCRETE PAVEMENT

Description

501.01 This work consists of constructing minor concrete pavement on a prepared surface.

Material

501.02 Conform to the following Section:

Minor concrete 601

Construction Requirements

501.03 Composition (Concrete Mix Design). See Subsection 601.03, except conform to Table 501-1.

Table 501-1 Composition of Concrete

Maximum Water/

Cementitious Material

Ratio

Slump (maximum), AASHTO

T 119

Air Content (minimum)

Coarse Aggregate

Size Number

AASHTO

M 43(1)

28-Day Compressive

Strength (minimum), AASHTO

T 22

0.45 4 inches

(100 millimeters) (fixed form)

5.0% 57 & 67 4000 psi (28 MPa)

(1) Meet the processing requirements of AASHTO M 43, Table 1 – Standard Sizes of Processed Aggregate.

501.04 Equipment. Conform to the following:

(a) Forms. Furnish straight, steel forms. For curved edges with radii less than 150 feet (45 meters), furnish flexible or curved forms. Provide forms conforming to the following:

(1) Height equal to the pavement thickness at the edge;

(2) 10-foot (3-meter) minimum length;

(3) Stabilizing devices to secure form to the prepared surface and to withstand paving operations and pressure of concrete with no visible movement or settlement;

(4) Joint locks to join form lengths tightly together; and

(5) Clean and free of hardened concrete, dirt, distortion, and rust.

(b) Paving and finishing.

(1) Fixed form construction. Furnish equipment conforming to either of the following:

(a) Mechanical, self-propelled, finishing machines capable of consolidating and finishing the concrete with minimal hand finishing. Coordinate the number of driving wheels, power of the motor, and the machine's mass to prevent slippage. Do not use machines that displace the fixed forms; or

(b) Manual finishing machines or roller screeds capable of consolidating and finishing the concrete.

(2) Vibrators. Furnish internal immersed tube or multiple spud type vibrators for paving more than 8 inches (200 millimeters) thick. Surface pan type vibrators are acceptable for full-width concrete consolidation of slabs 8 inches (200 millimeters) or less in thickness. Operate the vibrators at frequencies within 5,000 to 8,000 vibrations per minute. Attach vibrators to the spreader or finishing machine or mount on a separate carriage that precedes the finishing machine. For construction of irregular areas, use hand-held vibrators operated at a frequency recommended by the manufacturer.

(c) Concrete saws. Furnish concrete saws that are capable of sawing new concrete for crack control to the required depth and alignment. Equip saws with blade guards and devices to control alignment and depth.

(d) Joint sealing. Furnish sealing equipment according to the sealant manufacturer’s recommendations.

501.05 Production Start-Up Procedures. Conduct a pre-minor concrete pavement preparatory phase meeting according to Subsection 153.04(a).

501.06 Surface Preparation and Setting Forms. Prepare the roadbed surface according to Section 301.

Maintain the surface to avoid the development of loose and uncompacted material.

Set and align forms to the plan dimensions and elevations. Securely brace forms so they will not bulge or warp during concrete placement. Apply form release agent or form oil to the inside form faces. Align forms to the dimensions and elevations in the plans and assure there is no bulging or warping.

Check and correct roadbed surface deformations and rutting exceeding ½ inch (13 millimeters) and uniformly dampen the surface before placing concrete.

501.07 Placing Concrete. At least 14 days before the start of concrete placement operations, arrange a pre-paving conference. Coordinate attendance with the CO and applicable subcontractors. Submit and be prepared to discuss the following:

(a) Proposed pour sequence and placement schedule;

(b) Approved concrete mix design;

(c) Contractor quality control plan;

(d) Equipment, batching, mixing, placing, and curing requirements;

(e) Subsections 106.03 and 106.04;

(f) Jointing plan, joint forming or sawing operations, rain protection plan, hot and cold weather paving plan, and opening to traffic requirements; and

(g) Traffic control plan.

Conform to Subsections 552.04 through 552.08 and 552.10 for weather limitations, handling, storing, batching, and mixing material and delivering concrete.

Deposit concrete between the forms to a uniform height. Consolidate concrete to remove voids and air pockets. Do not move concrete horizontally with vibrators.

Strike off and place concrete with a form-riding paving machine or manual fixed form paving equipment.

In irregular areas where a paving machine is impractical, place concrete using templates, screeds, or other methods approved by the CO.

Carry a slight excess of concrete in front of the leading edge of the template or screed. After strikeoff and before bleed water appears on the surface, float to the required grade and cross-section. Finish the concrete pavement to minus ¼ inch (6 millimeters) or plus ⅜ inch (10 millimeters) of the thickness required.

When concrete is placed adjoining a previously-constructed lane of pavement, do not operate mechanical equipment on the existing lane until the lane has attained:

• A minimum flexural strength of 450 pounds per square inch (3.1 megapascals) according to AASHTO T 23 and AASHTO T 97; or

• A compressive strength of 3,000 pounds per square inch (21 megapascals) according to AASHTO T 22 and AASHTO T 23.

When required, place reinforcing steel according to Section 554. If placing rebar before placing concrete, position the rebar on acceptable supports. If placing rebar after placing concrete, mechanically insert the rebar to the required depth. Reinforcing bars and steel supports are to be epoxy-coated. Keep epoxy-coated reinforcing steel free of damage and distortion. Steel wire fabric and mats are not required to be epoxy-coated.

When rain is threatening during paving operations, stop paving operations and protect the concrete pavement from rain with plastic sheeting or other methods approved by the CO. Remove, replace, or repair pavement damaged by rain or hail as directed by the CO at no cost to the Government.

501.08 Joints. Construct joints at locations and dimensions indicated in the plans. If jointing locations are not indicated in the plans, submit a jointing plan according to Subsection 104.03. Indicate locations of contraction, construction, and isolation joints.

Do not vary longitudinal joints more than ½ inch (13 millimeters) and transverse joints more than ¼ inch (6 millimeters) from true alignment. When curbs or medians are constructed integral with the pavement, construct transverse joints continuous through the curb or median. Clean joints of deleterious material, including concrete slurry, and protect the joints until sealed.

(a) Longitudinal joints. Construct longitudinal construction joints by using steel fixed forms and a keyway along the joint.

Where required, place deformed steel tie bars perpendicular to the longitudinal joints with mechanical equipment or rigidly secured chairs without damaging or disrupting the concrete. Along longitudinal construction joints, tie bars may be bent at right angles against the form of the first lane constructed and straightened into final position before placing concrete in the adjacent lane. Repair or replace broken or damaged tie bars.

Threaded hook bolts may be used instead of tie bars. Fasten hook bolts to the form of the longitudinal construction joint.

Construct joints as follows:

(1) Formed joints. Form joints with an approved nonmetallic or removable device while the concrete is plastic, but set sufficiently to maintain the formed joint. When adjacent lanes are constructed separately, form the sealant reservoir in the lane placed last.

(2) Sawed joints. After placing concrete, saw joints approximately ⅛ inch (3 millimeters) wide as soon as equipment can be supported and before uncontrolled cracking occurs. Do not ravel the joints while sawing. Saw longitudinal joints immediately after sawing transverse joints. Protect the sawed concrete faces from drying during the curing period. Saw sealant reservoirs no sooner than 72 hours after placing the concrete.

If necessary, continue sawing day and night, regardless of weather conditions.

Do not saw a joint if a crack occurs at or near the joint location before sawing. Discontinue sawing when a crack develops ahead of the saw.

Remove and replace newly-placed concrete pavement where uncontrolled cracking occurs. Dowel and tie replacement pavement to adjacent pavement as specified.

(b) Transverse contraction joints. When required, construct contraction joints according to Subsection 501.08(a)(1) or (a)(2).

Where required, place dowel bars through and centered on traverse joints and in the middle of the slab depth. Align and hold dowels parallel to the surface and centerline of the slab by a metal assembly that remains in the pavement and is rigidly secured to the base or subgrade using stakes or nails. Limit deviations from parallel to ¼ inch (6 millimeters) in the length of the dowel bar. Assure proper alignment of joint and dowel bar assemblies.

Coat each dowel bar with an approved bond breaker. Limit bond breaker coating thickness to 15 mils (380 micrometers).

Concrete edges adjacent to the joint may be rounded or beveled to a radius no greater than ¼ inch (6 millimeters) or as approved. Resaw or grind joints having an insufficient opening. Where a joint is larger than required, furnish a larger size joint seal as approved.

(c) Transverse construction joints. Construct transverse construction joints only at locations specified, at the end of each work shift, or when concrete placement is interrupted for more than 30 minutes. If necessary, remove and dispose of the excess concrete to the last preceding joint.

When required, install dowel bars in transverse construction joints according to Subsection 501.08(b).

Use a metal or wooden bulkhead to form the joint, shaped to the pavement cross-section and designed to permit the installation of dowel bars.

(d) Isolation joints. Form isolation joints around manholes, utility boxes, foundations, other fixed objects, or as indicated in the plans. Place a ½-inch (13-millimeter) pre-formed joint filler continuously around or along each structure that extends into or through the pavement before concrete is placed.

After the concrete hardens, recess the joint filler about ¾ inch (19 millimeters) to allow a reservoir for sealant.

When required, place steel wire fabric at the location and orientation specified. Use metal or plastic chairs or other methods approved by the CO to support the steel wire fabric.

501.09 Surface Finishing. Protect the surface from rain damage.

After floating, check the surface of the fresh concrete with a 10-foot (3-meter) straightedge. Remove high areas indicated by the straightedge. Lap each successive check with the straightedge 5 feet (1.5 meters) over the previous check path.

Before the concrete has initially set, work the pavement edges on each side of isolation joints, formed joints, transverse and longitudinal construction joints, and emergency construction joints to produce a ¼ inch (6 millimeters) or less continuous radius and a smooth, dense mortar finish. Do not use mortar buildup to round edges.

As soon as excess moisture has disappeared and while the concrete is still plastic enough to make a granular surface possible, texture the surface to produce a skid resistant surface. Use the method specified and conform to the following:

(a) Transverse tine finish. Drag two layers of moistened burlap along the pavement in the direction of paving without tearing or marring the surface. Following the burlap drag, use a tining comb to form grooves in the pavement surface. Space tines randomly ½ to ¾ inches (13 to 19 millimeters) apart.

Produce grooves that are 1/16 to 3/16 inches (1.6 to 5 millimeters) wide and ⅛ to 3/16 (3 to 5 millimeters) inches deep. Tine perpendicular to the centerline without tearing the concrete surface or loosening surface aggregate.

(b) Broom finish. Broom the surface with a steel or stiff-bristled fiber broom to produce corrugations between 1/16 and ⅛ inch (1.6 to 3 millimeters) deep. Broom perpendicular to the centerline from edge to edge with adjacent strokes slightly overlapped. Use the same type and manufacture of broom for all paved surfaces to provide a consistent appearance.

(c) Exposed aggregate finish. Broom the surface. Use stiff brushes approved by the CO. Exercise care to prevent marring of the surface and cracking or chipping of slab edges or joints. If approved by the CO, apply a light spray of retardant to the unfinished surface to facilitate this work.

Broom transversely across the pavement. Pull the loosened semi-stiff mortar off the pavement.

Remove the mortar from adjacent pavement. Broom parallel to the centerline. Continue this operation until a sufficient quantity of coarse aggregate is exposed. Other methods of aggregate exposure will be permitted if satisfactory results are demonstrated.

After curing, wash the surface with water and brush to remove laitance and cement from the exposed coarse aggregate.

501.10 Curing. Immediately after finishing and when marring will not occur; cure the surface and exposed sides of concrete for at least 72 hours. Do not leave the concrete exposed for more than 30 minutes during the curing period. Cure using one of the following methods:

(a) Water method. Cure according to Subsection 552.15(b). Cover the entire surface of the pavement and edges of the slab with water saturated mats. Extend the mats at least twice the thickness of the pavement beyond the edges of the slab. Place the mats in complete contact with the surface. Use weights or other approved methods to maintain contact; or

(b) Liquid membrane curing compound method. Cure according to Subsection 552.15(c).

Remove forms when the concrete has hardened sufficiently to resist damage, but no earlier than 12 hours after placing concrete. Protect the sides of the exposed slabs with a curing method equal to that provided for the surface. Prevent erosion of the base course beneath the exposed pavement edges until shoulders are constructed.

501.11 Sealing Joints. Saw cut and seal joints before the pavement is opened to construction or public traffic.

Where sealant reservoirs are required, clean each sealant reservoir of foreign material including membrane curing compound and concrete slurry. Blow dry joints with moisture free compressed air. Do not apply sealing material unless the joint faces are clean and surface dry, and the joint is free of incompressibles.

Use preformed joint seals, silicone sealant, or hot-poured sealant for isolation joints. Use silicone or hot-poured sealants for longitudinal and transverse contraction joints.

(a) Silicone or hot-poured sealants. Install backer rod with a steel wheel to the depth required. Do not stretch or twist the backer rod during installation. Limit the length of backer rod installed to that which can be sealed during the same workday.

Place joint sealing material when the air temperature is over 40 °F (4 °C) or as specified by the manufacturer. Remove excess or spilled material and clean the pavement surface. Do not use sand or similar material to cover the seal. For sealants that are not self-leveling, tool the surface of the sealant to the dimensions required in the plans.

(b) Preformed joint seals. Furnish the seal in one piece in the size specified for the joint opening.

Install seals with a lubricant adhesive covering both sides of the joint. Compress the seal to between 20 and 50 percent of its nominal width or as specified by the manufacturer. Install the top of the seal about ¼ inch (6 millimeters) below the pavement surface.

Remove and replace seals that are damaged, twisted, improperly positioned, or stretched more than 3 percent.

501.12 Pavement Straightedge Measurement. Measure the pavement surface after the concrete has cured. Use a 10-foot (3-meter) metal straightedge to measure at right angles and parallel to the centerline.

Defective areas are deviations between the surface and the bottom of the straightedge in excess of ¼ inches (6 millimeters), measured between two contacts of the straightedge, or deviations in excess of ¼ inches (6 millimeters) measured at the end of the straightedge.

Correct defective areas by diamond grinding, slab removal, or other methods approved by the CO.

501.13 Opening to Traffic. Do not allow traffic on new concrete pavement earlier than 14 days after concrete placement unless concrete tests indicate one of the following conditions is obtained:

(a) Flexural strength of 550 pounds per square inch (4 megapascals) according to AASHTO T 97; or

(b) Compressive strength of 4000 pounds per square inch (28 megapascals) according to

AASHTO T 22.

Do not allow traffic on the pavement when joint sealant is tacky and traffic debris would imbed into the sealant.

501.14 Acceptance. See Table 501-2 for sampling, testing, and acceptance requirements.

Material for minor concrete pavement will be evaluated under Section 601.

The concrete mixture's slump, air content, density, temperature, and compressive strength will be evaluated under Subsections 106.02 and 106.04.

Construction of concrete pavement will be evaluated under Subsections 106.02 and 106.04.

Pavement straight edge will be evaluated under Subsection 106.04.

Measurement

501.15 Measure the Section 501 pay items listed in the bid schedule according to Subsection 109.02 and the following as applicable:

When measuring concrete pavement by the square yard (square meter), measure the length horizontally along the centerline of the roadway. Measure the width including allowable curve widening.

Payment

501.16 The accepted quantities will be paid at the contract price per unit of measurement for the Section 501 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05.

Table 501-2 Sampling, Testing, and Acceptance Requirements

Material or Product

(Subsection)

Type of Acceptance (Subsection)

Characteristic Category Test Methods Specifications

Sampling Frequency

Point of Sampling

Split Sample

Reporting Time

Remarks

Source Aggregate

(703.01 & 703.02)

Measured and tested for conformance (106.04 & 105)

Quality − AASHTO M 80 M 6

M 43

1 per material type

Source of material

Yes 14 days before paving

Mix Design Concrete composition (501.03)

Measured and tested for conformance (106.04 & 105)

All − Subsection 501.03

1 per mix design

Source of material

Yes 14 days before paving

Table 501-2 (continued) Sampling, Testing, and Acceptance Requirements

Material or Product

(Subsection)

Type of Acceptance (Subsection)

Characteristic Category Test Methods Specifications

Sampling Frequency

Point of Sampling

Split Sample

Reporting Time

Remarks

Production Concrete Measured and tested for conformance

(106.04)

Density − AASHTO T 121

1 per load (2)

Point of discharge (3)

No Upon completing tests

Air content − AASHTO T 152 or T 196

Slump − AASHTO T 119

Temperature − Field measured " " " " − Compressive strength (1)(4)

− AASHTO

T 23 & T 22

1 set per 200 yd2

(170 m2), but not less than 1 set per day

" See Note (4)

" Deliver verification cylinders to the CO or designated location in time for 28-day break

Aggregate (coarse & fine)

Process control

(153.03)

Gradation − AASHTO T 27 & T 11

1 per day min

Bin discharge, conveyor belt, or stockpile

No Before batching

Moisture − AASHTO T 255

Concrete " Surface tolerance

− Straightedge measurements

Subsection 501.07

Subsection 501.07

Concrete surface, after floating

" While concrete is still workable

Table 501-2 (continued) Sampling, Testing, and Acceptance Requirements

Material or Product

(Subsection)

Type of Acceptance (Subsection)

Characteristic Category Test Methods Specifications

Sampling Frequency

Point of Sampling

Split Sample

Reporting Time

Remarks

Finished Roadway Concrete pavement

Measured and tested for conformance (106.04)

Surface tolerance

− Straightedge measurements

Subsection 501.12

Successively, after concrete has hardened

Finished pavement surface

No 24 hours

Pavement thickness

− AASHTO

T 148

" " " " When directed by the CO

(1) A single compressive strength test result is the average result from two 6 by 12 inch (150 by 300 millimeter) or three 4 by 8 inch (100 by 200 millimeter) cylinders cast from the same load and tested at 28 days.

(2) This frequency may be reduced by the CO if produced material proves to be consistent.

(3) Sample according to AASHTO R 60, except composite samples are not required.

(4) Make at least four 6 by 12 inch (150 by 300 millimeter) or six 4 by 8 inch (100 by 200 millimeter) compressive strength test cylinders and carefully transport the cylinders to the project curing facility. Two or three cylinders will be used for 28-day compressive strength tests. The remaining cylinders will be used by the CO for verification testing or other designated purposes.

Section 502

Section 502. — CONCRETE PAVEMENT RESTORATION

Description

502.01 This work consists of concrete pavement restoration. Concrete pavement restoration includes full depth patching, partial-depth patching, pavement jacking, subsealing, surface grinding, crack and joint repair, and cleaning.

Material

502.02 Conform to the following Section and Subsections:

Epoxy resin adhesive 725.18 Latex modifier 711.04 Minor concrete pavement 501 Nonshrink grout 725.13(b) Polymer concrete and mortar 725.14 Reinforcing steel 709.01

502.03 Composition of Mix (Concrete Mix Design). Design the concrete mix according to Subsection 501.03.

502.04 Equipment. Furnish equipment conforming to the following:

(a) Waterblaster. Furnish a high-pressure water jet machine with at least 2500 pounds per square inch (17.5 megapascals) pressure and is capable of removing residual sealant, oil, or other foreign material in joints.

(b) Air compressors. Furnish air compressors with a minimum nozzle pressure of 100 pounds per square inch (700 kilopascals) and capable of dislodging loose debris and drying joints and cracks.

(c) Grout plant. Furnish a grout plant which consists of a positive displacement cement injection pump and a high-speed colloidal mill. Operate colloidal mill at speeds necessary to make a homogeneous mixture.

Furnish an injection pump having a pressure capability of 275±25 pounds per square inch (1900±170 kilopascals) when pumping a grout slurry mixed to a 12-second flow cone time and that continuously pumps at a minimum rate of 1.5 gallons (6.0 liters) per minute. The system may be modified by adding a recirculating hose and valve at the discharge end of the pump.

Produce grout through a meter or scale capable of measuring the total day's consumption. Furnish hoses and fittings to provide a positive seal during grout injection.

(d) Drills. Furnish drills that meet the following:

(1) Drills for pavement jacking. Furnish rock drills capable of drilling straight, minimum 1½-inch (38-millimeter) diameter holes through the concrete slab, steel reinforcement, and base material. Furnish rock drills weighing less than 60 pounds (27 kilograms) that are capable of drilling with a downward pressure of less than 200 pounds (90 kilograms). Furnish an auger to open clogged holes and existing pavement jacking holes.

(2) Drills for dowels and tie bars. Furnish drills capable of drilling specified hole diameters for dowel bars or reinforcing steel tie bars. Drills for dowel bars must be capable of drilling holes that meet the vertical and horizontal tolerance of ±¼ inch (±6 millimeters) along the centerline of the dowel with respect to a horizontal line that is perpendicular to the plane established by the joint.

(e) Surface diamond grinder. Furnish power driven, self-propelled grinding equipment, specifically designed to smooth and texture concrete pavement with diamond blades. Furnish equipment that:

(1) Cuts or planes at least 36 inches (900 millimeters) in width;

(2) Does not encroach on traffic movement outside of the work area; and

(3) Grinds the surface without spalling.

(f) Hydroblaster. Provide hydroblasting equipment conforming to Subsection 560.05.

(g) Cold planing (milling) machine. Provide a milling machine, with a micromilling head that does not exceed the bearing capacity of the concrete pavement and that conforms to Subsection 413.02(a).

(h) Slab stabilization testing. Furnish the following testing equipment:

(1) A 2-axle truck with dual rear wheels. Load the rear axle to 18 kips (80 kilonewtons) evenly distributed between the 2 wheel paths;

(2) Static load measuring gauges consisting of 4 gauges on 2 gauge mounts, 2 gauges per mount, capable of detecting slab movement under load; and

(3) A modified Benkelman beam or similar approved device.

502.05 Partial-Depth Patching (less than 4 inches (100 millimeters) in depth). This work consists of patching spalls, potholes, corner breaks, or other surface distresses in concrete pavement.

(a) Patch material. Use a polymer concrete for patches less than or equal to 1½ inches (38 millimeters) deep. Use hydraulic cement concrete designed and approved according to Subsection 501.03 for patches greater than 1½ inches (38 millimeters) deep.

(b) Patch area preparation. Extend the limits of repair at least 4 inches (100 millimeters) outside the deteriorated area. Saw vertically along the perimeter of the patch area, parallel to the existing joint, and to a minimum depth of 1½ inches (38 millimeters). Near vertical edges from milling or grinding machines are acceptable. Repair saw overcuts and nicks to adjacent pavement outside the perimeter of the repair area with noncorrosive, non-shrink grout.

Break out concrete within the patch area to a minimum depth of 1½ inches (38 millimeters) to expose sound concrete. Sandblast exposed concrete faces clean of loose particles, oil, dust, traces of asphalt concrete, and other contaminants before patching.

Remove non-concrete shoulders adjacent to the patch longitudinally to the depth of the patch and to a maximum width of 12 inches (300 millimeters) to facilitate placing form work.

Dispose of the concrete according to Subsection 203.05.

(c) Placing concrete. Remove sandblasting residue immediately before placing the epoxy resin adhesive. Apply an epoxy resin adhesive according to the manufacturer’s recommendations. Delay concrete placement until the epoxy becomes tacky.

Place and consolidate the concrete to eliminate voids at the interface of the patch and existing concrete. Place and consolidate hydraulic cement concrete according to Subsection 501.07. Place and consolidate polymer concrete according to climate conditions and methods recommended by the manufacturer.

(d) Joints. If a repair area abuts a working joint, repair the joint similar to the existing joint to maintain a working joint. Form a new joint to the same width as the existing joint. Use compressible joint filler material as inserts to prevent intrusion of the repair material into the joint. Seal the joint according to Subsection 502.08.

(e) Finishing and coloring concrete. Finish patches according to Subsection 501.09 to match the plane and texture of the contiguous pavement. Cure hydraulic cement concrete according to Subsection 501.10. Cure polymer concrete as recommended by the manufacturer.

When colored concrete is required, begin concrete pavement restoration work after colored test panels submitted according to Subsection 501.03 are approved.

Restore and compact shoulders with material similar to the existing shoulder.

502.06 Full Depth Patching (welded wire reinforced, jointed, plain doweled, or plain concrete pavement). This work consists of removing existing concrete pavement the full depth and replacing with new concrete. Begin pavement patch work after the concrete mix design has been approved according to Subsection 501.03.

(a) Concrete removal. Saw cut slabs full depth leaving vertical edges at the limits of the patch.

Prevent adjacent concrete slabs from being damaged.

Remove the concrete by lifting the slab in one or more pieces without disturbing the underlying surface. Clean out the area with hand tools. Dispose of the concrete according to Subsection 203.05.

When required, excavate the underlying material to a maximum depth of 12 inches (300 millimeters) and replace with aggregate base according to Section 302. Prevent adjacent concrete slabs from being undermined.

Remove and replace adjacent slabs damaged by concrete removal. Repair spalls using partial-depth patching methods according to Subsection 502.05.

Repair saw overcuts of repair areas and nicks to adjacent pavement outside the perimeter of the repair area with nonshrink grout.

(b) Joints. Construct joints according to Subsection 501.08 and the following:

Install dowels, tie bars, or both into existing concrete pavement slabs as shown in the plans. Drill dowel or tie bar holes into the face of the existing concrete at the required diameter, length, and spacing using a drill according to Subsection 502.04(d)(2). Clean and dry the holes before installing the dowels or tie bars. Use an epoxy resin to permanently anchor the dowel or tie bar into the existing concrete. Place the epoxy resin starting from the back of the hole and use a sufficient quantity to insure the epoxy material will be forced up and around the dowel or tie bar after insertion. Place a thin, donut-shaped grout retention disk around the dowel or tie bar and up against the face of the existing concrete to prevent epoxy resin material from flowing out of the hole.

Seal joints according to Subsection 501.11.

(c) Welded wire reinforcement. When required, provide 4- by 4-inch (100- by 100-millimeter), W6 by W6 (M15 by M15) steel welded wire reinforcement for crack control. Support welded wire fabric on chairs or bolsters.

(d) Concrete placement. Compact base and subgrade material within the patch area according to Subsection 302.05. Construct side forms to overlap the ends of the existing slab. Securely fasten side forms so they do not move when concrete is placed. To accommodate forms for the patch, excavate the adjacent shoulders a maximum width of 12 inches (300 millimeters). Place concrete according to Subsection 501.07.

Cast each patch in one continuous full-depth operation. After removal of the forms, backfill, compact, and return the excavated shoulder area to its previous condition.

(e) Finishing and coloring concrete. Finish patches according to Subsection 502.05(e).

502.07 Resealing Joints and Crack Repair. This work consists of repairing or resealing joints and cracks in existing concrete pavement.

(a) Preparation of joints and cracks. Limit the length of joints and cracks prepared to that which can be resealed within the same shift. Do not damage joints or previously repaired patches.

Remove existing sealant with a waterblaster, router, concrete saw, or other method approved by the

CO.

Remove old sealant from the crack faces to expose new, clean concrete. When the crack widths vary and the crack faces are raveling and irregular, cut a crack reservoir to a depth of ¾ inch (19 millimeters).

Thoroughly clean the joint or crack of foreign material by sandblasting, waterblasting, or with a mechanical wire brush. Repeat the process until a new, clean concrete face is exposed. Dry the joint with compressed air.

Use sawing if other methods do not properly clean the joint. Limit sawing to exposing clean, new, concrete faces in the joint with a maximum allowable cut of ⅛ inch (3 millimeters) on each face of the joint.

(b) Backer rod. Install the backer rod to the required depth after the joints and cracks are clean and dry. Do not stretch or twist the backer rod during installation. Limit the length of backer rod installed to that which can be sealed during the same shift.

(c) Sealant application. Seal joints and cracks immediately after placing the backer rod. Apply sealant at air and surface temperatures recommended by the sealant manufacturer. Comply with installation recommendations provided by the sealant manufacturer. If the joint or crack becomes contaminated or damp, remove the backer rod, clean and dry the joint or crack, and reinstall a new backer rod before placing the sealant. For a non-self-leveling joint sealant, tool the sealant immediately after application to provide firm contact with the joint faces and to form the required recess below the slab surface.

502.08 Pavement Jacking. This work consists of raising and supporting the concrete pavement to the specified grade tolerances by drilling and injecting non-shrink hydraulic cement grout.

(a) Drilling holes. Determine a pattern for grout injection holes and submit for approval. Drill vertical holes less than 2 inches (50 millimeters) in diameter.

(b) Jacking. Establish string lines from the pavement high points to monitor slab movement. Lower an expanding rubber packer or hose into the holes. Provide a positive seal and connected to the discharge hose on the grout plant. Do not allow the discharge end of the packer or hose to extend below the bottom of the concrete pavement.

Allow pumping to raise the pavement to within ⅛ inch (3 millimeters) of the string line grade when jacking continuously-reinforced concrete pavement. Allow pumping to raise the pavement to within ¼ inch (6 millimeters) of the transverse and longitudinal grades when jacking jointed pavement and bridge approach slabs.

Continuous jacking pressures to 200 pounds per square inch (1.4 megapascals) are permitted. Use pressures to 300 pounds per square inch (2.1 megapascals) only for short periods of 30 seconds or less. If the pavement is bonded to the subbase, brief pressure rises of 10 seconds or less to 600 pounds per square inch (4.1 megapascals) may be allowed. Stop pumping if grout extrudes through cracks, joints, or shoulders. Discontinue pumping if back pressure in the hose exceeds 600 pounds per square inch (4.1 megapascals).

(c) Overjacking. Grind pavement raised above the specified tolerances to grade. Remove and replace the pavement according to Subsection 502.06 if the overjacking is greater than 1 inch (25 millimeters).

(d) Cracks. Radial cracks from the grout injection holes will be considered caused by improper injection technique. Remove and replace the slab or a portion of the slab with more than 10 feet (3 meters) of new cracks according to Subsection 502.06. For slabs with less than 10 feet (3 meters) of new cracks, seal cracks according to Subsection 502.07.

(e) Hole patching. After completing the jacking and the hole plugs are removed, fill drill holes flush with the pavement surface with a nonshrink grout or epoxy mortar.

502.09 Undersealing and Slab Stabilization. This work consists of pumping a nonshrink grout mixture through holes drilled in the pavement into voids underneath the slabs to stabilize and underseal concrete pavement.

(a) Preliminary testing. Perform testing at night or when there is no evidence of slab lock-up due to thermal expansion. Testing may be allowed to continue if the slabs are not interlocked or under compression. Furnish testing equipment as provided in Subsection 502.04(h). Test each designated slab using a static method as follows:

(1) Position one set of gauges with one gauge referenced to the corner of each slab on both sides of the joint near the pavement edge;

(2) Set the gauges to zero with no load on the slab on either side of the joint;

(3) Move the test truck into position and stop with the center of the test axle 12 inches (300 millimeters) behind the joint and the outside test wheel 12 inches (300 millimeters) from the pavement edge. Read the back gauge;

(4) Move the test truck across the joint to a similar position 12 inches (300 millimeters) forward from the joint and stop. Read the forward gauge; and

(5) Repeat for each joint to be tested. Underseal slabs with a deflection of more than 1/32 inch (0.08 millimeters).

(b) Drilling holes. Drill holes using the required hole pattern. An altered hole pattern may be approved based on field conditions. Drill vertical holes less than 2 inches (50 millimeters) in diameter to provide a positive seal for the pumping nozzle. For the first undersealing, drill holes to a depth that penetrates into unbound base or subgrade. Avoid penetrating the subgrade by more than 3 inches (75 millimeters).

(c) Cleaning holes. After the holes are drilled and before pumping the underseal grout, clean the hole with compressed air to remove debris and provide a passage for the grout.

(d) Pumping underseal grout. Pump nonshrink grout in each hole. Seal the nozzle of the discharge hose in the hole to maintain the nonshrink grout pressure underneath the slab. Do not allow the nozzle end to extend below the bottom of the concrete. Monitor slab lift according to Subsection

502.08. Limit upward movement of the pavement to ⅛ inch (3 millimeters).

Continue pumping into a hole until grout flows out other holes, joints, or cracks, or until the slab begins to lift. Stop grouting if there is lift in the slab or the adjacent shoulder.

During stabilization operations, limit continuous pumping pressures to 125 pounds per square inch (0.9 megapascals). Allow a short pressure surge of up to 300 pounds per square inch (2 megapascals) when starting to pump grout into the hole to ensure grout penetrates the void structure. Do not plug other holes while grouting.

Grind pavement raised more than the ⅛ inch (3 millimeters).

(e) Cracks. If cracks develop, complete the required repairs according to Subsection 502.07.

(f) Hole patching. See Subsection 502.08(e).

(g) Stability testing. Test for stability 24 hours after designated slabs have been undersealed according to Subsection 502.09 (a). Complete a second underseal operation on slabs that continues to show excess movement. Submit the number, depth and location of holes for the second undersealing for approval. The CO may accept or direct replacement of slabs that continues to show movement in excess of that specified after undersealing twice. Remove and replace designated slabs according to Subsection 502.06.

502.10 Surface Diamond Grinding. This work consists of grinding existing concrete pavement to eliminate joint or crack faults and providing positive lateral drainage. Uniformly transition auxiliary or ramp lane grinding from the mainline edge to provide positive drainage and an acceptable riding surface.

Provide a grinding unit conforming to the requirements of Subsection 502.04(e).

Produce a pavement surface that is true to grade, smooth, and consisting of a longitudinal corduroy-type texture. Produce grooves between 0.08 and 0.15 inches (2 to 4 millimeters) wide. Produce a surface area between the grooves between 0.065 and 0.125 inches (1.7 to 3.5 millimeters) wide. Produce peak ridges approximately 1/16 inch (1.6 millimeters) higher than the grooves. Adjust blade spacing to achieve the specified texture. Establish a positive and immediate means for removal of grinding residue. Remove and dispose of solid residue from the pavement surfaces before it is blown by traffic action or wind. Do not allow residue to flow into gutters or drainage facilities.

Test the ground pavement surfaces for pavement roughness according to Subsection 501.12. Limit misalignment of surface planes on adjacent sides of the joints or cracks and between each grinding pass to less than 1/16 inch (1.6 millimeters). Produce a transverse slope of the pavement with no depressions or slope misalignment greater than ¼ inch in 10 feet (6 millimeters in 3 meters) tested perpendicular to the centerline. Straightedge requirements do not apply across longitudinal joints or outside of ground areas.

502.11 Concrete Cleaning. This work consists of cleaning the existing concrete pavement surface with a high pressure washing device approved by the CO. Remove dust, dirt, oil, and other foreign material (including the existing crack sealant material) without causing damage to the surface or exposing coarse aggregate.

Vacuum the concrete surface to remove and collect water and debris after the pavement cleaning.

Dispose of the water and debris at a site approved by the CO.

502.12 Opening to Traffic. Do not allow traffic on restored pavement until the concrete has a compressive strength of 4000 pounds per square inch (28 megapascals) when tested according to AASHTO T 22 or until the grout used for jacking or undersealing the pavement has attained 600 pounds per square inch (4 megapascals) when tested with a 0.25 square inch (64 square millimeters) probe according to AASHTO T 197. As an alternative method of determining the compressive strength of the restored pavement; in situ compressive strength can be measured by developing a strength-maturity relationship of the approved concrete mixture according to AASHTO T 325. Submit the strength-maturity relationship for approval at least 14 days before production. Provide a concrete maturity meter during the test placement and production that meets the following:

(a) Conforms to AASHTO T 325;

(b) Rugged, waterproof, and can withstand the construction environment;

(c) Able to operate without an external power source for at least 14 days;

(d) Able to collect and store temperature and maturity data for at least 14 days; and

(e) Able to determine equivalent maturity hours according to the Arrhenius function.

Do not allow traffic on sealed joints when the sealant is tacky and traffic debris embeds into the sealant.

502.13 Acceptance. See Table 502-1 for sampling, testing, and acceptance requirements.

Material for concrete pavement restoration will be evaluated under Subsections 106.02 and 106.03.

Furnish a production certification with each shipment of hydraulic cement.

The concrete mixture's slump, air content, density, temperature, and compressive strength will be evaluated under Subsections 106.02 and 106.04.

Grout will be evaluated under Subsections 106.02 and 106.03.

Construction (including batching, placing, finishing, and curing) of the concrete will be evaluated under Subsections 106.02 and 106.04.

Concrete pavement restoration work (including partial-depth patching, pavement jacking, subsealing, surface grinding, crack and joint repair, cleaning, and breaking and seating will be evaluated under Subsections 106.02 and 106.04.

Measurement

502.14 Measure the Section 502 pay items listed in the bid schedule according to Subsection 109.02 and the following as applicable:

When measuring grout for pavement jacking and undersealing by the cubic foot (cubic meter), measure by metering.

Measure aggregate base under Section 302.

Payment

502.15 The accepted quantities will be paid at the contract price per unit of measurement for the Section 502 pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section. See Subsection 109.05.

Table 502-1 Sampling, Testing, and Acceptance Requirements

Material or Product

(Subsection)

Type of Acceptance (Subsection)

Characteristic Category Test Methods Specifications

Sampling Frequency

Point of Sampling

Split Sample

Reporting Time

Remarks

Source Aggregate

(703.01 & 703.02)

Measured and tested for conformance (106.04 & 105)

Quality − AASHTO M 80, M 6, & M 43

1 per material type

Source of material

Yes 14 days before paving

Mix Design Concrete composition (501.03)

Measured and tested for conformance (106.04 & 105)

All − Subsection 501.03

1 per mix design

Source of material

Yes 14 days before paving

Production Concrete Measured and tested for conformance

(106.04)

Density − AASHTO T 121

1 per load (2)

Point of discharge (3)

No Upon completing tests

Air content − AASHTO T 152 or T 196

Slump − AASHTO T 119

Temperature − Field measured " " " " −

Table 502-1 (continued) Sampling, Testing, and Acceptance Requirements

Material or Product

(Subsection)

Type of Acceptance (Subsection)

Characteristic Category Test Methods Specifications

Sampling Frequency

Point of Sampling

Split Sample

Reporting Time

Remarks

Production (continued) Concrete Measured and tested for conformance

(106.04)

Compressive strength (1)(4)

− AASHTO

T 23 & T 22

1 set per 200 yd2

(170 m2), but not less than 1 set per day

Point of discharge (3)

See Note (4)

" Deliver verification cylinders to the CO or designated location with in 28 days

Aggregate (coarse & fine)

Process control

(153.03)

Gradation − AASHTO T 27 & T 11

Minimum 1 per day

Bin discharge, conveyor belt, or stockpile

No Before batching

Moisture − AASHTO T 255 " " " " − Concrete " Surface tolerance − Straightedge measurements Subsection

501.12

Subsection 501.08

Concrete surface, after floating

" While concrete is still workable

Table 502-1 (continued) Sampling, Testing, and Acceptance Requirements

Material or Product

(Subsection)

Type of Acceptance (Subsection)

Characteristic Category Test Methods Specifications

Sampling Frequency

Point of Sampling

Split Sample

Reporting Time

Remarks

Finished Product Concrete pavement

Measured and tested for conformance (106.04)

Surface tolerance

− Straightedge measurements

Subsection 501.12

Successively, after concrete has hardened

Finished pavement surface

No 24 hours

(1) A single compressive strength test result is the average result from two 6 by 12 inch (150 by 300 millimeter) or three 4 by 8 inch (100 by 200 millimeter) cylinders cast from the same load and tested at 28 days.

(2) This frequency may be reduced by the CO if produced material proves to be consistent.

(3) Sample according to AASHTO R 60.

(4) Make at least four 6 by 12 inch (150 by 300 millimeter) or six 4 by 8 inch (100 by 200 millimeter)compressive strength test cylinders and carefully transport the cylinders to the project curing facility. Two or three cylinders will be used for 28-day compressive strength tests. The remaining cylinders will be used by the CO for verification testing or other designated purposes.