Attch 2e UFGS 32 01 19.61 Sealing of Joints in Rigid Pavement.pdf

SECTION 32 01 19.61 Page 1

SECTION 32 01 19.61

SEALING OF JOINTS IN RIGID PAVEMENT

11/19

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.

ASTM INTERNATIONAL (ASTM)

ASTM C603 (2014; R 2019) Standard Test Method for

Extrusion Rate and Application Life of Elastomeric Sealants

ASTM C639 (2015; R 2020)Standard Test Method for

Rheological (Flow) Properties of

ASTM C661 (2015) Indentation Hardness of

Elastomeric-Type Sealants by Means of a Durometer

ASTM C679 (2003; E 2009; R 2009) Tack-Free Time of

ASTM C719 (2014; R 2019) Standard Test Method for Adhesion and Cohesion of Elastomeric Joint Sealants Under Cyclic Movement (Hockman Cycle)

ASTM C792 (2015; R 2020) Effects of Heat Aging on

Weight Loss, Cracking, and Chalking of

ASTM C793 (2005; R 2017) Standard Test Method for

Effects of Laboratory Accelerated Weathering on Elastomeric Joint Sealants

ASTM C920 (2018) Standard Specification for

Elastomeric Joint Sealants

ASTM C1016 (2014) Standard Test Method for Determination of Water Absorption of Sealant Backing (Joint Filler) Material

ASTM C1193 (2013) Standard Guide for Use of Joint

Sealants

ASTM D412 (2016) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers - Tension

ASTM D789 (2015) Determination of Relative Viscosity and Moisture Content of Polyamide (PA)

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ASTM D903 (1998; R 2017) Standard Test Method for Peel or Stripping Strength of Adhesive Bonds

ASTM D5249 (2010; R 2016) Standard Specification for

Backer Material for Use with Cold-and Hot-Applied Joint Sealants in Portland-Cement Concrete and Asphalt Joints

ASTM D5329 (2016) Standard Test Methods for Sealants and Fillers, Hot-Applied, for Joints and Cracks in Asphalt Pavements and Portland Cement Concrete Pavements

ASTM D5893/D5893M (2016) Standard Specification for Cold

Applied, Single Component, Chemically Curing Silicone Joint Sealant for Portland Cement Concrete Pavements

ASTM D6690 (2015) Standard Specification for Joint and Crack Sealants, Hot Applied, for Concrete and Asphalt Pavements U.S.

ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 525 (1989) Corps of Engineers Test Method for

Evaluation of Hot-Applied Joint Sealants for Bubbling Due to Heating

1.2 SUBMITTALS

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

submittals not having a "G" designation are for information only. Submit the following in accordance with Contract Requirements:

SD-03 Product Data

Sealants, G

Submit catalog cuts, specifications, Safety Data Sheets and other information documenting conformance to Contract requirements.

Manufacturer's Recommendations

SD-04 Samples

Blocking Media/Backup Materials

Backer Rod

Bond Breaking Tapes

SD-06 Test Reports

Sealants

SD-07 Certificates

Equipment List

SD-08 Manufacturer's Instructions

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Sealants

Provide instructions that include, but not limited to: storage requirements, ambient temperature and humidity ranges, and moisture condition of joints for successful installation;

requirements for preparation of joints; safe heating temperature;

mixing instructions; installation equipment and procedures;

application and disposal requirements; compatibility of sealant with filler material; curing requirements; and restrictions to be adhered to in order to reduce hazards to personnel or to the environment. Submit instructions at least 30 days prior to use.

1.3 QUALITY ASSURANCE

1.3.1 Test Requirements

Test the sealant and backup or separating material for conformance with the referenced material specification. Perform testing of the materials in an approved independent laboratory and submit certified copies of the test reports for approval 14 days prior to the use of the materials at the job site. Submit samples to be retained by the Government for possible future testing if the materials appear defective during or after application. Conformance with the requirements of the laboratory tests specified does not constitute final acceptance of the materials. Base final acceptance on the performance of the in-place materials. Submit samples of the materials (sealant, primer if required, and backup material), in sufficient quantity for testing and approval 14 days prior to the beginning of work. Do not use material until it has been approved.

1.3.2 Trial Joint Sealant Installation

Prior to cleaning and sealing the joints for the entire project, prepare a test section at least 20 ft long using the specified materials and approved equipment, so as to demonstrate the proposed joint preparation and sealing of the types of joints in the project. Following the completion of the test section and before any other joint is sealed, inspect the test section to determine that the materials and installation meet the requirements specified. Inspect joint seal test section.

Correct deficiencies and obtain approval of test section prior to installing joint seals. If it is determined that the materials or installation do not meet the requirements, remove the materials, and reclean and reseal the joints at no cost to the Government. Permit the test section meeting the requirements to be incorporated into the permanent work and paid for at the Contract unit price per linear foot for sealing items scheduled. Prepare and seal other joints in the manner approved for sealing the test section. Notify the Contracting Officer upon completion of the test section.

1.4 DELIVERY, STORAGE, AND HANDLING

Inspect materials delivered to the site for visible damage, and unload and store with a minimum of handling. Deliver joint materials in original sealed containers and protect from freezing or overheating. Provide jobsite storage facilities capable of maintaining temperature ranges within manufacturers recommendations.

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1.5 ENVIRONMENTAL REQUIREMENTS

Do not proceed with work when weather conditions detrimentally affect the quality of cleaning joints or applying sealants. Proceed with joint preparation and sealing only when weather conditions are in accordance with manufacturer's instructions. Install joint sealant to dry surfaces and protect sealant and bond breakers from moisture.

1.6 TRAFFIC CONTROL

Do not permit vehicular or heavy equipment traffic on the pavement in the area of the joints being sealed during the protection and curing period of the sealant. Permit traffic on the pavement at the end of the curing period.

PART 2 PRODUCTS

2.1 SEALANTS

NOTE: Select joint sealants based on the proposed use and local experience. Specify ASTM D6690 (Type II or Type III) sealants for areas that do not receive fuel spillage, engine blast and heat exposure (i.e., areas where aircraft warm up the engines). Type III contains the requirements of Type II and has additional requirements for a water immersed bond test and an oven-aged resilience test. ASTM D6690 (Type II or Type III) sealants are normally used on roadways, vehicle parking lots, and on some aircraft taxiways. Test ASTM D6690 sealants in accordance with ASTM D5329 and COE CRD-C 525 in addition to the appropriate specification.

Permit ASTM D5893/D5893M sealants to be specified in place of ASTM D6690 sealants. ASTM D5893/D5893M covers silicone sealants that provide improved life-cycle cost benefits. Permit silicone sealant to be used for general purpose sealing and re-sealing of joints in concrete pavements not subject to severe jet fuel or lubricant spillage.

Silicone swells up under fuel spills. This may result in an unsatisfactory seal in aircraft or vehicle servicing areas where spillage is frequent.

Use materials for sealing cracks in accordance with ASTM D5893/D5893M.

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Use self leveling, non-acid curing silicone sealant meeting the following requirements in accordance with ASTM C920 or ASTM C1193:

TEST TEST METHOD REQUIREMENTS

Weight Loss ASTM (see

C792 Note

Modified 1 below)

10 percent max.

Flow ASTM C639 (Type I) Smooth and level

Extrusion Rate ASTM C603 30 sec. max.

Tack Free Time ASTM C679 5 hours max.

Hardness (Shore 00) (see Note 2 below)

ASTM C661 30 - 80

Tensile Stress at 150 Percent Elongation (see Note 2 below)

ASTM D412 (Die C) 30 psi max.

Percent Elongation (see Note 2 below)

ASTM D412 (Die C) 700 min.

Accelerated Weathering ASTM C793 Pass 5000 hours

Bond and Movement Capability ASTM C719 Pass 10 cycles at plus 50 percent movement (no adhesion or cohesion failure)

Peel ASTM D903 Minimum 20 psi of width with at least 75 percent cohesive failure

NOTES:

1. Percent weight loss of wet (uncured) sample after placing in forced-draft oven maintained at 70 degrees plus 2 degrees C 158 degrees plus 1 degree F for two hours.

2. Specimen cured 21 days at 23 degrees C plus 2 degrees C 73 degrees plus 1 degree F and 50 percent plus 5 percent humidity.

ACCELERATED WEATHERING FACTORY TEST REPORT. For the Accelerated Weathering test, in lieu of testing of actual sealant to be used on the project, it is permitted to submit a report of a factory test, performed within two years of Contract award.

2.2 PRIMERS

Use primers in accordance with the recommendation of the manufacturer.

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2.3 BOND BREAKERS

2.3.1 Blocking Media/Backup Materials

Provide backup (joint filler) material that is a compressible, nonshrinking, nonstaining, nonabsorbing, nonreactive material with the sealant. Use backup material compliant with ASTM D5249. Use material with a melting point at least 5 degrees F greater than the pouring temperature of the sealant being used when tested in accordance with ASTM D789. Use material with a water absorption of not more than 5 percent of the sample weight when tested in accordance with ASTM C1016. Use backup (joint filler) material that is 25 plus or minus 5 percent larger in diameter than the nominal width of the crack or joint. Use blocking media consistent with the sealant manufacturer's installation instructions.

2.3.2 Bond Breaking Tapes

Provide a bond breaking tape or separating material that is a flexible, nonshrinkable, nonabsorbing, nonstaining, and nonreacting adhesive-backed tape. Use material with a melting point at least 5 degrees F greater than the pouring temperature of the sealant being used when tested in accordance with ASTM D789. Use bond breaker tape approximately 1/8 in wider than the nominal width of the joint and that does not bond to the sealant. Use bond breaking tape shall be consistent with the sealant manufacturer's installation instructions.

PART 3 EXECUTION

3.1 EXECUTING EQUIPMENT

Submit equipment list and description of the equipment to be used and a statement from the supplier of the sealant that the proposed equipment is acceptable for installing the specified sealant. Use equipment for heating, mixing, and installing seals in accordance with the instructions provided by the sealant manufacturer. Provide equipment, tools, and accessories necessary to clean existing joints and install liquid joint sealants. Maintain machines, tools, and other equipment in proper working condition. Submit a list of proposed equipment to be used in performance of construction work including descriptive data, 14 days prior to use on the project.

3.1.1 Joint Cleaning Equipment

3.1.1.1 Tractor-Mounted Routing and Plowing Tool

Use routing tools for removing old sealant from the joints, of such shape and dimensions and so mounted on the tractor that do not damage the sides of the joints. Use tools designed to be adjusted to remove the old material to varying depths and widths as required. Use equipment capable of maintaining accurate cutting depth and width control. Use a joint plow equipped with a spring or hydraulic mechanism to release pressure on the tool prior to spalling the concrete. Do not permit the use of V-shaped tools or rotary impact routing devices. Permit the use of hand-operated spindle routing devices to clean and enlarge random cracks.

3.1.1.2 Concrete Saw

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

SECTION 32 01 19.61 Page 7 a clean joint, widening, or deepening existing joints as specified without damaging the sides, bottom, or top edge of joints. Permit single or gang type blades with one or more blades mounted in tandem for fast cutting.

Select saw adequately powered and sized to cut specified opening with not more than two passes of the saw through the joint.

3.1.1.3 Sandblasting Equipment

NOTE: Sandblasting equipment with a 6 mm 1/4 in nozzle requires at least 65 L per second 137 cubic ft per minute of air to function efficiently.

Include with the sandblasting equipment an air compressor, hose, and long-wearing venturi-type nozzle of proper size, shape and opening. Do not permit the maximum nozzle opening to exceed 6 mm 1/4 in. Use a portable air compressor capable of providing not less than 71 L/s 150 cfm and maintaining a line pressure of not less than 620 kPa 90 psi at the nozzle while in use. Demonstrate compressor capability, under job conditions, before approval. Use a compressor equipped with traps that maintain the compressed air free of oil and water. Use a nozzle with an adjustable guide that holds the nozzle aligned with the joint approximately 25 mm 1 in above the pavement surface. Adjust the height, angle of inclination and the size of the nozzle to secure satisfactory results.

3.1.1.4 Waterblasting Equipment

NOTE: Waterblasting equipment varies considerably with respect to design of wand, nozzle, water pressure, and water volume, depending upon the manufacturer. Consequently, the effectiveness of a

SECTION 32 01 19.61 Page 8 particular set of equipment cannot be predicted.

Delete this paragraph if waterblasting is not used.

Include with the waterblasting equipment a trailer-mounted water tank, pumps, high-pressure hose, wand with safety release cutoff control, nozzle, and auxiliary water resupply equipment. Provide water tank and auxiliary resupply equipment of sufficient capacity to permit continuous operations. Use a nozzle with an adjustable guide that holds the nozzle aligned with the joint approximately 1 in above the pavement surface.

Adjust the height, angle of inclination and the size of the nozzle to obtain satisfactory results. Use a pressure gauge mounted at the pump that shows the pressure in psi at which the equipment is operating.

3.1.1.5 Air Compressor

Use a portable air compressor capable of operating the sandblasting equipment and capable of blowing out sand, water, dust adhering to sidewalls of concrete, and other objectionable materials from the joints.

Use a compressor that provides air at a pressure not less than 90 psi and a minimum rate of 150 cubic ft of air per minute at the nozzles and free of oil.

3.1.1.6 Vacuum Sweeper

Use a self-propelled, vacuum pickup sweeper capable of completely removing loose sand, water, joint material, and debris from pavement surface.

3.1.1.7 Hand Tools

Permit the use of hand tools, such as brooms and chisels, when approved, for removing defective sealant from a crack and repairing or cleaning the crack faces.

3.1.2 Sealing Equipment

Use joint sealing equipment of a type required by the sealant manufacturer's installation instructions. Use equipment capable of installing sealant to the depths, widths and tolerances indicated. Do not proceed with joint sealing when malfunctions are noted until the malfunctions are corrected.

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3.1.2.1 Cold-Applied, Single-Component Sealing Equipment

Use equipment for installing ASTM D5893/D5893M single component joint sealants that consists of an extrusion pump, air compressor, following plate, hoses, and nozzle for transferring the sealant from the storage container into the joint opening. Use a nozzle with dimensions that allows the tip of the nozzle to extend into the joint to allow sealing from the bottom of the joint to the top.Maintain the initially approved equipment in good working condition, serviced in accordance with the supplier's instructions, and unaltered in any way without obtaining prior approval. Use lined hoses and seals to prevent moisture penetration and withstand pumping pressures. Use equipment free of contamination from previously used or other type sealant. Permit use of small hand-held air-powered equipment (i.e., caulking guns) for small applications.

3.2 SAFETY

Do not place sealant within 25 ft of LOX equipment, LOX storage, or LOX piping. Clean joints in this area and leave them unsealed.

3.3 PREPARATION OF JOINTS

Unless otherwise indicated, remove existing material, saw, clean and reseal joints. Do not proceed with final cleaning operations by more than one working day in advance of sealant. Clean joints by removing existing joint sealing compound, bond-breakers, dirt, laitance, curing compound, filler, and protrusions of hardened concrete from the sides and upper edges of the joint space to be sealed and other foreign material with the equipment. Do not permit cleaning procedures that damage joints or previously repaired patches by chipping or spalling. Remove existing sealant to the required depth. Precise shape and size of existing joints vary, and conditions of joint walls and edges vary and include but are not limited to rounding, square edges, sloping, chips, voids, depressions, and projections.

3.3.1 Existing Sealant Removal

Cut loose the in-place sealant from both joint faces and to the required depth, using the equipment as specified in the individual task order.

Provide a depth sufficient to accommodate blocking media and bond breakers that are required to maintain the depth of new sealant to be installed.

For expansion joints, remove existing sealant to a depth of not less than the indicated depth. When existing preformed expansion-joint material is more than 1 in below the surface of the pavement, remove existing sealant to the top of the preformed joint filler. Prior to further cleaning operations, remove loose old sealant remaining in the joint opening by blowing with compressed air. Permit use of hand tools to remove sealant from random cracks. Do not permit chipping, spalling, or other damage to the concrete. Clean pavement surface with vacuum sweeper. Protect previously cleaned joints from being contaminated by subsequent cleaning operations.

3.3.2 Sawing

3.3.2.1 Refacing of Joints

Accomplish refacing of joints using a concrete saw as specified in paragraph EQUIPMENT to remove residual old sealant and a minimum of concrete from the joint face to provide exposure of newly cleaned concrete, and, if required, to enlarge the joint opening to the width and depth required; or to saw through sawed and filler-type joints to loosen

SECTION 32 01 19.61 Page 10 and remove material until the joint is clean and open to the full specified width and depth. Provide exposure of newly clean concrete through removal. Remove burrs and irregularities from sides of joint faces. Stiffen the blade with a sufficient number of dummy (used) blades or washers. Clean, immediately following the sawing operation, the joint opening using a water jet to remove saw cuttings and debris and adjacent concrete surface. Protect adjacent previously cleaned joint spaces from receiving water and debris during the cleaning operation.

a. Joint Widening (Except Expansion Joints): Saw joints having grooves less than 3/8 in wide and less than 1 in deep to a minimum width of 3/8 in and to the minimum depth, 1 in.

3.3.2.2 Refacing of Random Cracks

Accomplish sawing of the cracks using a power-driven concrete saw as specified in paragraph EQUIPMENT. Use a saw blade 6 in or less in diameter to enable the saw to follow the trace of the crack. Stiffen the blade with dummy (or used) blades or washers. Immediately following the sawing operation, clean the crack opening using a water jet to remove saw cuttings and debris.

3.3.3 Final Cleaning of Joints

3.3.3.1 Sandblasting

Following removal of existing sealant, and sawing, and immediately before resealing, clean newly exposed concrete joint faces and pavement surface extending to a mimimum of 1/2 in up to 2 in from each joint edge by sandblasting until concrete surfaces in the joint space are free of sealants, dust, dirt, water and other foreign materials that prevent bonding of new sealants to the concrete. Use sand particles of the proper size and quality for the work. Perform sandblasting with specified nozzles, air compressor, and other appurtenant equipment.

Position nozzles to clean the joint faces. Make at least two passes; one for each joint face. Make as many passes as required for proper cleaning. Immediately prior to sealing the joint, blow out the joint spaces with compressed air until completely free of sand, water, and dust. Install joint sealants to dry joints. Replace expansion joint filler material damaged in performing the work with new materials of the same type and dimensions as the existing material, or with appropriate blocking media.

3.3.4 Bond Breaker

At the time the joints receive the final cleaning and are dry, install bond breaker material as indicated with a steel wheel or other approved device.

3.3.4.1 Blocking Media (Backer Rod) (Except for Expansion Joints)

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

3.3.4.2 Bond Breaking Tape

Where inserts or filler materials contain bitumen, or the depth of the

SECTION 32 01 19.61 Page 11 joint opening does not allow for the use of a backup material, insert a bond breaker separating tape to prevent incompatibility with the filler materials and three-sided adhesion of the sealant. Bond the tape to the bottom of the joint opening to prevent it from floating up into the new sealant.

3.3.5 Rate of Progress of Joint Preparation

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

3.3.6 Disposal of Debris

Sweep pavement surface to remove excess joint material, dirt, water, sand, and other debris by vacuum sweepers or hand brooms. Remove the debris immediately.

3.4 PREPARATION OF SEALANT

3.4.1 Single-Component, Cold-Applied Sealants

Inspect the ASTM D5893/D5893M sealant and containers prior to use. Reject materials that contain water, hard caking of any separated constituents, nonreversible jell, or materials that are otherwise unsatisfactory. Do not reject sealants that exhibit settlement of constituents in a soft mass that can be readily and uniformly remixed in the field with simple tools.

3.5 INSTALLATION OF SEALANT

3.5.1 Time of Application

After approval of the test section, seal joints immediately following final cleaning and placing of bond breakers. Commence sealing joints when walls are dust free and dry, and when weather conditions meet sealant manufacturer's instructions. If the above conditions cannot be met, or when rain interrupts sealing operations, reclean and permit the joints to dry prior to installing the sealant.

3.5.2 Sealing Joints

Do not install joint sealant until joints to be sealed have been inspected and approved. Install bond breaker just prior to pouring sealant. Fill the joints with sealant from bottom up until joints are uniformly filled solid from bottom to top using the specified equipment for the type of sealant required. Fill joints to 1/4 in plus or minus 1/16 in below top of pavement, and without formation of voids or entrapped air. Do not permit gravity methods or pouring pots to be used to install the sealant material. Except as otherwise permitted, tool the sealant immediately after application to provide firm contact with the joint walls and to form the indicated sealant profile below the pavement surface. Remove excess sealant that has been inadvertently spilled on the pavement surface. Do not permit traffic over newly sealed pavement until authorized. When a primer is recommended by the manufacturer, apply it evenly to the joint faces in accordance with the manufacturer's recommendations. Check sealed joints frequently to ensure that newly installed sealant is cured to a tack-free condition within the specified time. Protect new sealant from rain during curing period.

3.6 INSPECTION/FIELD QUALITY CONTROL

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3.6.1 Joint Cleaning

Inspect joints during the cleaning process to correct improper equipment and cleaning techniques that damage the concrete pavement in any manner.

Approve cleaned joints prior to installation of the separating or back-up material and joint sealant.

3.6.2 Sealant Application Equipment

Inspect the application equipment to ensure conformance to temperature requirements, proper proportioning and mixing (if two-component sealant) and proper installation. Suspend operations if there is evidences of bubbling, improper installation, or failure to cure or set until causes of the deficiencies are determined and corrected.

3.6.3 Joint Sealant

Inspect the joint sealant for proper rate of cure and set, bonding to the joint walls, cohesive separation within the sealant, reversion to liquid, entrapped air and voids. Remove sealants exhibiting these deficiencies prior to the final acceptance of the project from the joint, wasted, and replace at no additional cost to the Government. Obtain approval for each joint seal installation.

3.7 ACCEPTANCE

Reject sealer that fails to cure properly, or fails to bond to joint walls, or reverts to the uncured state, or fails in cohesion, or shows excessive air voids, blisters, surface defects, swelling, or other deficiencies, or is not properly recessed within indicated tolerances.

Remove rejected sealer and reclean and reseal joints. Perform removal and reseal work promptly by and at the expense of the Contractor.

3.8 CLEAN-UP

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

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