32 01 19 61 - Resealing of Joints in Rigid Pavement.docx

DIVISION 32 – EXTERIOR IMPROVEMENTS

SECTION 32 01 19.61

RESEALING OF JOINTS IN RIGID PAVEMENT

PART 1 GENERAL

This guide specification covers the requirements for removal of old sealing materials from existing joints of Portland cement concrete pavement and resealing of joints.

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 C 603 (2004; R 2008) Extrusion Rate and Application Life of Elastomeric Sealants

ASTM C 639 (2001; R 2007) Rheological (Flow) Properties of Elastomeric Sealants

ASTM C 661 (2006) Indentation Hardness of Elastomeric-Type Sealants by Means of a Durometer

ASTM C 679 (2003; R 2009e1) Tack-Free Time of Elastomeric Sealants

ASTM C 719 (1993; R 2005) Adhesion and Cohesion of Elastomeric Joint Sealants Under Cyclic Movement (Hockman Cycle)

ASTM C 792 (2004; R 2008) Effects of Heat Aging on Weight Loss, Cracking, and Chalking of Elastomeric Sealants

ASTM C 793 (2005) Effects of Accelerated Weathering on Elastomeric Joint Sealants

ASTM D 412 (2006ae2) Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers – Tension

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS SS-S-1401 (Rev C; Am 1) Sealant, Joint, Non-Jet-Fuel-Resistant, Hot-Applied, for Portland Cement and Asphalt Concrete Pavements

FS SS-S-1614 (Rev A; Am 1) Sealants, Joint, Jet-Fuel-Resistant, Hot-Applied, for Portland Cement and Tar Concrete Pavements

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

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Joint sealant, G

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

SD-04 Samples

Joint filler, G

Separating tape, G

Joint backer rod, G

Joint sealant, G

Furnish for testing a five gallon sample of each joint seal with associated primer to the Contracting Officer a minimum of 60 days prior to its use on the job. Each container shall be factory sealed and must contain a factory applied label showing the following information:

Name of sealant

Identification of component, or primer

Specification number and type

Manufacturer's name

Manufacturer's lot and batch number

Date of Manufacture (month and year)

Shelf life re-test date (month and year)

List of hazardous components

Quantity of material in container (volume)

Storage instructions

Instructions for use

SD-06 Test Reports

Joint sealant, G

SD-07 Certificates

Equipment list, G

SD-08 Manufacturer's Instructions

Joint sealant, G

Instructions shall include, but not be 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 DELIVERY, STORAGE, AND HANDLING

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

1.4 ENVIRONMENTAL REQUIREMENTS

Work shall not proceed when weather conditions detrimentally affect the quality of cleaning joints or applying joint sealants. Joint preparation and sealing shall proceed only when weather conditions are in accordance with manufacturer's instructions. During installation, surfaces shall be dry and sealant and bond breakers shall be protected from moisture.

1.5 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 joint sealant. At the end of the curing period, traffic may be permitted on the pavement when approved.

1.6 EQUIPMENT

Submit an equipment list and description of the equipment to be used and a statement from the supplier of the joint sealant that the proposed equipment is acceptable for installing the specified sealant. Equipment for heating, mixing, and installing joint seals shall be in accordance with the instructions provided by the joint seal manufacturer. Furnish equipment, tools, and accessories necessary to clean existing joints and install liquid joint sealants. Maintain machines, tools, and other equipment in proper working condition.

1.6.1 Joint Cleaning Equipment

1.6.1.1 Routing Tool

To remove old sealant from joints, select rectangular shaped routing tool that is adjustable to varying widths and depths required. The equipment shall be capable of maintaining accurate cutting depth and width control. The joint plow shall be equipped with a spring or hydraulic mechanism to release pressure on the tool prior to spalling the concrete.

1.6.1.2 Concrete Saw

Self-propelled power saw with diamond saw blades designed for sawing, re-facing, widening, or deepening existing joints as specified without damaging the sides, bottom, or top edge of joints. Blades may be single or gang type 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.

1.6.1.3 Sandblasting Equipment

Commercial type capable of removing residual sealer, oil, or other foreign material. Equipment shall include an air compressor, hose and nozzles of proper size, shape, and opening. Attach an adjustable guide that will hold the nozzles aligned with the joint to effectively and efficiently clean without damage to concrete edges. Adjust height, angle of inclination, or size of nozzles to sandblast joint faces and not bottom of joint.

1.6.1.4 Air Compressor

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. The compressor shall furnish air at a pressure not less than 90 psi and a minimum rate of 150 cubic feet of air per minute at the nozzles and free of oil.

1.6.1.5 Vacuum Sweeper

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

1.6.1.6 Hand Tools

When approved, hand tools such as brooms and chisels may be used in small areas for removing old sealant from joints and repairing or cleaning the joint faces.

1.6.2 Joint Sealing Equipment

Joint sealing equipment shall be of a type required by the joint seal manufacturer's installation instructions. Equipment shall be capable of installing sealant to the depths, widths and tolerances indicated. When malfunctions are noted, joint sealing shall not proceed until they are corrected.

1.6.2.1 Hot-Poured Liquid Sealant

Install hot-poured sealant materials with unit applicators which will heat and extrude the sealant. Equip the mobile units with double-wall agitator type kettles with an oil medium in the outer space for heat transfer, a direct-connected pressure-type extruding device with nozzles shaped for insertion in the joints to be filled, and a positive device for controlling the temperature of oil and sealer. Design the applicator so that the sealant will circulate through the delivery hose and return to the kettle when not sealing a joint. Insulate the applicator wand from the kettle to the nozzle. Select dimensions of the nozzles such that the tip of the nozzle will easily feed sealant into the void space of the joint. Equip the nozzle tip with a metal cross-bar to ensure that the top of the sealant fed into the joint is level and within the indicated tolerance below the pavement surface.

1.6.2.2 Two-Component Cold-Applied Liquid Sealants

For two component cold applied machine mixed sealants the equipment shall be capable of delivering each component within an accuracy of 5 percent. Equip reservoirs for each component with mechanical agitation devices. Equip equipment with thermostatically controlled indirect heating of components when required. Equipment shall include screens over each reservoir to eliminate foreign particles or partially polymerized material which may clog lines. Equipment shall be capable of intimately mixing the two components through a range of application rates from 10 to 60 gallons per hour and through a range of pressures from 50 to 150 pounds per square inch. Hand-mixing of cold-applied two component sealant may be done at the option of the Contractor for sealants conforming to FS SS-S-200, Type H.

1.6.2.3 Equipment for Silicone Sealant

Equipment for silicone sealant shall be air powered pump, components, and hoses as recommended by the sealant manufacturer. Hoses and seals shall be lined to prevent moisture penetration and withstand pumping pressures. Equipment shall be free of contamination from previously used or other type sealant.

1.7 SAFETY PROVISIONS

In accordance with the provisions of the contract respecting "Accident Prevention," the Contractor shall take appropriate measures to control worker exposure to toxic substances during the work. Provide personnel protective equipment as required. Material Safety Data Sheets (Department of Labor Form OSHA-20 or comparable form) shall be available on the site.

PART 2 PRODUCTS

2.1 MATERIALS

2.1.1 Joint Sealant

2.1.1.1 Two Component Cold-Applied Sealing Compound

FS SS-S-200, Type H and/or Type M. The contractor may use both types depending on field conditions and/or schedule. The use of Type H is restricted to small projects or limited areas of large projects.

2.1.1.2 Sealant, Joint, Jet-Fuel Resistant, Hot-Applied

FS SS-S-1614, for portland cement and tar concrete pavements.

2.1.1.3 Sealant, Joint, Non-Jet Fuel Resistant, Hot Applied

FS SS-S-1401, for portland cement and asphalt concrete pavements.

2.1.1.4 Single Component Cold-Applied Silicone

Silicone sealant shall be self leveling, non-acid curing, and meet the following requirements:

TEST TEST METHOD REQUIREMENTS

Weight Loss ASTM C 792 Modified 10 percent max.

(see note 1 below)

Flow ASTM C 639 (Type I) smooth and level

Extrusion Rate ASTM C 603 30 sec. max.

Tack Free Time ASTM C 679 5 hours max.

Hardness (Shore 00) ASTM C 661 30 – 80 (see note 2 below)

(see note 2 below)

Percent Elongation ASTM D 412 (Die C) 700 min.

(see note 2 below)

Accelerated Weathering ASTM C 793 pass 5000 hours

Bond and Movement Capability ASTM C 719 pass 10 cycles at +50 percent movement (no adhesion or cohesion failure)

Flame Resistance FS SS-S-200 pass

Notes:

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

2. Specimen cured 21 days at 73 degrees + 1 degrees F and 50 percent + 5 percent humidity.

ACCELERATED WEATHERING FACTORY TEST REPORT. For the Accelerated Weathering test, in lieu of testing of actual joint sealant to be used on the project, a report of a factory test, performed within two years of contract award, may be submitted.

2.1.2 Primers

Select concrete primer recommended by the manufacturer of the proposed liquid joint sealant.

2.1.3 Bond Breakers

2.1.3.1 Blocking Media

Compressible, non-shrinkable, non-reactive with joint sealant and non-absorption type such as plastic backer rod, free of oils or bitumens. Blocking media shall be consistent with the joint seal manufacturer's installation instructions and be at least 25 percent larger in diameter than the width of the cleaned and re-faced joints as shown.

2.1.3.2 Separating Tape

Polyethylene or polyester tape, 3 mil minimum thickness, or masking tape, nonreactive, non-absorptive, adhesive-back tape, width equal to width of cleaned and refaced joints as indicated. Separating tape shall be consistent with the joint seal manufacturer's installation instructions.

PART 3 EXECUTION

3.1 JOINT PREPARATION

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. Thoroughly clean joints by removing existing joint sealing compound, bond-breakers, dirt, and other foreign material with the equipment specified herein, but not limited thereto. Cleaning procedures which damage joints or previously repaired patches by chipping or spalling will not be permitted. Remove existing sealant to the required depth as indicated. 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.

3.1.1 Removal of Existing Material

Remove from the joint the existing sealants by using the specified routing tool. After cutting free the existing sealant from both joint faces, remove sealant to the depth required to accommodate the bond breaking material and to maintain the specified depth for the new sealant. For expansion joints, remove existing sealant to a depth of not less than one inch. When existing preformed expansion-joint material is more than one inch below the surface of the pavement, remove existing sealant to the top of the preformed joint filler. For joints other than expansion joints, remove in-place sealant to the depth as indicated. At the completion of routing operations, clean pavement surface with vacuum sweeper and clean the joint opening by blowing with compressed air. Protect previously cleaned joints from being contaminated by subsequent cleaning operations.

3.1.2 Re-facing of Joints

Reface concrete joint walls. Re-facing shall be by power-driven concrete saw specified herein to remove residual sealant and a minimum of concrete. Removal shall provide exposure of newly clean concrete. Remove burrs and irregularities from sides of joint faces. Immediately after sawing each joint, thoroughly clean saw cut and adjacent concrete surface. Flush with water under pressure, simultaneously blowing water out with compressed air until debris is removed from the joint. Protect adjacent previously cleaned joint spaces from receiving water and debris during the cleaning operation.

3.1.2.1 Joint Widening (Except Expansion Joints)

Saw joints having grooves less than 3/8 inch wide and less than one inch deep to a minimum width of 1/2 inch and to the minimum depth, of 1 1/2 inches or as indicated.

Items to be determined in the field and noted on drawings:

1. Spacing, width, and type of joints in concrete pavements to be sealed.

2. Typical details of existing joints.

3. Depth of existing sealant to be removed for each type of joint, if not specified.

4. Detail of type of joint to be refaced or widened with a concrete saw. Show extent of new width and depth of sawing to provide the proper shape factor of the void space in the joint. For materials, other than silicone, the ratio of the depth to width (d/w) of the sealant reservoir should generally be not less than 1 nor greater than 1.5. For silicone sealant a depth to width ratio of approximately 0.5 is preferred. Depending upon the width of the refaced joint, the thickness of the sealant bead should be between 1/4 and 1/2 inch.

Following are the recommended details for silicone sealants:

Refaced Joint Width 3/8" 1/2" 3/4" 1"

5. Location and type of bond breaker or back-up.

6. Identify type of sealant based on proposed use of pavements. (See note in paragraph entitled "Joint Sealant.")

7. For joint details see MIL-HDBK-1021/4.

3.1.3 Final Cleaning of Joints

3.1.3.1 Sandblasting Cleaning

Following removal of existing sealant, and sawing, and immediately before resealing, thoroughly clean newly exposed concrete joint faces and pavement surface extending up to 2 inches from each joint edge by sandblasting until concrete surfaces in the joint space are free of sealants, dust, dirt, water and other foreign materials which would 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. Joints shall be dry before installation of joint sealant. 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.

3.1.4 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.

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

Plug or seal off the lower portion of the groove by installing the specified blocking media as indicated.

3.1.4.2 Separating Tape

Insert the specified tape as indicated.

3.1.5 Rate of Progress

The final stages of joint preparation, which include placement of bond breakers, if required, shall be limited to only that length of joint that can be resealed during the same workday.

3.1.6 Disposal of Debris

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

3.2 PREPARATION OF SEALANT

3.2.1 Hot-Poured Type

Heat hot-poured sealing materials in accordance with safe heating temperature ranges recommended by the manufacturer. Withdraw and waste sealant that has been overheated or subjected to heating for over 3 hours or that remain in the applicator at the end of the day's operation. Heat sealant in specified equipment.

3.2.2 Cold-Applied, Two Component Type

Reject materials which contain water, hard caking of separated constituents, nonreversible jell, or other unsatisfactory conditions such as settlement of constituents into a soft mass that cannot be readily and uniformly remixed in the field with simple tools. In conformance with the manufacturer's recommendations, mix individual components in separate shipping containers before transferring components to appropriate reservoirs of application equipment. Thoroughly mix components to ensure homogeneity of components and incorporation of constituents at time of transfer. When necessary, for remixing prior to transfer, warm components to a temperature not exceeding 90 degrees F by placing components in heated storage or by other approved methods. In no case shall components be heated by direct flame or in single-walled, non-oil-bath heating kettles. Hand mixing of cold-applied two component sealant may be done at the option of the Contractor for sealants conforming to FS SS-S-200, Type H.

3.3 INSTALLATION OF SEALANT

3.3.1 Test Section

Install a test section of 200 linear feet at the start of the sealing operation for each type sealant to be used. Test section shall meet contract requirements. The Contracting Officer shall be notified upon completion of the test section.

3.3.2 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 joint seal manufacturer's instructions. If the above conditions cannot be met, or when rains interrupts sealing operations, re-clean and permit the joints to dry prior to installing the sealant.

3.3.3 Sealing the 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 inch below top of pavement within tolerances as indicated, and without formation of voids or entrapped air. 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. When two-component sealants are placed, each day check hourly the proportioning capability of the equipment to determine that the preset volume output for each component is being maintained. The material used for these checks may be returned to the proper component reservoir. In no case shall two component sealants be installed using gravity methods and pouring spouts, except for approved hand mixing methods. When a primer is supplied or recommended by the manufacturer of a two component sealant, apply the primer evenly to the joint faces in accordance with the manufacturer's recommendations. Check sealed joints frequently to assure that newly installed sealant is cured to a tack-free condition within 3 hours; 5 hours tack free time for silicone. Protect new sealant from rain during curing period.

3.4 FIELD QUALITY CONTROL

3.4.1 Sampling Joint Seal

Obtain a one gallon sample of each type of joint seal on the project from material used for each 10,000 linear feet or less of joints sealed. Store samples according to joint seal manufacturer's instructions. Retain samples until final acceptance of the work by the Contracting Officer.

3.4.2 Joints

Inspect and approve joints which have been cleaned and have backer rods or bond breaking tape installed prior to sealing.

3.4.3 Joint Seal Test Section

Inspect joint seal test section. Correct deficiencies and obtain approval of test section by the Contracting Officer prior to installing joint seals.

3.4.4 Joint Sealer

Inspect installed joint seals for conformance to contract requirements, joint seal manufacturer's instructions, and the test section. Obtain approval for each joint seal installation.

3.5 ACCEPTANCE

Reject joint 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 re-clean and reseal joints in accordance with the specification. Perform removal and reseal work promptly by and at the expense of the Contractor.

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