32 13 11 - Concrete Pavement for Airfield and Other Heavy-Duty Pavements.docx

DIVISION 32 – EXTERIOR IMPROVEMENTS

SECTION 32 13 11

CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY-DUTY PAVEMENTS

08/10

PART 1 GENERAL

This guide specification covers the requirements for construction of concrete pavement for Army and Air Force airfields and heavy-duty roads, parking areas, hardstands, and vehicular pavement.

1.1 UNIT PRICES

1.1.1 Measurements

The quantity of concrete to be paid for will be the volume of concrete in cubic yards including thickened edges, monolithic curb, where required, placed in the completed and accepted pavement. Concrete will be measured in place in the completed and accepted pavement only within the neat line dimensions shown in the plan and cross section. No deductions will be made for rounded or beveled edges or the space occupied by pavement reinforcement, dowel bars, tie bars, or electrical conduits, nor for any void, or other structure extending into or through the pavement slab, measuring 3 cubic feet or less in volume. No other allowance for concrete will be made unless placed in specified locations in accordance with written instructions previously issued by the Contracting Officer. The quantity of other materials specified herein, and used in the construction of the work covered by this section, will not be measured for payment, but will be considered a subsidiary obligation of the Contractor, covered under the price per cubic yard for concrete. Joint sealing materials are covered in Section 32 01 19 FIELD MOLDED SEALANTS FOR SEALING JOINTS IN RIGID PAVEMENTS or Section 32 13 73 COMPRESSION JOINT SEALS FOR CONCRETE PAVEMENTS.

1.1.2 Payments

1.1.2.1 Unit Price

The quantity of concrete measured as specified above will be paid for at the contract unit price when placed in completed and accepted pavements. Payment will be made at the contract price for cubic yard for the scheduled item, with necessary adjustments as specified below. Payment will constitute full compensation for furnishing all materials, equipment, plant and tools, and for all labor and other incidentals necessary to complete the concrete pavement, except for other items specified herein for separate payment.

1.1.3 Payment of Lots

When a lot of material fails to meet the specification requirements, that lot will be accepted at a reduced price or shall be removed and replaced. The lowest computed percent payment determined for any pavement characteristic (i.e., thickness, grade, and surface smoothness) discussed below shall be the actual percent payment for that lot. The actual percent payment will be applied to the unit price and the measured quantity of concrete in the lot to determine actual payment. Use results of strength tests to control concreting operations. Strength will be evaluated, but will not be considered for payment adjustment. Any pavement not meeting the required 'specified strength' shall be removed and replaced at no additional cost to the Government.

1.1.4 Payment Adjustment for Smoothness

a. Straightedge Testing: Location and deviation from straightedge for all measurements shall be recorded. When more than 5.0 and less than or equal to 10.0 percent of all measurements made within a lot exceed the tolerance specified in paragraph "Surface Smoothness", after any reduction of high spots or removal and replacement, the computed percent payment based on surface smoothness will be 95 percent. When more than 10.0 percent and less than or equal to 15.0 percent of all measurements exceed the tolerance, the computed percent payment will be 90 percent. When more than 15.0 and less than or equal to 20.0 percent of all measurements exceed the tolerance, the computed percent payment will be 75 percent. When more than 20.0 percent of the measurements exceed the tolerance, the lot shall be removed and replaced at no additional cost to the Government.

b. Profilograph Testing: Location and data from all profilograph measurements shall be recorded. When the Profile Index of a 0.1 mile segment of a lot exceeds the tolerance specified in paragraph "Surface Smoothness" by 1.0 inch per mile but less than 2.0 inches per mile, after any reduction of high spots or removal and replacement, the computed percent payment based on surface smoothness will be 95 percent. When the Profile Index exceeds the tolerance by 2.0 inches per mile but less than 3.0 inches per mile, the computed percent payment will be 90 percent. When the Profile Index exceeds the tolerance by 3.0 inches per mile but less than 4.0 inches per mile, the computed percent payment will be 75 percent. When the Profile Index exceeds the tolerance by 4.0 inches per mile or more, the lot shall be removed and replaced at no additional cost to the Government.

1.1.5 Payment Adjustment for Plan Grade

When more than 5.0 and less than or equal to 10.0 percent of all measurements made within a lot are outside the specified tolerance, the computed percent payment for that lot will be 95 percent. When more than 10.0 percent but less than 50 percent are outside the specified tolerances, the computed percent payment for the lot will be 75 percent. In any areas where the deviation from grade exceeds the specified tolerances by 50 percent or more, the deficient area shall be removed and replaced at no additional cost to the Government.

1.1.6 Payment Adjustment for Thickness

Using the Average Thickness of the lot, determine the computed percent payment for thickness by entering the following table:

Computed Percent Payment for Thickness

Deficiency in Thickness

Where 0 percent payment is indicated, the entire lot shall be removed and replaced at no additional cost to the Government. Where either of the two cores from a sublot show a thickness deficiency of 0.75 inch or greater, 0.50 inch for pavements 8 inches or less in thickness, two more cores shall be drilled in the sublot and the average thickness of the four cores computed. If this average shows a thickness deficiency of 0.75 inch or more, 0.50 inch for pavements 8 inches or less in thickness, the entire sublot shall be removed.

1.2 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.

ACI INTERNATIONAL (ACI)

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

ACI 214R (2002; Errata 2010) Evaluation of Strength Test Results of Concrete

ACI 305R (1999; Errata 2006) Specification for Hot Weather Concreting

ACI 306R (1988; R 2002) Cold Weather Concreting

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO M 182 (2009) Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats

ASTM INTERNATIONAL (ASTM)

ASTM A 184 (2006) Standard Specification for Fabricated Deformed Steel Bar Mats for Concrete Reinforcement

ASTM A 185 (2007) Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete

ASTM A 497 (2007) Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete

ASTM A 615 (2009b) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A 775 (2007b) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A 996 (2009b) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ASTM C 1017 (2007) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C 1064 (2008) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C 1077 (2010c) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

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

ASTM C 123 (2004) Standard Test Method for Lightweight Particles in Aggregate

ASTM C 1240 (2005) Standard Specification for Silica Fume Used in Cementitious Mixtures

ASTM C 1260 (2007) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C 131 (2006)Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C 136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C 138 (2010a) Standard Test Method for Density ("Unit Weight"), Yield, and Air Content (Gravimetric) of Concrete

ASTM C 142 (1997; R 2004) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C 143 (2010) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C 150 (2009) Standard Specification for Portland Cement

ASTM C 1567 (2008) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C 1602 (2006) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM C 1646 (2008a) Making and Curing Test Specimens for Evaluating Frost Resistance of Coarse Aggregate in Air-Entrained Concrete by Rapid Freezing and Thawing

ASTM C 172 (2008) Standard Practice for Sampling Freshly Mixed Concrete

ASTM C 174 (2006) Standard Test Method for Measuring Thickness of Concrete Elements Using Drilled Concrete Cores

ASTM C 192 (2007) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C 231 (2009b) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C 260 (2006) Standard Specification for Air-Entraining Admixtures for Concrete

ASTM C 29 (2009) Standard Test Method for Bulk Density ("Unit Weight") and Voids in Aggregate

ASTM C 294 (2005) Standard Descriptive Nomenclature for Constituents of Concrete Aggregates

ASTM C 295 (2008) Petrographic Examination of Aggregates for Concrete

ASTM C 309 (2007) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C 31 (2009) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C 33 (2008) Standard Specification for Concrete Aggregates

ASTM C 39 (2009a) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C 494 (2010) Standard Specification for Chemical Admixtures for Concrete

ASTM C 595 (2010) Standard Specification for Blended Hydraulic Cements

ASTM C 618 (2008a) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C 666 (2003; R 2008) Resistance of Concrete to Rapid Freezing and Thawing

ASTM C 78 (2009) Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

ASTM C 88 (2005) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM C 881 (2002) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C 94 (2009a) Standard Specification for Ready-Mixed Concrete

ASTM C 989 (2009a) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM D 1751 (2004; R 2008) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Non-extruding and Resilient Bituminous Types)

ASTM D 1752 (2004a; R 2008) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

ASTM D 2419 (2009) Sand Equivalent Value of Soils and Fine Aggregate

ASTM D 2995 (1999; R 2009) Determining Application Rate of Bituminous Distributors

ASTM D 3665 (2007) Random Sampling of Construction Materials

ASTM D 4791 (2005e1) Flat Particles, Elongated Particles, or Flat and Elongated Particles in Coarse Aggregate

ASTM D 75 (2009) Standard Practice for Sampling Aggregates

INNOVATIVE PAVEMENT RESEARCH FOUNDATION (IPRF)

IPRF INTERIM TEST PROTOCOL Test Method to Assess Potential Reactivity of Aggregates in Presence of Airfield Deicing Chemicals (Mortar Bar Test)

NATIONAL READY MIXED CONCRETE ASSOCIATION (NRMCA)

NRMCA QC 3 (2003) Quality Control Manual: Section 3, Plant Certifications Checklist: Certification of Ready Mixed Concrete Production Facilities

STATE OF CALIFORNIA DEPARTMENT OF TRANSPORTATION (CDT)

CDT Test 526 (2002) Operation of California Profilograph and Evaluation of Profiles

U.S. ARMY CORPS OF ENGINEERS (USACE)

COE CRD-C 130 (2001) Standard Recommended Practice for Estimating Scratch Hardness of Coarse Aggregate Particles

COE CRD-C 143 (1962) Specifications for Meters for Automatic Indication of Moisture in Fine Aggregate

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

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

COE CRD-C 55 (1992) Test Method for Within-Batch Uniformity of Freshly Mixed Concrete

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

1.3 SYSTEM DESCRIPTION

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

1.3.1 Surface Smoothness

Use the profilograph method for all longitudinal testing, except for paving lanes less than 200 feet in length. Use the straightedge method for transverse testing, for longitudinal testing where the length of each pavement lane is less than 200 feet, and at the ends of the paving limits for the project. Where drawings show required deviations from a plane surface (crowns, drainage inlets, etc.), finish the surface to meet the approval of the Contracting Officer. Detailed notes shall be kept of the results of the testing and a copy furnished to the Government after each day's testing.

a. Straightedge Testing: The finished surfaces of the pavements shall have no abrupt change of 1/4 inch or more, and all pavements shall be within the limits specified hereinafter when checked with an approved 12 foot straightedge. Runways and taxiways shall have a variation from the specified straight edge not greater than 1/8 inch in the longitudinal direction and not greater than 1/4 inch in the transverse direction. All other airfield areas shall have a variation from a straight edge not greater than 1/4 inch in either the longitudinal or transverse direction. Roads, streets, tank hardstands, vehicular parking areas, and open storage areas shall have a variation from the specified straight edge not greater than 1/4 inch in either the longitudinal or transverse direction.

b. Profilograph Testing: The finished surfaces of the pavements shall have no abrupt change of 1/4 inch or more, and each 0.1 mile segment of each pavement lot shall have a Profile Index not greater than specified hereinafter when tested with an approved California-type profilograph. Runways and taxiways shall have a Profile index not greater than 7 inches per mile in the longitudinal direction. Runway and taxiway transverse smoothness shall be measured with the straight edge method and the straight edge requirements shall apply. All other airfield areas shall have a Profile Index not greater than 9 inches per mile in the longitudinal direction. Roads, streets, tank hardstands, vehicular parking areas and open storage areas shall have a Profile index not greater than 9 inches per mile in the longitudinal direction.

c. Bumps ("Must Grind" Areas): Any bumps ("must grind" areas) shown on the profilograph trace which exceed 0.4 inch in height shall be reduced by diamond grinding in accordance with subparagraph "Diamond Grinding of PCC Surfaces" below until they do not exceed 0.3 inch when retested. Such grinding shall be tapered in all directions to provide smooth transitions to areas not requiring grinding.

d. Testing Method: After the concrete has hardened sufficiently to permit walking thereon, but not later than 48 hours after placement, test the entire surface of the pavement in each lot in such a manner as to reveal all surface irregularities exceeding the tolerances specified above. If any pavement areas are ground, these areas shall be retested immediately after diamond grinding. The entire area of the pavement shall be tested in both a longitudinal and a transverse direction on parallel lines. The transverse lines shall be 15 feet or less apart, as directed. The longitudinal lines shall be at the centerline of each paving lane shown on the drawings, regardless of whether the Contractor is allowed to pave two lanes at a time, and at the 1/8th point in from each side of the lane. Other areas having obvious deviations shall also be tested. Longitudinal testing lines shall be continuous across all joints. Transverse testing lines for pilot lanes shall be carried to construction joint lines and for fill-in lanes shall be carried 24 inches across construction joints, and the readings in this area applied to the fill-in lane. Straightedge testing of the longitudinal edges of slipformed pilot lanes shall also be performed before paving fill-in lanes as specified below.

1). Straightedge Testing: The straightedge shall be held in contact with the surface and moved ahead one-half the length of the straightedge for each successive measurement. Determine the amount of surface irregularity by placing the freestanding (unleveled) straightedge on the pavement surface and measuring the maximum gap between the straightedge and the pavement surface. Measurements shall be determined along the entire length of the straight edge.

2). Profilograph Testing: Perform profilograph testing using approved equipment and procedures described in CDT Test 526. The equipment shall utilize electronic recording and automatic computerized reduction of data to indicate "must-grind" bumps and the Profile Index for each 0.1 mile segment of the pavement lot. Grade breaks on aprons [parking lots] shall be accommodated by breaking the profile segment into short sections and repositioning the blanking band on each section. The "blanking band" shall be 0.2 inches wide and the "bump template" shall span 1 inch with an offset of 0.4 inch. The profilograph testing of the last 30 feet of a paving lane in the longitudinal direction from each day's paving operation shall be counted on the following day's continuation lane. The profile index shall be computed for each pass of the profilograph (3 per lane) in each 0.1 mile segment. The profile index for each segment shall be the average of the profile indices for each pass in each segment. Profilographs of unequal lengths shall be scaled and proportioned to an equivalent 0.1 mile as outlined in the CDT Test 526. A copy of the reduced tapes shall be furnished the Government at the end of each day's testing.

1.3.2 Edge Slump and Joint Face Deformation

a. Edge Slump: When slip-form paving is used, not more than 15.0 percent of the total free edge of each pavement panel shall have an edge slump exceeding 1/4 inch and none of the free edge of the pavement lot shall have an edge slump exceeding 3/8 inch. (A pavement panel is defined as a lane width by the length between two adjacent transverse contraction joints. The total free edge of the pavement will be considered to be the cumulative total linear measurement of pavement panel edge originally constructed as non-adjacent to any existing pavement; i.e., 100 feet of pilot lane originally constructed as a separate lane, will have 200 feet of free edge; 100 feet of fill-in lane will have no free edge, etc.,). The area affected by the downward movement of the concrete along the pavement edge shall not exceed 18 inches back from the edge.

b. Joint Face Deformation: In addition to the edge slump limits specified above, the vertical joint face shall have a surface within the maximum limits shown below:

Airfield Pavement

1/8 in 1/4 in 3/8 in 1/8 in 1 in/12 in All other Pavement

1/4 in All other items same as airfield pavement

c. Slump Determination: Immediately after the concrete has hardened sufficiently to permit walking thereon, the pavement surface of each lot shall be tested by the Contractor. Testing shall be performed with a minimum 12 foot straightedge to reveal irregularities exceeding the edge slump tolerance specified above. The vertical edge slump shall be determined at each free edge of each slipformed paving lane constructed. The straightedge shall be placed transverse to the direction of paving and the end of the straightedge located at the edge of the paving lane. Measurements shall be made at 5 to 15 foot spacings, as directed, commencing at the header where paving was started. Initially measurements shall be made at 5 foot intervals in each lane. When no deficiencies are present, the Contracting Officer may approve an increase in the interval. When any deficiencies exist, the interval will be returned to 5 feet. In no case shall the interval exceed 15 feet. In addition to the transverse edge slump determination above, the Contractor, at the same time, shall check the longitudinal surface smoothness of the joint on a continuous line 1 inch back from the joint line using the 12 foot straightedge advanced one-half its length for each reading. Other tests of the exposed joint face shall be made to ensure that a uniform, true vertical joint face is attained. The measurements shall be made by the Contractor, shall be properly referenced in accordance with paving lane identification and stationing, and a report given to the Contracting Officer within 24 hours after measurement is made. The report shall also identify areas requiring replacement.

d. Excessive Edge Slump: When edge slump exceeding the limits specified above is encountered on either side of the paving lane, additional straightedge measurements shall be made, if required, to define the linear limits of the excessive slump. The concrete slabs having excessive edge slump or joint deformation shall be removed and replaced to the next transverse joint in conformance with paragraph: REPAIR, REMOVAL, REPLACEMENT OF NEWLY CONSTRUCTED SLABS. Use of slip-form paving equipment and procedures that fail to consistently provide edges within the specified tolerances on edge slump and joint face deformation shall be discontinued and the pavements shall be constructed by means of standard paving procedures using fixed forms.

1.3.3 Plan Grade

Within 5 days after paving of each lot, the finished surface of the pavement area shall be tested, by running lines of levels at intervals corresponding with every longitudinal and transverse joint to determine the elevation at each joint intersection. The results of this survey shall be recorded and a copy given to the Government at the completion of the survey of each lot. The finished surfaces of airfield runway, taxiway, and apron pavements shall vary not more than 1/2 inch above or below the plan grade line or elevation indicated. The surfaces of other pavements shall vary not more than 3/4 inch. The above deviations from the approved grade line and elevation will not be permitted in areas where closer conformance with the planned grade and elevation is required for the proper functioning of appurtenant structures. The finished surfaces of new abutting pavements shall coincide at their juncture.

1.3.4 Flexural Strength

Each lot of pavement will be evaluated for acceptance in accordance with the following procedures.

a. Sampling and Testing: For acceptance, one composite sample of concrete from each sublot shall be obtained in accordance with ASTM C 172 from one batch or truckload. Test beams 6 x 6 inches shall be fabricated and cured in accordance with ASTM C 31/C 31M; and tested in accordance with ASTM C 78. Two test beams per sublot (8 per lot) shall be tested at 14 days.

b. Computations: Average the eight 14-day strength tests for the lot. The average strength shall be used in accordance with paragraph "Concrete Strength for Final Acceptance" in PART 2.

1.3.5 Thickness

Each lot of pavement will be evaluated for acceptance and payment adjustment in accordance with the following procedure. Two cores, between 4 and 6 inches in diameter, shall be drilled from the pavement, per sublot (8 per lot). The Contractor is responsible for drilling the cores within 3 days after lot placement, filling the core holes with an approved non-shrink concrete, re-spraying the cored areas with curing compound, and for measuring the cores. Each core shall be inspected for voids, thickness of paste on the surface, and depth of reinforcement (if required). Provide the results with the thickness measurement data. Eight measurements of thickness shall be made around the circumference of each core and one in the center, in accordance with ASTM C 174/C 174M, using calibrated calipers for specimens longer than 10 inches. The pavement thickness from the 8 cores for the lot shall be averaged and shall be evaluated as described in paragraph: PAYMENT ADJUSTMENT FOR THICKNESS above.

1.3.6 Diamond Grinding of PCC Surfaces

In areas not meeting the specified limits for surface smoothness and plan grade, high areas shall be reduced to attain the required smoothness and grade, except as depth is limited below. High areas shall be reduced by grinding the hardened concrete with an approved diamond grinding machine after the concrete is 14 days or more old. Grinding shall be accomplished by sawing with an industrial diamond abrasive which is impregnated in the saw blades. The saw blades shall be assembled in a cutting head mounted on a machine designed specifically for diamond grinding that will produce the required texture and smoothness level without damage to the concrete pavement or joint faces. The saw blades shall be 1/8-inch wide and there shall be a minimum of 55 to 60 blades per 12 inches of cutting head width depending on the hardness of the aggregate. Each machine shall be capable of cutting a path 3 to 4 ft wide. Grinding equipment that causes ravels, aggregate fractures, spalls or disturbance to the joints will not be permitted. The area corrected by grinding the surface of the hardened concrete shall not exceed 10 percent of the total area of any sublot. The depth of diamond grinding shall not exceed 1/4 inch. All pavement areas requiring plan grade or surface smoothness corrections in excess of the limits specified above, shall be removed and replaced in conformance with paragraph REPAIR, REMOVAL, REPLACEMENT OF NEWLY CONSTRUCTED SLABS. In pavement areas given a wire comb or tined texture, areas exceeding 25 square feet that have been corrected by diamond grinding shall be retextured by transverse grooving using an approved grooving machine of standard manufacture. The grooves shall be 1/4 inch deep by 1/4 inch wide on 1-1/2 inch centers and shall be carried into, and tapered to zero depth within the non-corrected surface, or shall match any existing grooves in the adjacent pavement. All areas in which diamond grinding has been performed will be subject to the thickness tolerances specified in paragraph: Thickness, above.

1.4 SUBMITTALS

Government approval is required for submittals with a "G" designation; submittals not having a "G" designation are for Contractor Quality Control approval. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-03 Product Data

Equipment; G

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

b. A certified copy of the NRMCA QC Manual Section 3 Concrete Plant Certification Checklist and Calibration documentation on all measuring and weighing devices, submitted prior to uniformity testing.

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

d. A description of the equipment proposed for the machine and hand literature on the paver and finisher, together with the manufacturer's written instructions on adjustments and operating procedures necessary to assure a tight, smooth surface on the concrete pavement. The literature shall show that the equipment meets all details of these specifications.

Proposed Techniques; G

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

SD-05 Design Data

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

SD-06 Test Reports

Sampling and Testing; G, Certified copies of laboratory test reports and sources for cement, supplementary cementitious materials (SCM), aggregates, admixtures, curing compound, epoxy, and proprietary patching materials proposed for use on this project. All aggregate tests shall have been performed no earlier than 6 months prior to contract award.

SD-07 Certificates

Contractor Quality Control Staff; G, American Concrete Institute certification for Contractor Quality Control staff. Qualifications and resumes for petrographer, surveyor, concrete batch plant operator, and profilograph operator.

Laboratory Accreditation; G, Accreditation of the commercial laboratory by an independent evaluation authority, indicating conformance to ASTM C 1077, including all applicable test procedures.

1.5 QUALITY ASSURANCE

1.5.1 Contractor Quality Control Staff

All Contractor Quality Control personnel assigned to concrete construction shall be American Concrete Institute (ACI) certified in the following grade or shall have written evidence acceptable to the Contracting Officer's representative of having completed similar qualification programs:

a. CQC personnel responsible for inspection of concrete paving operations: ACI Concrete Transportation Inspector.

b. Lead Foreman or Journeyman of the Concrete Placing, Finishing, and Curing Crews: ACI Concrete Flatwork Technician/Finisher.

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

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

1.5.2 Other Staff

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

a. Petrographer: Bachelor of Science degree in geology or petrography, trained in petrographic examination of concrete aggregate according to ASTM C 294 and ASTM C 295 and trained in identification of the specific deleterious materials and tests identified in this specification. Resume shall detail the education, training and experience related to the project-specific test methods and deleterious materials and shall be submitted at least 20 days before petrographic and deleterious materials examination is to commence.

b. Licensed Surveyor: All survey work shall be performed under the supervision of a Licensed Surveyor.

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

d. Profilograph Operator: Certification by equipment manufacturer or a state Department of Transportation.

1.5.3 Laboratory Accreditation

Laboratory and testing facilities shall be provided by and at the expense of the Contractor. The laboratories performing the tests shall be accredited in accordance with ASTM C 1077, including ASTM C 78 and ASTM C 1260. The accreditation shall be current and shall include the required and optional test methods, as specified throughout this Section. Onsite temperature-controlled concrete curing facilities shall be provided.

a. Aggregate Testing and Mix Proportioning: Aggregate testing and mixture proportioning studies shall be performed by a commercial laboratory.

b. Acceptance Testing: Furnish all materials, labor, and facilities required for molding, curing, testing, and protecting test specimens at the site and in the laboratory. Steel molds shall be used for molding the beam specimens. Furnish and maintain boxes or other facilities suitable for storing and curing the specimens at the site while in the mold within the temperature range stipulated by ASTM C 31/C 31M. Flexural loading equipment shall be in accordance with ASTM C 78.

c. Contractor Quality Control: All sampling and testing shall be performed by an approved, onsite, independent, commercial laboratory, or for cementitious materials and admixtures, the manufacturer's laboratory.

d. Laboratory Inspection: The Government will inspect the laboratory equipment and test procedures prior to the start of concreting operations for conformance to ASTM C 1077. The laboratory shall maintain this certification for the duration of the project.

1.5.4 Preconstruction Testing of Materials

All sampling and testing shall be performed by, and at the expense of, the Contractor. Use an approved commercial laboratory or, for cementitious materials and chemical admixtures, a laboratory maintained by the manufacturer of the material. No material shall be used until notice of acceptance has been given. The Contractor will not be entitled to any additional payment or extension of time due to failure of any material to meet project requirements, or for any additional sampling or testing required. Additional tests may be performed by the Government at the discretion of the Contracting Officer; such Government testing will not relieve the Contractor of any testing responsibilities.

1.5.4.1 Aggregates

Aggregates shall be sampled in the presence of a Government Representative. Samples shall be obtained in accordance with ASTM D 75/D 75M and shall be representative of the materials to be used for the project. Test results shall be submitted 7 days before commencing mixture proportioning studies.

1.5.4.2 Chemical Admixtures, Curing Compounds and Epoxies

At least 30 days before the material is used, submit certified copies of test results for the specific lots or batches to be used on the project. Test results shall be not more than 6 months old prior to use in the work. Chemical admixtures that have been in storage at the project site for longer than 6 months or that have been subjected to freezing will be retested at the expense of the Contractor and will be rejected if test results are not satisfactory.

1.5.4.3 Cementitious Materials

Cement and pozzolan will be accepted on the basis of manufacturer's certification of compliance, accompanied by mill test reports showing that the material in each shipment meets the requirements of the specification under which it is furnished. Mill test reports shall be no more than 1 month old, prior to use in the work. No cementitious material shall be used until notice of acceptance has been given by the Contracting Officer. Cementitious material may be subjected to check testing by the Government from samples obtained at the mill, at transfer points, or at the project site. If tests prove that a cementitious material that has been delivered is unsatisfactory, it shall be promptly removed from the site of the work. Cementitious material that has not been used within 6 months after testing shall be retested at the Contractor's expense and shall be rejected if test results are not satisfactory.

1.5.5 Testing During Construction

During construction, the Contractor is responsible for sampling and testing aggregates, cementitious materials, and concrete as specified herein. The Government will sample and test concrete and ingredient materials as considered appropriate. Provide facilities and labor as may be necessary for procurement of representative test samples. Testing by the Government will in no way relieve the Contractor of the specified testing requirements.

1.5.6 Test Section

At least 10 days, but not more than 60 days, prior to construction of the concrete pavement, construct a test section as part of the production paving area at an outer edge as indicated on the drawings. Use the test section to develop and demonstrate to the satisfaction of the Contracting Officer the proposed techniques of mixing, hauling, placing, consolidating, finishing, curing, initial saw cutting, start-up procedures, testing methods, plant operations, and the preparation of the construction joints. Variations in mixture proportions, other than water, shall be made if directed. Vary the water content, as necessary, to arrive at the appropriate content. The mixing plant shall be operated and calibrated prior to start of placing the test section. Use the same equipment, materials, and construction techniques on the test section as will be used in all subsequent work. Base course preparation, concrete production, placing, consolidating, curing, construction of joints, and all testing shall be in accordance with applicable provisions of this specification. Three days after completion of the test section, provide eight cores at least 6 inch diameter by full depth cut from points selected in the test section by the Government. The cores will be evaluated for homogeneity, consolidation and segregation. Construct the test section meeting all specification requirements and being acceptable to the Contracting Officer in all aspects, including surface texture. Failure to construct an acceptable test section will necessitate construction of additional test sections at no additional cost to the Government. Test sections allowed to be constructed as part of the production paving which do not meet specification requirements shall be removed at the Contractor's expense. If the Contractor proposes to use slipform paving and is unable to construct an acceptable test section, the slipform paving equipment shall be removed from the job and the construction completed using stationary side forms and equipment compatible with them. Production paving shall not commence until the results on aggregates and concrete, including evaluation of the cores, and all pavement measurements for edge slump, joint face deformation, actual plan grade, surface smoothness and thickness have been submitted and approved by the Contracting Officer. Pavement accepted as a production lot will be evaluated and paid in accordance with Paragraph: ACCEPTABILITY OF WORK below.

1.5.6.1 Pilot Lane

The test section shall consist of one paving lane at least 400 feet long and shall be constructed to the same thickness as the thickest portion of pavement shown on the Drawings. The lane width shall be the same as that required for use in the project. The test section shall contain at least one transverse construction joint. If doweled longitudinal construction joints are required in any of the production pavements, they shall be installed full length along one side of the test strip throughout the test section. Two separate days shall be used for construction of the test section.

1.5.6.2 Fill-In Lane

The first 400 feet of the initial production fill-in lane shall be considered a fill-in lane test section for purposes of testing and evaluation. All requirements for the test section are applicable, as appropriate. Obtain cores from the fill-lane lane side of the longitudinal construction joint with the pilot lane. The cores will be evaluated for homogeneity, consolidation, and segregation.

1.5.7 Acceptability of Work

The materials and the pavement itself will be accepted on the basis of tests made by the Contractor. The Government may make check tests to validate the results of the Contractor's testing. If the results of the Contractor tests vary by less than 2.0 percent of the Government's test results, the results of the Contractor's tests will be used. If the results of the Government and Contractor tests vary by 2.0 percent, but less than 4.0 percent, the average of the two will be considered the value to be used. If these vary by 4.0 percent or more, each sampling and testing procedure shall be carefully evaluated and both the Government and the Contractor shall take another series of tests on duplicate samples of material. If these vary by 4.0 percent or more, the results of the tests made by the Government shall be used and the Government will continue check testing of this item on a continuous basis until the two sets of tests agree within less than 4.0 percent on a regular basis. Testing performed by the Government will in no way at any time relieve the Contractor from the specified testing requirements.

1.5.8 Acceptance Requirements

1.5.8.1 Pavement Lots

A lot will be that quantity of construction that will be evaluated for acceptance with specification requirements. A lot will be equal to one shift of production not to exceed 1000 cubic yards. In order to evaluate thickness, each lot will be divided into four equal sub-lots. Grade determinations will be made on the lot as a whole. Surface smoothness determinations will be made on every 0.1 mile segment in each lot. Location of all samples shall be selected on a random basis in accordance with ASTM D 3665. When operational conditions cause a lot to be terminated before the specified four sub-lots have been completed, the following procedure shall be used to adjust the lot size and number of tests for the lot. Where three sub-lots have been completed, they shall constitute a lot. Where one or two sub-lots have been completed, they shall be incorporated into the next lot (except for the last lot), and the total number of sub-lots shall be used and acceptance criteria adjusted accordingly.

1.5.8.2 Evaluation

Provide all sampling and testing required for acceptance and payment adjustment at the Contractor's expense. Individuals performing sampling, testing and inspection duties shall meet the required Qualifications. The Contracting Officer reserves the right to direct additional samples and tests for any area which appears to deviate from the specification requirements. Testing in these areas will be in addition to the sublot or lot testing, and the requirements for these areas will be the same as those for a sublot or lot. Provide facilities for and, where directed, personnel to assist in obtaining samples for any Government testing.

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Bulk Cementitious Materials

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

1.6.2 Aggregate Materials

Store aggregate at the site of the batching and mixing plant avoiding breakage, segregation, intermixing or contamination by foreign materials. Each size of aggregate from each source shall be stored separately in free-draining stockpiles. Aggregate stored on ground shall have a minimum 24 inch thick sacrificial layer left undisturbed. Fine aggregate and the smallest size coarse aggregate shall remain in free-draining storage for at least 24 hours immediately prior to use. Sufficient aggregate shall be maintained at the site at all times to permit continuous uninterrupted operation of the mixing plant at the time concrete pavement is being placed. Tracked equipment shall not be allowed on coarse aggregate stockpiles.

1.6.3 Other Materials

Store reinforcing bars and accessories above the ground on supports. All materials shall be stored avoiding contamination and deterioration.

PART 2 PRODUCTS

2.1 CEMENTITIOUS MATERIALS

Cementitious materials shall be portland cement or only portland cement in combination with supplementary cementitious materials (SCM), and shall conform to appropriate specifications listed below. New submittals are required when the cementitious materials sources or types change.

2.1.1 Portland Cement

Provide portland cement conforming to ASTM C 150/C 150M, Type I, II, or I/II. Type III cement shall be used only in concrete that is approved by the Project Engineer. Low alkali cement is required if the proposed aggregates are found to have greater than 0.04 percent expansion when tested in accordance with paragraph: Alkali-Silica Reactivity below.

2.1.3 Pozzolan

2.1.3.1 Fly Ash

Fly ash shall conform to ASTM C 618, Class F, including the optional requirements for uniformity and effectiveness in controlling Alkali-Silica reaction and shall have a loss on ignition not exceeding 6 percent. Class F fly ash for use in mitigating Alkali-Silica Reactivity shall have a Calcium Oxide (CaO) content of less than 13 percent and a total equivalent alkali content less than 3 percent.

2.1.3.2 Raw or Calcined Natural Pozzolan

Natural pozzolan shall be raw or calcined and conform to ASTM C 618, Class N, including the optional requirements for uniformity and effectiveness in controlling Alkali-Silica reaction and shall have a loss on ignition not exceeding 6 percent. Class N pozzolan for use in mitigating Alkali-Silica Reactivity shall have a Calcium Oxide (CaO) content of less than 13 percent and a total equivalent alkali content less than 3 percent.

2.1.3.3 Ultra Fine Fly Ash and Ultra Fine Pozzolan

Ultra Fine Fly Ash (UFFA) and Ultra Fine Pozzolan (UFP) shall conform to ASTM C 618, Class F or N, and the following additional requirements:

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

b. The average particle size shall not exceed 6 microns.

2.2 AGGREGATES

2.2.1 Aggregate Sources

2.2.1.1 Durability

Aggregate shall have a satisfactory service record in freezing and thawing of at least 5 years successful service in three concrete paving projects. The service record shall include a condition survey of the existing concrete and a review of the concrete-making materials, including coarse and fine aggregates, cement, and mineral admixtures. This review should consider the previous aggregate source and test results, cement mill certificate data, mineral admixture chemical and physical composition, and the mix design (cement factor and water-cementitious material ratio). Aggregate not having a satisfactory demonstrable service record shall have a durability factor of 50 or more when subjected to freezing and thawing of specimens prepared in accordance with ASTM C 1646/C 1646M and tested in accordance with ASTM C 666/C 666M, Procedure A.

2.2.1.2 Alkali-Silica Reactivity

Fine and coarse aggregates to be used in all concrete shall be evaluated and tested for alkali-aggregate reactivity. Both coarse aggregate size groups shall be tested.

a. The fine and coarse aggregates shall be evaluated separately, using ASTM C 1260. Test results of the individual aggregates shall have a measured expansion equal to or less than 0.08 percent after 28 days of immersion in a 1N NaOH solution. Should the test data indicate an expansion of greater than 0.08 percent, the aggregate(s) shall be rejected or additional testing shall be performed as follows: utilize the Contractor's proposed low alkali portland cement, and/or SCM, in combination with each individual aggregate. If only SCMs are being evaluated, the testing shall be in accordance with ASTM C 1567. Determine the quantity that will meet all the requirements of these specifications and that will lower the expansion equal to or less than 0.08 percent after 28 days of immersion in a 1N NaOH solution. Mixture proportioning shall be based on the highest percentage of SCM required to mitigate ASR-reactivity

b. If any of the above options does not lower the expansion to less than 0.08 percent after 28 days of immersion in a 1N NaOH solution, reject the aggregate(s) and submit new aggregate sources for retesting. Submit the results of testing to the Contracting Officer for evaluation and acceptance.

2.2.1.3 Not Used

2.2.1.4 Combined Aggregate Gradation

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

a. The materials selected and the proportions used shall be such that when the Coarseness Factor (CF) and the Workability Factor (WF) are plotted on a diagram as described in d. below, the point thus determined shall fall within the parallelogram described therein.

b. The Coarseness Factor (CF) shall be determined from the following equation:

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

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

d. A diagram shall be plotted using a rectangular scale with WF on the Y-axis with units from 20 (bottom) to 45 (top), and with CF on the X-axis with units from 80 (left side)…