32_13_11_PCC_Airfield_Pavements_revised.docx

SECTION TABLE OF CONTENTS DIVISION 32 - EXTERIOR IMPROVEMENTS

SECTION 32 13 11

CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY-DUTY PAVEMENTS

04/15

PART 1 GENERAL

1.1 UNIT PRICES

1.1.1 Measurements

1.1.2 Payments

1.1.2.1 Unit Price

1.1.3 Payment of Slabs

1.1.4 Payment Adjustment for Smoothness

1.1.5 Payment Adjustment for Plan Grade

1.2 REFERENCES

1.3 SYSTEM DESCRIPTION

1.3.1 Surface Smoothness

1.3.2 Joint Face Deformation

1.3.3 Flexural Strength

1.3.4 Diamond Grinding of PCC Surfaces

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.5.1 Contractor Quality Control Staff

1.5.2 Other Staff

1.5.3 Laboratory Accreditation

1.5.4 Preconstruction Testing of Materials

1.5.4.1 Aggregates

1.5.4.2 Chemical Admixtures, Curing Compounds and Epoxies

1.5.4.3 Cementitious Materials

1.5.5 Testing During Construction

1.5.6 Acceptability of Work

1.5.7 Acceptance Requirements

1.5.7.1 Pavement Lots

1.5.7.2 Evaluation

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 Bulk Cementitious Materials

1.6.2 Aggregate Materials

1.6.3 Other Materials

PART 2 PRODUCTS

2.1 CEMENTITIOUS MATERIALS

2.1.1 Portland Cement

2.1.2 Blended Cements

2.1.3 Pozzolan

2.1.3.1 Fly Ash

2.1.3.2 Raw or Calcined Natural Pozzolan

2.1.3.3 Ultra Fine Fly Ash and Ultra Fine Pozzolan

2.1.4 Ground Granulated Blast-Furnace (GGBF) Slag

2.1.5 Supplementary Cementitious Materials (SCM) Content

2.2 AGGREGATES

2.2.1 Aggregate Sources

2.2.1.1 Durability

2.2.1.2 Alkali-Silica Reactivity

2.2.1.3 Combined Aggregate Gradation

2.2.2 Coarse Aggregate

2.2.2.1 Material Composition

2.2.2.2 Particle Shape Characteristics

2.2.2.3 Size and Grading

2.2.2.4 Deleterious Materials - Airfield Pavements

2.2.2.5 Testing Sequence/Deleterious Materials in Coarse Aggregate

- Airfields Only

2.2.2.6 Deleterious Material - Road Pavements

2.2.3 Fine Aggregate

2.2.3.1 Composition

2.2.3.2 Grading

2.2.3.3 Deleterious Material

2.3 CHEMICAL ADMIXTURES

2.3.1 General Requirements

2.3.2 Lithium Nitrate

2.4 MEMBRANE FORMING CURING COMPOUND

2.5 WATER

2.6 JOINT MATERIALS

2.6.1 Expansion Joint Material

2.7 DOWELS

2.7.1 Dowels

2.7.2 Dowel Bar Assemblies

2.8 EPOXY RESIN

2.9 EQUIPMENT

2.9.1 Concrete Mixers

2.9.2 Finishing Equipment

2.9.3 Curing Equipment

2.9.4 Texturing Equipment

2.9.5 Sawing Equipment

2.9.6 Straightedge

2.10 REINFORCING STEEL

2.11 SPECIFIED CONCRETE STRENGTH AND OTHER PROPERTIES

PART 3 EXECUTION

3.1 PREPARATION FOR PAVING

3.1.1 Weather Precaution

3.1.2 Proposed Techniques

3.2 CONDITIONING OF UNDERLYING MATERIAL

3.2.1 General Procedures

3.2.2 Traffic on Underlying Material

3.3 WEATHER LIMITATIONS

3.3.1 Placement and Protection During Inclement Weather

3.3.2 Paving in Hot Weather

3.3.3 Prevention of Plastic Shrinkage Cracking

3.3.4 Paving in Cold Weather

3.4 CONCRETE PRODUCTION

3.4.1 Batching and Mixing Concrete

3.4.2 Transporting and Transfer - Spreading Operations

3.5 PAVING

3.5.1 General Requirements

3.5.2 Consolidation

3.5.3 Operation

3.5.4 Required Results

3.5.5 Fixed Form Paving

3.5.5.1 Forms for Fixed-Form Paving

3.5.5.2 Form Removal

3.5.6 Placing Dowels

3.5.6.1 Construction Joints-Fixed Form Paving

3.5.6.2 Dowels Installed in Hardened Concrete

3.5.6.3 Lubricating Dowel Bars

3.6 FINISHING

3.6.1 Machine Finishing With Fixed Forms

3.6.2 Surface Correction and Testing

3.6.3 Hand Finishing

3.6.3.1 Equipment and Template

3.6.3.2 Finishing and Floating

3.6.4 Texturing

3.6.4.1 Burlap Drag Surface

3.6.4.2 Surface Grooving

3.6.5 Edging

3.7 CURING

3.7.1 Protection of Concrete

3.7.2 Membrane Curing

3.8 JOINTS

3.8.1 General Requirements for Joints

3.8.2 Construction/Expansion Joints

3.8.3 Contraction/Control Joints

3.9 REPAIR, REMOVAL AND REPLACEMENT OF NEWLY CONSTRUCTED SLABS

3.9.1 General Criteria

3.9.2 Slabs with Cracks

3.9.3 Removal and Replacement of Full Slabs

3.9.4 Repairing Spalls Along Joints

3.9.5 Repair of Weak Surfaces

3.9.6 Repair of Pilot Lane Vertical Faces

3.10 EXISTING CONCRETE PAVEMENT REMOVAL AND REPAIR

3.10.1 Removal of Existing Pavement Slab

3.10.2 Edge Repair

3.10.2.1 Spall Repair

3.10.2.2 Underbreak and Underlying Material

3.11 PAVEMENT PROTECTION

3.12 TESTING AND INSPECTION FOR CONTRACTOR QUALITY CONTROL

3.12.1 Testing and Inspection by Contractor

3.12.2 Testing and Inspection Requirements

3.12.3 Concrete Strength Testing for Contractor CQC

3.12.4 Reports

-- End of Section Table of Contents --

FA4626-15-R-0008

Bi-annual PCC Slab Repair

SECTION 32 13 11 Page 21

SECTION 32 13 11

CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY-DUTY PAVEMENTS

02/15

PART 1 GENERAL

1.1 UNIT PRICES

1.1.1 Measurements

The quantity of concrete to be paid for will be the number of complete 25 ft x 25 ft slabs replaced. 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 slab for concrete. Joint sealing materials are covered in Section 32 13 11 1 Joints in PCC 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 per slab 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 Slabs

When a slab fails to meet the specification requirements, that slab 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 slab. 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 slab 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 slab shall be removed and replaced at no additional cost to the Government.

b. Profilograph Testing: Not used.

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 slab are outside the specified tolerance, the computed percent payment for that slab 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.

1.2 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.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)

AASHTO M 182 (2005; R 2009) Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton Mats

AMERICAN CONCRETE INSTITUTE INTERNATIONAL (ACI)

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

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

ACI 305R (2010) Guide to Hot Weather Concreting

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

ASTM A497/A497M (2007) Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete

ASTM A615/A615M (2012) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A775/A775M (2007b) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A996/A996M (2009b) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ASTM C1017/C1017M (2007) Standard Specification for Chemical Admixtures for Use in Producing Flowing Concrete

ASTM C1064/C1064M (2011) Standard Test Method for Temperature of Freshly Mixed Hydraulic-Cement Concrete

ASTM C1077 (2011c) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

ASTM C117 (2004) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

ASTM C123/C123M (2011) Standard Test Method for Lightweight Particles in Aggregate

ASTM C1260 (2007) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C131 (2006) Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136 (2006) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C138/C138M (2012) Standard Test Method for Density ("Unit Weight"), Yield, and Air Content (Gravimetric) of Concrete

ASTM C142/C142M (2010) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C143/C143M (2010a) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2012) Standard Specification for Portland Cement

ASTM C1567 (2011) Standard Test Method for Potential Alkali-Silica Reactivity of Combinations of Cementitious Materials and Aggregate (Accelerated Mortar-Bar Method)

ASTM C1602/C1602M (2012) Standard Specification for Mixing Water Used in Production of Hydraulic Cement Concrete

ASTM C1646/C1646M (2008a) Making and Curing Test Specimens for Evaluating Frost Resistance of Coarse Aggregate in Air-Entrained Concrete by Rapid Freezing and Thawing

ASTM C172/C172M (2010) Standard Practice for Sampling Freshly Mixed Concrete

ASTM C174/C174M (2006) Standard Test Method for Measuring Thickness of Concrete Elements Using Drilled Concrete Cores

ASTM C192/C192M (2007) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C231/C231M (2010) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

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

ASTM C294 (2005) Standard Descriptive Nomenclature for Constituents of Concrete Aggregates

ASTM C295/C295M (2012) Petrographic Examination of Aggregates for Concrete

ASTM C309 (2011) Standard Specification for Liquid Membrane-Forming Compounds for Curing Concrete

ASTM C31/C31M (2010) Standard Practice for Making and Curing Concrete Test Specimens in the Field

ASTM C33/C33M (2011a) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2012) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C494/C494M (2011) Standard Specification for Chemical Admixtures for Concrete

ASTM C595/C595M (2012) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2012) Standard Specification for Coal Fly

Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C666/C666M (2003; R 2008) Resistance of Concrete to Rapid Freezing and Thawing

ASTM C78/C78M (2010) Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

ASTM C88 (2005) Standard Test Method for Soundness of Aggregates by Use of Sodium Sulfate or Magnesium Sulfate

ASTM C881/C881M (2010) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C94/C94M (2012) Standard Specification for Ready-Mixed Concrete

ASTM C989/C989M (2012) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM D1751 (2004; R 2008) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D1752 (2004a; R 2008) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion

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

ASTM D3665 (2007e1) Random Sampling of Construction Materials

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

ASTM D75/D75M (2009) Standard Practice for Sampling Aggregates

ASTM E1274 (2003; R 2008) Standard Test Method for Measuring Pavement Roughness Using a Profilograph

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

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 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 straightedge method for transverse testing and for longitudinal testing. Where drawings show required deviations from a plane surface (crowns, drainage inlets, etc.) or existing rough or high PI pavement, 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 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.

b. Slab edges shall be formed to match the vertical height of the adjacent slab edge. Vertical height variation between existing and repaired slabs shall not exceed 1/4 inch.

c. Profilograph Testing: Not used

d. Bumps ("Must Grind" Areas): Any bumps ("must grind" areas) 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.

e. 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 slab 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 15 ft or less apart, as directed. Longitudinal testing lines shall be continuous across the slab.

(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: Not used.

1.3.2 Joint Face Deformation

a. Joint Face Deformation: The vertical joint face shall have a surface within the maximum limits shown below:

Vertical

Airfield Pavement

All Other Pavement

b. Excessive Joint Face Deformation: The concrete slabs having excessive joint deformation shall be removed and replaced to the next transverse joint in conformance with paragraph: REPAIR, REMOVAL, REPLACEMENT OF NEWLY CONSTRUCTED SLABS.

1.3.3 Flexural Strength

Submit 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. 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 slab shall be obtained in accordance with ASTM C172/C172M from one batch or truckload. Test cylinders 6 x 12 inches shall be fabricated and cured in accordance with ASTM C31/C31M, and tested in accordance with ASTM C39/C39M. Test two test cylinders per slab at 14 days.

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

1.3.4 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 slab. 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.

1.4 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 Section 01 00 00 3.15 SUBMITTAL PROCEDURES:

SD-03 Product Data Equipment; G Proposed Techniques; G Dowels; G Dowel Bar Assemblies; G Curing Compound; G Expansion Joint Material; G Reinforcing Steel (tie downs); G Epoxy for Dowels; G Epoxy for Spall Repair; G Spall Repair Plan; G

SD-05 Design Data

Proportioning Studies; G Tie Down design; G

Test Reports Sampling and Testing; G Certificates Contractor Quality Control Staff; G Laboratory Accreditation; G Commercial Laboratory; G

1.5 QUALITY ASSURANCE

1.5.1 Contractor Quality Control Staff

Submit American Concrete Institute certification for Contractor Quality Control staff. All Contractor Quality Control (CQC) 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 for the following staff:

a. Concrete Batch Plant Operator

1.5.3 Laboratory Accreditation

Laboratory and testing facilities shall be provided by and at the expense of the Contractor. Submit accreditation of the commercial laboratory by an independent evaluation authority, indicating conformance to ASTM C1077, including all applicable test procedures. The laboratories performing the tests shall be accredited in accordance with ASTM C1077, including ASTM C78/C78M and ASTM C1260. 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 C31/C31M. Flexural loading equipment shall be in accordance with ASTM C78/C78M.

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 C1077. 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 D75/D75M 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 concrete materials 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, ground granulated blast furnace (GGBF) slag, 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 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 Acceptability of Work

The materials and the pavement itself will be accepted on the basis of tests made by the Contractor and inspection of the pavement by the Government. 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.

1.5.7 Acceptance Requirements

1.5.7.1 PCC Pavement Slab Lots

A slab (25 ft x 25 ft) will be that quantity of construction that will be evaluated for acceptance with specification requirements. Grade determinations and edge finish determinations will be made on each slab as a whole. Surface smoothness determinations will be made on each slab.

1.5.7.2 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 specified testing, and the requirements for these areas will be the same as those for required testing. 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

Sufficient cementitious materials shall be in storage to sustain continuous operation of the concrete mixing plant while the pavement is being placed.

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 dowel 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, blended 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 C150/C150M, Type I or II including false set requirements.

2.1.2 Blended Cements

Blended cement shall conform to ASTM C595/C595M, Type IP or IS, including the optional requirement for mortar expansion and sulfate soundness. The pozzolan added to the Type IP blend shall be ASTM C618 Class F or Class N and shall be interground with the cement clinker. The manufacturer shall state in writing that the amount of pozzolan in the finished cement will not vary more than plus or minus 5 mass percent of the finished cement from lot to lot or within a lot. The percentage and type of mineral admixture used in the blend shall not change from that submitted for the aggregate evaluation and mixture proportioning. The requirements of Table 2 in paragraph SUPPLEMENTARY CEMENTITIOUS MATERIALS (SCM) CONTENT do not apply to the SCM content of blended cement.

2.1.3 Pozzolan

2.1.3.1 Fly Ash

Fly ash shall conform to ASTM C618, Class F, including the optional requirements for uniformity and effectiveness in controlling Alkali-Silica reaction and shall have a loss on ignition not exceeding 3 percent. Class F fly ash for use in mitigating Alkali-Silica Reactivity shall have 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 C618, Class N, including the optional requirements for uniformity and effectiveness in controlling Alkali-Silica reaction and shall have a loss on ignition not exceeding 3 percent. Class N pozzolan for use in mitigating Alkali-Silica Reactivity shall have 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 C618, 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.

2.1.4 Ground Granulated Blast-Furnace (GGBF) Slag

Ground Granulated Blast-Furnace Slag shall conform to ASTM C989/C989M, Grade 100 or Grade 120.

2.1.5 Supplementary Cementitious Materials (SCM) Content

The Contractor may elect to use one of the SCMs listed below, unless the SCM is required to mitigate ASR. The use of SCMs is encouraged in accordance with Section 01 62 35, Recycled/Recovered Materials.

TABLE 2

SUPPLEMENTARY CEMENTITIOUS MATERIALS CONTENT

Class N Pozzolan and Class F Fly Ash

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 C1646/C1646M and tested in accordance with ASTM C666/C666M, 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 C1260. 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, blended cement, and/or SCM, and/or Lithium Nitrate in combination with each individual aggregate. If only SCMs are being evaluated, the testing shall be in accordance with ASTM C1567. If Lithium Nitrate is being evaluated, with or without SCMs, the testing shall be in accordance with COE CRD-C 662. 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 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) to 30 (right side). On this diagram a parallelogram shall be plotted with corners at the following coordinates (CF-75, WF-28), (CF-75, WF-40), (CF-45, WF-32.5), and (CF-45, WF-44.5). If the point determined by the intersection of the computed CF and WF does not fall within the above parallelogram, the grading of each size of aggregate used and the proportions selected shall be changed as necessary.)

2.2.2 Coarse Aggregate

2.2.2.1 Material Composition

Coarse aggregate shall consist of crushed or uncrushed gravel, crushed stone, or a combination thereof. Aggregates, as delivered to the mixers, shall consist of clean, hard, uncoated particles meeting the requirements of ASTM C33/C33M except as specified herein. Coarse aggregate shall be washed. Washing shall be sufficient to remove dust and other coatings. Coarse aggregate shall be cleaned by processing with an approved log washer shall be required if standard washing is not sufficient to remove dust and other coatings. Coarse aggregate shall not show more than 40 percent loss when subjected to the Los Angeles abrasion test in accordance with ASTM C131. The sodium sulfate soundness loss shall not exceed 12 percent, or the magnesium sulfate soundness loss shall not exceed 18 percent after five cycles when tested in accordance with ASTM C88.

2.2.2.2 Particle Shape Characteristics

Particles of the coarse aggregate shall be generally spherical or cubical in shape. The quantity of flat and elongated particles in any size group coarser than the3/8 inch sieve shall not exceed 20 percent by weight as determined by the Flat Particle Test and the Elongated Particle Test of ASTM D4791. A flat particle is defined as one having a ratio of width to thickness greater than 3; an elongated particle is one having a ratio of length to width greater than 3.

2.2.2.3 Size and Grading

The nominal maximum size of the coarse aggregate shall be 1.5 inch. Grade and furnish the individual aggregates in two size groups meeting the individual grading requirements of ASTM C33/C33M, Size No. 4 (1.5 to 0.75 inches) and Size No. 67 (0.75 inches to No. 4) to meet the coarseness and workability factor criteria for the contractor-proposed combined gradation. A third aggregate size group may be required to meet the above mentioned coarseness and workability criteria of paragraph COMBINED AGGREGATE GRADATION.

2.2.2.4 Deleterious Materials - Airfield Pavements

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

TABLE 5a

LIMITS OF DELETERIOUS MATERIALS IN COARSE AGGREGATE FOR AIRFIELD PAVEMENTS

Percentage by Mass

Materials (h)

TABLE 5b

LIMITS OF DELETERIOUS MATERIALS IN COARSE AGGREGATE FOR AIRFIELD PAVEMENTS

Percentage by Mass

Materials (h)

Material finer than No. 200 sieve

(b) (ASTM C117) 0.5

Chert and cherty stone (less than

2.40 Sp. Gr.) (e) (ASTM C123/C123M and ASTM C295/C295M)

0.1

Shaly and argillaceous limestone

(g) (ASTM C295/C295M) 0.2

(a) Shale is defined as a fine-grained, thinly laminated or fissile sedimentary rock. It is commonly composed of clay or silt or both. It has been indurated by compaction or by cementation, but not so much as to have become slate.

(b) Limit for material finer than No. 200 sieve will be increased to 1.5 percent for crushed aggregates if the fine material consists of crusher dust that is essentially free from clay or shale.

(c) The separation medium shall have a density of Sp. Gr. of 2.0. This limit does not apply to coarse aggregate manufactured from blast-furnace slag unless contamination is evident.

(d) Clay ironstone is defined as an impure variety of iron carbonate, iron oxide, hydrous iron oxide, or combinations thereof, commonly mixed with clay, silt, or sand. It commonly occurs as dull, earthy particles, homogeneous concretionary masses, or hard-shell particles with soft interiors. Other names commonly used for clay ironstone are "chocolate bars" and limonite concretions.

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

TABLE 5c

LIMITS OF DELETERIOUS MATERIALS IN COARSE AGGREGATE FOR AIRFIELD PAVEMENTS

Percentage by Mass

Materials (h)

(f) Claystone, mudstone, or siltstone, is defined as a massive fine-grained sedimentary rock that consists predominantly of indurated clay or silt without laminations or fissility. It may be indurated either by compaction or by cementation.

(g) Shaly limestone is defined as limestone in which shale occurs as one or more thin beds or laminae. These laminae may be regular or very irregular and may be spaced from a few inches down to minute fractions of an inch. Argillaceous limestone is defined as a limestone in which clay minerals occur disseminated in the stone in the amount of 10 to 50 percent by weight of the rock; when these make up from 50 to 90 percent, the rock is known as calcareous (or dolomitic) shale (or claystone, mudstone, or siltstone).

(h) Perform testing in accordance with the referenced test methods, except that the minimum sample size shall be as specified below.

2.2.2.5 Testing Sequence/Deleterious Materials in Coarse Aggregate - Airfields Only

The Contractor will not be entitled to any extension of time or additional payment due to any delays caused by the testing, evaluation, or personnel requirements. The size of the coarse aggregate sample shall be at least 200 pounds for the 3/4 inch and larger maximum size and 25 pounds for the No. 4 to 3/4 inch coarse aggregate and 10 pounds for the fine aggregate. Provide facilities for the ready procurement of representative test samples. The testing procedure on each sample of coarse aggregate for compliance with limits on deleterious materials shall be as follows:

Step 1: Wash each full sample of coarse aggregate for material finer than the No. 200 sieve. Discard material finer than the No. 200 sieve.

Step 2: Test remaining full sample for clay lumps and friable particles and remove.

Step 3: Test remaining full sample for lightweight particles (Sp. Gr. 2.0) and remove.

Step 4. Test remaining full sample for chert and/or cherty stone with SSD density of less than 2.40 specific gravity. Remove lightweight chert and/or cherty stone. Restore other materials less than 2.40 to the sample.

Step 5: Test remaining sample for clay-ironstone, shale, claystone, mudstone, siltstone, shaly and/or argillaceous limestone, and remove.

Step 6: Test approximately one-fifth of remaining full sample for other soft particles.

2.2.3 Fine Aggregate

2.2.3.1 Composition

Fine aggregate shall consist of natural sand, manufactured sand, or a combination of the two, and shall be composed of clean, hard, durable particles meeting the requirements of ASTM C33/C33M. Each type of fine aggregate shall be stockpiled and batched separately. Particles of the fine aggregate shall be generally spherical or cubical in shape.

2.2.3.2 Grading

Grading of the fine aggregate, as delivered to the mixer, shall conform to the requirements of ASTM C33/C33M and shall have a fineness modulus of not less than 2.50 nor more than 3.40.

2.2.3.3 Deleterious Material

Sample size for fine aggregate proposed for use in airfield paving shall be 10 pounds. The amount of deleterious material in the fine aggregate shall not exceed the following limits by mass:

2.3 CHEMICAL ADMIXTURES

2.3.1 General Requirements

Chemical admixtures may only be used when the specific admixture type and manufacturer is the same material used in the mixture proportioning studies. The air-entraining admixture shall conform to ASTM C260/C260M. An accelerator conforming to ASTM C494/C494M, Type C, may be used only when specified in paragraph: SPECIFIED CONCRETE STRENGTH AND OTHER PROPERTIES below and shall not be used to reduce the amount of cementitious material used. Calcium chloride and admixtures containing calcium chloride shall not be used. Retarding or water-reducing admixture shall meet the requirements of ASTM C494/C494M, Type A, B, or D, except that the 6-month and 1-year compressive strength tests are waived. ASTM C494/C494M, Type F and G high range water reducing admixtures and ASTM C1017/C1017M flowable admixtures shall not be used.

2.3.2 Lithium Nitrate

The lithium admixture shall be a nominal 30 percent aqueous solution of Lithium Nitrate, with a density of 10 pounds/gallon, and shall have the approximate chemical form as shown below:

SO -2 (Sulfate Ion)

0.1 (max)

Provide a trained representative to supervise the lithium nitrate admixture dispensing and mixing operations.

2.4 MEMBRANE FORMING CURING COMPOUND

Membrane forming curing compound shall conform to ASTM C309, white pigmented Type 2, Class B.

2.5 WATER

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

2.6 JOINT MATERIALS

2.6.1 Slab Joint Material

Slab construction/expansion joints shall be formed with full depth fibrous joint seal material, 3/4” thick, capped with plastic or other removable cap, to allow placement of a 3/4” deep hot-applied rubberized asphalt seal above the fibrous expansion joint filler material.

Control/contraction joints shall also be sealed with hot-applied rubberized asphalt.

See 32 13 11 2 Joint Seals in PCC Pavements

2.7 DOWELS

2.7.1 Dowels

Dowels shall be single piece bars fabricated or cut to length at the shop or mill before delivery to the site. Dowels may be sheared to length provided that the deformation from true shape caused by shearing does not exceed 0.04 inch on the diameter of the dowel and does not extend more than 0.04 inch from the end of the dowel. Dowels shall be plain (non-deformed) steel bars conforming to ASTM A615/A615M, Grade 40 or 60; ASTM A996/A996M, Grade 50 or 60. Dowel bars shall be completely epoxy coated, to include the ends, in conformance with ASTM A775/A775M. Grout retention rings shall be fully circular metal or plastic devices capable of supporting the dowel until the epoxy hardens. Dowel sleeves or inserts are not permitted.

2.7.2 Dowel Bar Assemblies

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

2.8 EPOXY RESIN

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

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

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

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

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

2.9 EQUIPMENT

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

a. Details and data on the batching and mixing plant…