W9128F20R0056-Am-0009-Specifications.pdf

Hydrant Fuel System Replacement, Ellsworth AFB, SD EL84

SECTION TABLE OF CONTENTS

DIVISION 32 - EXTERIOR IMPROVEMENTS

SECTION 32 13 13.03

CONCRETE PAVEMENT

03/10

PART 1 GENERAL

1.1 REFERENCES

1.2 SUBMITTALS

1.3 ACCEPTABILITY OF WORK

1.4 QUALIFICATIONS

1.4.1 Contractor Quality Control Staff

1.4.2 Laboratory Accreditation

1.5 DELIVERY, STORAGE, AND HANDLING OF MATERIALS

1.6 EQUIPMENT

1.6.1 Batching and Mixing Plant

1.6.2 Truck Mixers

1.6.3 Paver-Finisher

1.6.4 Curing Equipment

1.6.5 Sawing Equipment

1.6.6 Straightedge

1.7 PROPOSED TECHNIQUES

1.8 PROPORTIONING STUDIES

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

2.1.4 Ground Granulated Blast-Furnace (GGBF) Slag

2.2 AGGREGATES

2.2.1 Aggregate Sources

2.2.1.1 Durability

2.2.1.2 Alkali-Silica Reactivity

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 Material

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

2.4 MEMBRANE FORMING CURING COMPOUND

2.5 WATER

2.6 EXPANSION JOINT FILLER MATERIAL

2.7 REINFORCING

SECTION 32 13 13.03 Page 1 Am #0009

2.7.1 Reinforcing Bars

2.7.2 Deformed Welded Wire Reinforcement

2.8 DOWELS AND TIE BARS

2.8.1 Dowels

2.8.2 Dowel Bar Assemblies

2.8.3 Tie Bars

2.9 EPOXY RESIN

2.10 SPECIFIED CONCRETE STRENGTH AND OTHER PROPERTIES

2.10.1 Specified Compressive Flexural Strength

2.10.2 Water-Cement Ratio

2.10.3 Air Entrainment

2.10.4 Slump

2.10.5 Concrete Temperature

2.10.6 Concrete Strength for Final Acceptance

2.11 MIXTURE PROPORTIONS

2.11.1 Composition

2.11.2 Proportioning Studies

2.11.2.1 Water-Cement Ratio

2.11.2.2 Trial Mixture Studies

2.11.2.3 Mixture Proportioning Procedure

2.11.3 Average Strength Required for Mixtures

PART 3 EXECUTION

3.1 PREPARATION FOR PAVING

3.2 CONDITIONING OF UNDERLYING BASE COURSE

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

3.5 PAVING

3.5.1 General Requirements

3.5.2 Consolidation

3.5.2.1 Immersion Type Vibrating Equipment

3.5.2.2 Vibratory Screed

3.5.2.3 Hand-Operated Vibrators

3.5.3 Fixed Form Paving

3.5.3.1 Forms for Fixed Form Paving

3.5.4 Slipform Paving

3.5.4.1 General

3.5.4.2 Guidelines for Slipform Paving

3.5.4.3 Laser Controls

3.5.5 Placing Reinforcing Steel

3.5.6 Placing Dowels and Tie Bars

3.5.6.1 Contraction Joints

3.5.6.2 Construction Joints-Fixed Form Paving

3.5.6.3 Dowels Installed In Hardened Concrete

3.5.6.4 Lubricating Dowel Bars

3.6 FINISHING

3.6.1 Machine Finishing With Fixed Forms

3.6.2 Machine Finishing with Slipform Pavers.

3.6.3 Surface Correction and Testing

3.6.3.1 Edge Slump

3.6.4 Hand Finishing

3.6.5 Texturing

3.6.5.1 Burlap Drag Surface

3.6.5.2 Artificial Turf Drag Surface

SECTION 32 13 13.03 Page 2

3.6.6 Edging

3.7 CURING

3.8 JOINTS

3.8.1 General Requirements for Joints

3.8.2 Longitudinal Construction Joints

3.8.3 Transverse Construction Joints

3.8.4 Thickened Edge Expansion Joints

3.8.5 Contraction Joints

3.9 REPAIR, REMOVAL, REPLACEMENT OF NEWLY CONSTRUCTED SLABS

3.9.1 General Criteria

3.9.2 Slabs with Cracks

3.9.3 Repairing Spalls Along Joints

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 Sampling

3.12.1.1 Aggregates

3.12.1.2 Concrete

3.12.1.3 Sample Identification

3.12.2 Testing

3.12.2.1 Aggregate Tests

3.12.2.2 Concrete Testing

3.12.3 Surface Testing

3.12.3.1 Smoothnesss

3.12.3.2 Testing Method

3.12.3.3 Plan Grade

3.12.3.4 Areas Defective in Plan Grade or Smoothness

3.12.4 Reports

-- End of Section Table of Contents --

SECTION 32 13 13.03 Page 3

SECTION 32 13 13.03

CONCRETE PAVEMENT

03/10

PART 1 GENERAL

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1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN CONCRETE INSTITUTE (ACI)

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

ACI 301 (2016) Specifications for Structural Concrete

ACI 305R (2010) Guide to Hot Weather Concreting

ACI 306R (2016) Guide to Cold Weather Concreting

ACI 325.9R (2015) Guide for Construction of Concrete Pavements

ASTM INTERNATIONAL (ASTM)

ASTM A1064/A1064M (2017) Standard Specification for Carbon-Steel Wire and Welded Wire Reinforcement, Plain and Deformed, for Concrete

ASTM A615/A615M (2016) Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement

ASTM A775/A775M (2016) Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A996/A996M (2016) Standard Specification for Rail-Steel and Axle-Steel Deformed Bars for Concrete Reinforcement

ASTM C1017/C1017M (2013; E 2015) 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

SECTION 32 13 13.03 Page 4

ASTM C1077 (2016) Standard Practice for Laboratories Testing Concrete and Concrete Aggregates for Use in Construction and Criteria for Laboratory Evaluation

ASTM C117 (2013) Standard Test Method for Materials Finer than 75-um (No. 200) Sieve in Mineral Aggregates by Washing

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

ASTM C1260 (2014) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)

ASTM C131/C131M (2014) Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

ASTM C136/C136M (2014) Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

ASTM C142/C142M (2017) Standard Test Method for Clay Lumps and Friable Particles in Aggregates

ASTM C143/C143M (2015) Standard Test Method for Slump of Hydraulic-Cement Concrete

ASTM C150/C150M (2018) Standard Specification for Portland Cement

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

ASTM C174/C174M (2016) Standard Test Method for Measuring Thickness of Concrete Elements Using Drilled Concrete Cores

ASTM C192/C192M (2018) Standard Practice for Making and Curing Concrete Test Specimens in the Laboratory

ASTM C231/C231M (2017a) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure Method

ASTM C260/C260M (2010a; R 2016) Standard Specification for Air-Entraining Admixtures for Concrete

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

ASTM C31/C31M (2019) Standard Practice for Making and Curing Concrete Test Specimens in the Field

SECTION 32 13 13.03 Page 5

ASTM C33/C33M (2018) Standard Specification for Concrete Aggregates

ASTM C39/C39M (2018) Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens

ASTM C42/C42M (2018a) Standard Test Method for Obtaining and Testing Drilled Cores and Sawed Beams of Concrete

ASTM C494/C494M (2017) Standard Specification for Chemical Admixtures for Concrete

ASTM C595/C595M (2018) Standard Specification for Blended Hydraulic Cements

ASTM C618 (2019) Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete

ASTM C78/C78M (2018) Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading)

ASTM C881/C881M (2015) Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM C94/C94M (2018) Standard Specification for Ready-Mixed Concrete

ASTM C989/C989M (2018a) Standard Specification for Slag Cement for Use in Concrete and Mortars

ASTM D1751 (2004; E 2013; R 2013) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)

ASTM D1752 (2018) Standard Specification for Preformed Sponge Rubber, Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

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

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

ASTM D75/D75M (2014) Standard Practice for Sampling Aggregates

NATIONAL READY MIXED CONCRETE ASSOCIATION (NRMCA)

NRMCA CPMB 100 (2000; R 2006) Concrete Plant Standards

SECTION 32 13 13.03 Page 6

NRMCA QC 3 (2015) 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 114 (1997) Test Method for Soundness of Aggregates by Freezing and Thawing of Concrete Specimens

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

COE CRD-C 171 (1995) Standard Test Method for Determining Percentage of Crushed Particles in Aggregate

U.S. DEPARTMENT OF DEFENSE (DOD)

MIL-DTL-24441/20 (2009; Rev B) Paint, Epoxy-Polyamide, Green Primer, Formula 150, Type III

UFC 3-270-01 (2018) O&M Manual: Asphalt and Concrete Pavement Maintenance and Repair

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1.2 SUBMITTALS

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

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

SD-03 Product Data

Equipment

a. A description of the equipment proposed for the machine and hand placing, consolidating and curing of the concrete mixture, method of control, and manufacturer's literature on the paver and finisher.

Proposed Techniques; G, RO

Placing and protection methods; paving sequence; data on curing equipment; demolition of existing pavements; as specified.

SD-05 Design Data

Proportioning Studies; G-DO

SD-06 Test Reports

Sampling and Testing; G, DO

SECTION 32 13 13.03 Page 7

Concrete Slump; G, RO

Air Content; G, RO

Pavement Thickness; G, RO

Surface Testing

Compressive Flexural Strength; G, RO

SD-07 Certificates

Contractor Quality Control Staff; G, RO

Laboratory Accreditation; G, RO

Commercial Laboratory; G, RO

1.3 ACCEPTABILITY OF WORK

The materials and the pavement itself will be accepted on the basis of tests made in accordance with paragraph: Testing and Inspection for Contractor Quality Control. Sampling and testing shall be conducted by the Contractor, using an approved commercial laboratory conforming with ASTM C1077. Provide USACE validation letter for commercial laboratory.

All sampling and testing for preconstruction testing of materials shall be performed by, and at the expense of, the Contractor, using an approved commercial laboratory or, for cementitious materials and chemical admixtures, a laboratory maintained by the manufacturer of the material.

Certified copies of laboratory test reports and sources for cement, pozzolan, GGBF, aggregates, admixtures, curing compound, epoxy, and proprietary patching materials proposed for use on this project. All aggregate tests must have been performed no earlier than 6 months prior to contract award. During construction, the Contractor is responsible for sampling and testing aggregates, cementitious materials, and concrete as specified herein. The Government may sample and test concrete and ingredient materials as considered appropriate. The Contractor must provide facilities and labor as may be necessary for procurement of representative test samples for the Government. Testing by the Government will in no way relieve the Contractor of the specified testing requirements.

1.4 QUALIFICATIONS

1.4.1 Contractor Quality Control Staff

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

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

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

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

SECTION 32 13 13.03 Page 8

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

1.4.2 Laboratory Accreditation

Laboratory and testing facilities must be provided by and at the expense of the Contractor. The laboratories performing the tests must be accredited by sn independent authority indicating conformance to ASTM C1077, including ASTM C78/C78M and ASTM C1260. The accreditation must be current and must include the required and optional test methods specified herein.

Provide onsite temperature-controlled concrete curing facilities.

1.5 DELIVERY, STORAGE, AND HANDLING OF MATERIALS

Deliver, store and handle cementitious materials, fine and coarse aggregates and other concreting materials in accordance with ASTM C94/C94M.

1.6 EQUIPMENT

Maintain all plant, equipment, tools, and machines used in the work in satisfactory working conditions at all times.

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1.6.1 Batching and Mixing Plant

The batching plant shall conform to NRMCA CPMB 100 and the equipment requirements in ASTM C94/C94M. The batching and mixing plant shall conform to the requirements of NRMCA CPMB 100 and NRMCA QC 3, however NRMCA certification is not required. The batching and mixing plant shall be no more than 30 minutes haul time from the placing site. There must be operable telephonic or radio communication between the plant and the placing site at all times concreting is taking place.

1.6.2 Truck Mixers

Truck mixers, the mixing of concrete therein, and concrete uniformity and testing thereof shall conform to the requirements of ASTM C94/C94M.

Additional water may be added to bring the slump within the specified range provided the approved water-cement ratio is not exceeded.

1.6.3 Paver-Finisher

The paver-finisher must be a heavy-duty, self-propelled machine designed specifically for paving and finishing high quality pavement. Clary screeds, other rotating tube floats, or bridge deck finishers must not be allowed on mainline paving, but may be allowed on irregular or odd-shaped slabs, and near buildings or trench drains, subject to the Contracting Officer's approval. Bridge deck finishers must have a minimum operating weight of 9000 pounds and must have a transversely operating carriage containing a knock-down auger and a minimum of two immersion vibrators.

Use vibrating screeds or pans only for isolated slabs where hand finishing is permitted as specified, and only where specifically approved. Concrete finishing equipment of types other than specified above may be demonstrated on a test section outside the production pavement if approved in writing.

1.6.4 Curing Equipment

Equipment must be self-propelled, with spraying nozzles and pressure that

SECTION 32 13 13.03 Page 9 can be controlled and operated with a fine nozzle to completely and uniformly cover pavement surface with required amount of curing compound.

It must mechanically agitate curing compound throughout application. Small or irregular areas may be sprayed by hand methods. Calibrate the spraying system in accordance with ASTM D2995, Method A, for the rate of application required in paragraph: MEMBRANE CURING. Any hand-operated sprayers allowed by paragraph: MEMBRANE CURING must be compressed air supplied by a mechanical air compressor. Immediately replace curing equipment that fails to apply an even coating of compound at the specified rate.

1.6.5 Sawing Equipment

Equipment for sawing joints and for other similar sawing of concrete shall be standard diamond-type concrete saws mounted on a wheeled chassis which can be easily guided to follow the required alignment. Use diamond tipped blades. If demonstrated to operate properly, abrasive blades may be used.

Provide spares as required to maintain the required sawing rate. Use saws capable of sawing to the full depth required. Early-entry saws may be used, subject to demonstration and approval of the Contracting Officer. No change to the initial sawcut depth is permitted.

1.6.6 Straightedge

Furnish and maintain at the job site, in good condition, one 12 foot straightedge for each paving train for testing the hardened portland cement concrete surfaces. These straightedges must be constructed of aluminum or magnesium alloy and have blades of box or box-girder cross section with flat bottom, adequately reinforced to insure rigidity and accuracy.

Straightedges must have handles for operation on the pavement.

1.7 PROPOSED TECHNIQUES

Submit plans for placing and protection methods; paving sequence; data on curing equipment; demolition of existing pavements; and other techniques as specified to the Contracting Officer.

1.8 PROPORTIONING STUDIES

The results of the mixture proportioning studies must be 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 must 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. Base aggregate quantities on the mass in a saturated surface dry condition. Accompany the recommended mixture proportions by test results demonstrating that the proportions selected will produce concrete of the qualities indicated. The submittal must include:

a. Coarse and fine aggregate gradations and plots.

b. Combined aggregate gradation and coarseness/workability plots.

c. Coarse aggregate quality test results, including deleterious materials.

d. Fine aggregate quality test results.

e. Mill certificates for cement, pozzolan, and GGBF slag.

f. Certified test results for air entraining, water reducing, retarding, non-chloride accelerating admixtures.

g. Specified compressive flexural strength, slump, and air

SECTION 32 13 13.03 Page 10 content.

h. Documentation for average CQC compressive flexural strength increase.

i. Recommended proportions/volumes for proposed mixture and trial water-cementitious materials ratios.

j. Individual cylinder beam breaks.

k. Compressive Flexural strength summaries and plots.

l. Historical record of test results, documenting production standard deviation (if available).Text

PART 2 PRODUCTS

2.1 CEMENTITIOUS MATERIALS

Cementitious materials shall be portland cement, blended cement or only portland cement in combination with natural pozzolan or fly ash or ground granulated blast furnace slag and shall conform to the appropriate specifications listed below.

2.1.1 Portland Cement

Portland cement shall conform to ASTM C150/C150M, Type I or II, low alkali 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.

2.1.3 Pozzolan

2.1.3.1 Fly Ash

Fly ash shall conform to ASTM C618, Class F, including the optional requirements for drying shrinkage, uniformity, and effectiveness in controlling Alkali-Silica reaction and has a loss on ignition not exceeding 3 percent. Class F fly ash shall have a Calcium Oxide (CaO) content of less than 8 percent.

2.1.3.2 Raw or Calcined Natural Pozzolan

Natural pozzolan shall be raw or calcined and shall conform to ASTM C618, Class N, including the optional requirements for drying shrinkage, uniformity, and effectiveness in controlling Alkali-Silica reaction and shall have a loss on ignition not exceeding 3 percent. Class N pozzolan shall have a Calcium Oxide (CaO) content of less than 5 percent.

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.

2.2 AGGREGATES

2.2.1 Aggregate Sources

2.2.1.1 Durability

Aggregate must have a satisfactory service record in freezing and thawing

SECTION 32 13 13.03 Page 11 of at least 5 years successful service in three concrete paving projects.

The service record must 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 must have a durability factor of 50 or more when subjected to freezing and thawing in concrete in accordance with COE CRD-C 114.

2.2.1.2 Alkali-Silica Reactivity

Evaluate and test fine and coarse aggregates to be used in all concrete for alkali-aggregate reactivity in accordance with ASTM C1260. Test both coarse aggregate size groups if from different sources. Evaluate the fine and coarse aggregates separately and in combination, which matches the Contractor's proposed mix design proportioning. Test results of the combination must have a measured expansion equal to or less than 0.08 percent at 16 days after casting. Should the test data indicate an expansion of greater than 0.08 percent, reject the aggregate(s) or perform additional testing, using a modified version of ASTM C1260 using one of the following options:

a. Utilize the Contractor's proposed low alkali portland cement and Class F fly ash or Class N pozzolan in combination with the proposed aggregate percentage for the test proportioning. Use Class F fly ash or Class N pozzolan in the range of 25 percent to 40 percent of the total cementitious material by mass. 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 at 16 days after casting.

b. Utilize the Contractor's proposed low alkali portland cement and ground granulated blast furnace (GGBF) slag in combination with the proposed aggregate percentage for the test proportioning. Use GGBF slag in the range of 40 percent to 50 percent of the total cementitious material by mass. 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 at 16 days.

If any of the above options does not lower the expansion to less than 0.08 percent at 16 days after casting, reject the aggregate(s) and submit new aggregate sources for retesting. Submit the results of testing to the Contracting Officer for evaluation and acceptance.

2.2.2 Coarse Aggregate

2.2.2.1 Material Composition

Coarse aggregate shall consist of crushedor uncrushed gravel, crushed stone, or a combination thereof. Crushed gravel shall contain not less than 75 percent of crushed particles by mass in each sieve size, as determined by COE CRD-C 171. 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 not show more than 40 percent loss when subjected to the Los Angeles abrasion test in accordance with ASTM C131/C131M.

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2.2.2.2 Particle Shape Characteristics

Particles of the coarse aggregate shall generally be spherical or cubical in shape. The quantity of flat and elongated particles in any size group 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 inches. When the nominal maximum coarse size is greater than 1 inch, grade the coarse aggregates and furnish 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).

2.2.2.4 Deleterious Material

The amount of deleterious material in each size group of coarse aggregate shall not exceed the limits in the following table when tested as indicated.

LIMITS OF DELETERIOUS MATERIALS IN

COARSE AGGREGATE

Percentage by Mass

Clay lumps and friable particles 2.0

(ASTM C142/C142M)

Material finer than 0.075 mm 1.0 (No. 200 sieve) (ASTM C117)

Lightweight particles 1.0

(ASTM C123)

Other soft particles 2.0

(COE CRD-C 130)

Total of all deleterious substances, 5.0 exclusive of material finer than No. 200 sieve

The limit for material finer than the No. 200 sieve will be increased to

1.5 percent for crushed aggregates consisting of crusher dust that is essentially free from clay or shale. The separation medium for lightweight particles must have a density of 2.0 Mg/cubic meter (Sp. Gr. 2.0).

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 is composed of clean, hard, durable particles.

Irrespective of the source from which it is obtained, all fine aggregate must be composed of clean, hard, durable particles meeting the requirements of ASTM C33/C33M. Stockpile and batch each type of fine aggregate separately. Particles of the fine aggregate must be generally spherical or cubical in shape.

SECTION 32 13 13.03 Page 13

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 3.00.

2.2.3.3 Deleterious Material

The amount of deleterious material in the fine aggregate must not exceed the following limits by mass:

Material Percentage by Mass

Clay lumps and friable particles ASTM C142/C142M 1.0

Material finer than 0.075 mm (No. 200 sieve) ASTM C117 3.0

Lightweight particles ASTM C123 using a medium 0.5 with a density of 2.0 Mg/cubic meter (Sp. Gr. of 2.0))

Total of all above 3.0

2.3 CHEMICAL ADMIXTURES

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 must 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 and must not be used to reduce the amount of cementitious material used.

Calcium chloride and admixtures containing calcium chloride must 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 shall be waived. ASTM C494/C494M, Type F and G high range water reducing admixtures and ASTM C1017/C1017M admixtures must not be used.

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 must be fresh, clean, potable, and free of injurious amounts of oil, acid, salt, or alkali, except that non-potable water may be used if it meets the requirements of ASTM C94/C94M.

2.6 EXPANSION JOINT FILLER MATERIAL

Expansion joint filler must be a preformed material conforming to ASTM D1751 or ASTM D1752 Type II or III. Expansion joint filler must be 3/4 inch thick, and must be furnished in a single full depth piece.

2.7 REINFORCING

All reinforcement shall be free from loose, flaky rust, loose scale, oil, grease, mud, or other coatings that might reduce the bond with concrete.

SECTION 32 13 13.03 Page 14

Removal of thin powdery rust and tight rust is not required. However, do not use reinforcing steel which is rusted to the extent that it does not conform to the required dimensions or mechanical properties.

2.7.1 Reinforcing Bars

Reinforcing bars shall conform to ASTM A615/A615M, billet-steel or ASTM A996/A996M, rail and axle steel, Grade 60.

2.7.2 Deformed Welded Wire Reinforcement

Deformed Welded Wire Reinforcement shall conform to ASTM A1064/A1064M and shall be furnished in flat sheets.

2.8 DOWELS AND TIE BARS

2.8.1 Dowels

Dowels must be single piece bars fabricated or cut to length at the shop or mill before delivery to the site. Dowels shall be free of loose, flaky rust and loose scale and shall be clean and straight. 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 must be plain (non-deformed) steel bars conforming to ASTM A615/A615M, Grade 40 or 60; ASTM A996/A996M, Grade 50 or 60. Paint for dowels shall conform to MIL-DTL-24441/20. As an alternate to paint, epoxy coatings conforming to ASTM A775/A775M may be used. Grout retention rings shall be fully circular metal or plastic devices capable of supporting the dowel until the epoxy hardens.

2.8.2 Dowel Bar Assemblies

Dowel bar assemblies must 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. ensure the dowels are welded to the assembly or held firmly by mechanical locking arrangements that will prevent them from rising, sliding out, or becoming distorted during paving operations.

2.8.3 Tie Bars

Tie bars shall be deformed steel bars conforming to ASTM A615/A615M, or ASTM A996/A996M, Grade 60, and of the sizes and dimensions indicated.

Deformed rail steel bars and high-strength billet or axle steel bars, Grade 50 or higher, must not be used for bars that are bent and straightened during construction.

2.9 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 must meet the following requirements:

a. Epoxy-resin used for embedding dowels shall be Type IV, Grade 3.

b. Epoxy-resin used as patching materials for complete filling of spalls and other voids and for use in preparing epoxy resin mortar

SECTION 32 13 13.03 Page 15 shall be Type III, Grade as approved.

c. Epoxy resin used for injecting cracks must be Type IV, Grade 1.

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

2.10 SPECIFIED CONCRETE STRENGTH AND OTHER PROPERTIES

2.10.1 Specified Compressive Flexural Strength

Specified flexural strength, R, for concrete is 650 psi at 28 days, as determined by tests made in accordance with ASTM C78/C78M of beams fabricated and cured in accordance with ASTM C192/C192M.

2.10.2 Water-Cement Ratio

Maximum allowable water-cementitious material ratio is 0.45. The water-cementitious material ratio will be the equivalent water-cement ratio as determined by conversion from the weight ratio of water to cement plus pozzolan, and ground granulated blast furnace slag by the mass equivalency method described in ACI 211.1.

2.10.3 Air Entrainment

The concrete must be air-entrained with a total air content of 6 percent plus or minus 1.5 percentage points, at the point of placement. Determine air content in accordance with ASTM C231/C231M.

2.10.4 Slump

The maximum allowable slump of the concrete at the point of placement is 2 inches for pavement constructed with fixed forms. For slipformed pavement, at the start of the project, select a maximum allowable slump which will produce in-place pavement with an edge slump of 1/4 inch or less. The selected slump is applicable to both pilot and fill-in lanes.

2.10.5 Concrete Temperature

The temperature of the concrete as delivered must conform to the requirements of paragraphs: PAVING IN HOT WEATHER and PAVING IN COLD WEATHER. Determine temperature of concrete in accordance with

ASTM C1064/C1064M.

2.10.6 Concrete Strength for Final Acceptance

The strength of the concrete will be considered acceptable when the 28-day compressive flexural strengths for each lot are above the 'Specified Compressive Flexural Strength'.

2.11 MIXTURE PROPORTIONS

2.11.1 Composition

Concrete shall be composed of cementitious material, water, fine and coarse aggregates, and admixtures. Class F flyash or Class N Pozzolan, if used with non alkali reactive aggregates, must consist of not less than 15 percent of the cementitious material by mass and not more than 35 percent.

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GGBF slag, if used with non alkali reactive aggregates, must consist of not less than 20 percent of the cementitious material by mass and not more than 50 percent. If Class F fly ash, Class N pozzolan, or GGBF slag is required to mitigate potential alkali-aggregate reactivity, the percentage by mass, as determined from the modified ASTM C1260 testing must be used in the mixture proportioning studies. The total cementitious material content must be at least 517 lb./cu. yd.. Admixtures shall consist of air entraining admixture and may also include accelerator, retarder or water-reducing admixture.

2.11.2 Proportioning Studies

Trial design batches, mixture proportioning studies, and testing requirements are the responsibility of the Contractor. Mixture proportioning shall be performed by a commercial Testing Laboratory conforming with ASTM C1077. Base trial mixtures having proportions, slumps, and air content suitable for the work on methodology described in ACI 211.1, modified as necessary to accommodate compressive flexural strength.

2.11.2.1 Water-Cement Ratio

Use at least three different water-cement ratios, which will produce a range of strength encompassing that required on the project. The maximum allowable water-cement ratio required in paragraph: SPECIFIED COMPRESSIVE FLEXURAL STRENGTH will be the equivalent water-cement ratio as determined by conversion from the mass ratio of water to cement plus pozzolan, and ground granulated blast furnace (GGBF) slag by the weight equivalency method as described in ACI 211.1. In the case where GGBF slag is used, include the mass of the GGBF slag in the equations in ACI 211.1 for the term P, which is used to denote the mass of pozzolan. Proporation laboratory trial mixtures for maximum permitted slump and air content.

2.11.2.2 Trial Mixture Studies

Make separate sets of trial mixture studies for each combination of cementitious materials and each combination of admixtures proposed for use. Do not use a combination of either until proven by such studies, except that, if approved in writing and otherwise permitted by these specifications, an accelerator or a retarder may be used without separate trial mixture study. Design each mixture to promote easy and suitable concrete placement, consolidation and finishing, and to prevent segregation and excessive bleeding.

2.11.2.3 Mixture Proportioning Procedure

The Contractor must perform the following:

a. Fabricate, cure and test 6 test specimens per age for each mixture at 28 days.

b. Using the average strength for each w/(c+p), plot the results from each mixture on separate graphs for w/(c+p) versus 28-day strength.

c. From the graphs select a w/(c+p) which will produce a mixture giving a 28-day strength equal to the required strength.

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2.11.3 Average Strength Required for Mixtures

In order to ensure meeting, during production, the strength requirements specified, the mixture proportions selected must produce a required average strength, f'cr, exceeding the specified strength, f'c, in accordance with procedures in Chapter 3 of ACI 301, "Proportioning."

PART 3 EXECUTION

3.1 PREPARATION FOR PAVING

Before commencing paving, perform the following:

Forms shall be in place, cleaned, coated, and adequately supported.

Equipment for spreading, consolidating, screeding, finishing, and texturing concrete shall be at the paving site, clean and in proper working order.

All equipment and material for curing and for protecting concrete from weather or mechanical damage shall be at the paving site, in proper working condition, and in sufficient amount for the entire placement.

When windy conditions during paving appear probable, equipment and material must be at the paving site to provide windbreaks, shading, fogging, or other action to prevent plastic shrinkage cracking or other damaging drying of the concrete.

3.2 CONDITIONING OF UNDERLYING BASE COURSE

Underlying base course, upon which concrete is to be placed must be clean, damp, and free from debris, waste concrete or cement, frost, ice, and standing or running water. After the underlying material has been prepared for concrete placement, no equipment is permitted thereon.

3.3 WEATHER LIMITATIONS

3.3.1 Placement and Protection During Inclement Weather

Follow practice found in ACI 325.9R, Chapter 10.

3.3.2 Paving in Hot Weather

The temperature of concrete must not exceed 90 degrees F. Steel forms, dowels and reinforcing shall be cooled prior to concrete placement when steel temperatures are greater than 120 degrees F. Follow practices found in ACI 305R.

3.3.3 Prevention of Plastic Shrinkage Cracking

During weather with low humidity, and particularly with high temperature and appreciable wind, develop and institute measures to prevent plastic shrinkage cracks from developing. If plastic shrinkage cracking occurs, halt further placement of concrete until protective measures are in place to prevent further cracking. Periods of high potential for plastic shrinkage cracking can be anticipated by use of Fig. 2.1.5 of ACI 305R.

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3.3.4 Paving in Cold Weather

Cold weather paving shall conform to ACI 306R. Do not begin placement of concrete unless the ambient temperature is at least 35 degrees F and rising. Thereafter, halt placement of concrete whenever the ambient temperature drops below 40 degrees F. When the ambient temperature is less than 50 degrees F, ensure the temperature of the concrete when placed is not less than 50 degrees F nor more than 75 degrees F. Materials entering the mixer shall be free from ice, snow, and frozen lumps. Do not incorporate salt, chemicals or other materials in the concrete to prevent freezing. If allowed under paragraph: MIXTURE PROPORTIONS, an accelerating admixture may be used when the ambient temperature is below 50 degrees F.

Provide covering and other means for maintaining the concrete at a temperature of at least 50 degrees F for not less than 72 hours after placing, and at a temperature above freezing for the remainder of the curing period.

3.4 CONCRETE PRODUCTION

Batching, mixing, and transporting shall conform to ASTM C94/C94M. The equipment must have a capacity sufficient to maintain a continuous, uniform forward movement of the paver. A batch ticket from the operator of the batching plant must accompany every load of concrete delivered to the paving site. Tickets shall be on approved forms and shall show at least the mass, or volume, of all ingredients in each batch delivered, and the time of day. Deliver tickets to the placing foreman who must keep them on file and deliver them to the Government weekly.

3.5 PAVING

3.5.1 General Requirements

Construct pavement with paving and finishing equipment utilizing rigid fixed forms or by use of slipform paving equipment. Control paving equipment and its operation, and coordinate with all other operations, such that the paver-finisher has a continuous forward movement, at a reasonably uniform speed, from beginning to end of each paving lane, except for inadvertent equipment breakdown.

3.5.2 Consolidation

Concrete shall be consolidated using immersion type vibrating equipment .

3.5.2.1 Immersion Type Vibrating Equipment

Consolidate concrete with lane-spanning, gang-mounted, mechanical, immersion type vibrating equipment mounted in front of the paver. Insert the vibrators into the concrete to a depth that will provide the best full-depth consolidation but not closer to the underlying material than 2 inches. Hand-operated immersion type vibrators may be used in areas not accessible to lane-spanning pavers.

3.5.2.2 Vibratory Screed

Consolidate concrete using vibratory truss screed equipment capable of consolidating the full depth of concrete. Hand-operated vibratory screeds may be used in areas not accessible to vibratory truss screeds.

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3.5.2.3 Hand-Operated Vibrators

Text

3.5.3 Fixed Form Paving

Paving equipment for fixed-form paving and its operation shall conform to the requirements of paragraph EQUIPMENT, all requirements specified above under paragraph PAVING and as specified herein.

3.5.3.1 Forms for Fixed Form Paving

a. Straight forms shall be made of steel and furnished in sections not less than 10 feet in length. Use flexible or curved forms of proper radius for curves of 100-foot radius or less.

Wood forms for curves and fillets shall be made of well-seasoned, surfaced plank or plywood, straight, and free from warp or bend.

Wood forms shall be adequate in strength and rigidly braced.

Forms must have a depth equal to the pavement thickness at the edge. Maximum vertical deviation of top of any side form, including joints, must not vary from a true plane more than 1/8 inch in 10 feet, and the upstanding leg shall not vary more than 1/4 inch.

b. Tightly lock form sections and ensure they are free from play or movement in any direction. Provide forms with adequate devices for secure settings so that when in place they will withstand, without visible spring or settlement, the impact and vibration of the consolidating and finishing equipment.

c. Set forms for full bearing on foundation for entire length and width and in alignment with edge of finished pavement. Support forms during entire operation of placing, compaction, and finishing so that forms will not deviate vertically more than 0.01 foot from required grade and elevations indicated. Do not place concrete until setting of forms has been checked and approved by the CQC team.

3.5.4 Slipform Paving

3.5.4.1 General

Paving equipment for slipform paving and its operation shall conform to the requirement of paragraph EQUIPMENT and all requirements specified above.

3.5.4.2 Guidelines for Slipform Paving

Guidelines must be accurately and securely installed well in advance of concrete placement. Provide supports at necessary intervals to eliminate all sag in the guideline when properly tightened. The guideline shall be high strength wire set with sufficient tension to remove all sag between supports. Securely stake supports to the underlying material or make other provisions to ensure that the supports will not be displaced when the guideline is tightened or when the guideline or supports are accidentally touched by workmen or equipment during construction.

3.5.4.3 Laser Controls

If the Contractor proposes to use any type of automatic laser controls, a

SECTION 32 13 13.03 Page 20 detailed description of the system must be submitted and a trial field demonstration performed in the presence of the Contracting Officer at least one week prior to start of paving. Approval of the control system is based on the results of the demonstration and on continuing satisfactory operation during paving.

3.5.5 Placing Reinforcing Steel

Position the reinforcement on suitable chairs securely fastened to the subgrade prior to concrete placement. Vibrate concrete after the steel has been placed. Regardless of placement procedure, ensure the reinforcing steel is free from coatings which could impair bond between the steel and concrete, and indicate laps in the reinforcement as indicated. In lieu of the above, automatic reinforcement depressing attachments may be used to position the reinforcement provided the entire operation is approved by the Contracting Officer. Regardless of the equipment or procedures used for installing reinforcement, ensure that the entire depth of concrete is adequately consolidated.

3.5.6 Placing Dowels and Tie Bars

The method used in installing and holding dowels in position must ensure that the error in alignment of any dowel from its required horizontal and vertical alignment after the pavement has been completed will not be greater than 1/8 in. per ft. Except as otherwise specified below, horizontal spacing of dowels must be within a tolerance of plus or minus 5/8 inch. Check the horizontal alignment with a framing square. Do not place dowels and tie bars closer than 0.6 times the dowel bar or tie bar length to the planned joint line. If the last regularly spaced dowel or tie bar is closer than that dimension, it must be moved away from the joint to a location 0.6 times the dowel bar or tie bar length. Install dowels as specified in the following subparagraphs.

3.5.6.1 Contraction Joints

Hold dowels and tie bars in longitudinal and transverse contraction joints within the paving lane securely in place, as indicated, by means of rigid metal frames or basket assemblies of an approved type. Hold the basket assemblies securely in the proper location by means of suitable pins or anchors.

3.5.6.2 Construction Joints-Fixed Form Paving

Install dowels and tie bars using the bonded-in-place method. Do not install by removing and replacing in preformed holes. Prepare dowels and tie bars and place across joints where indicated, correctly aligned, and securely held in the proper horizontal and vertical position during placing and finishing operations, by means of devices fastened to the forms.

3.5.6.3 Dowels Installed In Hardened Concrete

Install dowels in hardened concrete by bonding the dowels into holes drilled into the hardened concrete. Drill holes approximately 1/8 inch greater in diameter than the dowels into the hardened concrete. Repair any damage to the concrete face during drilling as directed. Bond dowels in the drilled holes using epoxy resin. Inject epoxy resin at the back of the hole before installing the dowel and extruded to the collar during insertion of the dowel so as to completely fill the void around the dowel.

Do not apply by buttering the dowel. Hold the dowels in alignment at the

SECTION 32 13 13.03 Page 21 collar of the hole, after insertion and before the grout hardens, by means of a suitable metal or plastic grout retention ring fitted around the dowel.

3.5.6.4 Lubricating Dowel Bars

Wipe clean the portion of each dowel intended to move within the concrete or expansion cap and coat with a thin, even film of lubricating oil before the concrete is placed.

3.6 FINISHING

Finishing operations shall be a continuing part of placing operations starting immediately behind the strike-off of the paver. Provide initial finishing by the transverse screed or extrusion plate. The sequence of operations are transverse finishing, longitudinal machine floating if used, straightedge finishing, texturing, and then edging of joints. Finish by the machine method. Use the hand method only on isolated areas of odd slab widths or shapes and in the event of a breakdown of the mechanical finishing equipment. Keep supplemental hand finishing for machine finished pavement to an absolute minimum. Make every effort to prevent bringing excess paste to the surface and halt any operations which produce more than 1/8 inch of paste (mortar, water, laitance, etc.) over the top layer of coarse aggregate immediately and the equipment, mixture, or procedures modified as necessary.

3.6.1 Machine Finishing With Fixed Forms

Use a machine designed to ride the forms and operate to screed and consolidate the concrete. Replace machines that cause displacement of the forms. The machine shall make only one pass over each area of pavement.

If the equipment and procedures do not produce a surface of uniform texture, true to grade, in one pass, immediately stop the operation and the equipment, mixture, and procedures adjusted as necessary.

3.6.2 Machine Finishing with Slipform Pavers.

Operate the slipform paver so that only a very minimum of additional finishing work is required to produce pavement surfaces and edges meeting the specified tolerances. A self-propelled nonrotating pipe float may be used while the concrete is still plastic, to remove minor irregularities and score marks. allow only one pass of the pipe float. If there is concrete slurry or fluid paste on the surface that runs over the edge of the pavement, immediately stop the paving operation and the equipment, mixture, or operation modified to prevent formation of such slurry.

3.6.3 Surface Correction and Testing

After all other finishing is completed but while the concrete is still plastic, eliminate minor irregularities and score marks in the pavement surface by means of cutting straightedges. Use straightedges 12 feet in length and operate from the sides of the pavement and from bridges. Equip a straightedge operated from the side of the pavement with a handle 3 feet longer than one-half the width of the pavement. Then test the surface for trueness with a straightedge held in successive positions parallel and at right angles to the center line of the pavement, and the whole area covered as necessary to detect variations. Advance the straightedge along the pavement in successive stages of not more than one-half the length of the straightedge. Immediately fill depressions with freshly mixed concrete, then strike off, consolidate, and refinish. Strike off and refinish

SECTION 32 13 13.03 Page 22 projections above the required elevation. Produce the surface finish of the pavement essentially by the finishing machine and not by subsequent hand finishing operations. All hand finishing operations are subject to approval and must be modified when directed.

3.6.3.1 Edge Slump

Determine slump of edges with a 12 foot straightedge. Before the concrete hardens, correct edge slump of pavement exceeding 1/4 inch at edge of pavement. Limit the area affected by the downward movement of the concrete along the pavement edge to not more than 18 inches from the edge.

3.6.4 Hand Finishing