02521.doc

SECTION 02521

REPAIR OF JOINTS AND CRACKS

RIGID AIRFIELD PAVEMENT

PART 1 - GENERAL

1.

APPLICABLE PUBLICATIONS: The publications listed below form a part of this specification. The publications are referred to in the text by basic designation only.

1.1 American Society for Testing and Materials (ASTM) Publications:

C 509-94

Specification for Elastomeric Cellular

Preformed Gasket and Sealing Material

C 603-90

Test Method for Extrusion Rate and

Application Life of Elastomeric Sealants

C 639-95

Test Method for Rheological (Flow)

Properties of Elastomeric Sealants

C 661-93

Test Method for Indentation Hardness of

Elastomeric-Type Sealants by Means of a Durometer

C 679-87

Test Method for Tack-Free Time of

Elastomeric Sealants

C 719-93

Test Method for Adhesion and Cohesion of Elastomeric Joint Sealants Under

Cyclic Movement (Hockman Cycle)

C 792-93

Test Method for Effects of Heat Aging on Weight Loss, Cracking, and Chalking of Elastomeric Sealants

C 793-91

Test Method for Effects of Accelerated

Weathering on Elastomeric Joint Sealants

D 412-92

Test Method for Vulcanized Rubber and

Thermoplastic Rubbers and Thermoplastic

Elastomers - Tension

D 789-94

Test Method for Determination of Relative

Viscosity Melting Point, and Moisture

Content of Polyamide (PA)

E 548-94

Guide for General Criteria Used for

Evaluating Laboratory Competence

1.2.

Department of the Army, Corps of Engineers, Handbook for Concrete and Cement:

CRD-C 525-89

Test Method for Evaluation of Hot

Applied Joint Sealants for Bubbling

Due to Heating

1.3. Federal Specifications:

FS SS-S-200E

Sealants, Joint, Two Component, Jet-Blast Resistant, Cold-Applied, for Portland Cement Concrete

Pavement

FS SS-S-1401C

Sealant, Joint, Non-Jet-Fuel-

Resistant, Hot-Applied, for

Portland Cement and Asphalt

Concrete Pavements

FS SS-S-1614A

Sealants, Joint, Jet-Fuel-Resistant, Hot Applied, for Portland Cement and Tar Concrete Pavements

2.

QUALITY ASSURANCE/ QUALITY CONTROL (QA/QC) PROCEDURES:

2.1 Construction Material Testing (QA) by Government: The Government will use the results of material testing accomplished by the Contractor to evaluate construction for acceptance and payment. The Contractor shall provide copies of all testing results and product certifications to the Contracting Officer representative within 24 hours of completion of testing.

2.2 Construction Material Testing (QC) by Contractor: The Contractor shall retain the services of an independent commercial testing laboratory, herein after referred to as QC LAB, to perform Quality Control (QC) functions necessary to the work. The QC LAB shall test the joint seal material to be used on the work and will perform monitoring of the work on a daily basis. The minimum daily monitoring requirements are described in paragraph CONTRACTOR QUALITY CONTROL. Within 15 days of the Notice to Proceed date the Contractor shall submit the qualifications statement of the QC LAB. The Government will review the qualifications of the laboratory and, if necessary, visit the QC LAB. The Contracting Officer will, within 7 working days from the date that all qualifications data are received, either approve or reject the proposed laboratory. Evaluation criteria shall include, as minimum, local area industry standards for the performance of materials testing, ASTM E-548, and respective State Highway Department certification where there is a State program.

2.3 Pavement Repair Test Section: Before proceeding with the work the Contractor shall demonstrate that he can perform to the intent of this specification. The Contractor shall place a test section in an area designated by the Contracting Officer. The Contractor shall demonstrate his ability to clean and prepare joints and cracks, place the joint sealing material, and perform the quality control functions specified. All processes and procedures used by the Contractor to construct an acceptable test section shall become the standard of evaluation for performance on the work. The Contractor shall obtain written approval of the test section before proceeding with the work. The Government will expect to see equipment, materials, and procedures which were used at the test section incorporated into the work.

3.

MATERIAL ACCEPTANCE by TESTING and SUBMITTALS:

3.1 Preconstruction Sampling and Testing:

3.1.1 Joint Sealant Material: The Contractor shall provide a sample of the joint sealant material which is to be used on the work. The sample will be tested to determine compliance with Federal specifications for materials characteristics.

3.1.2 Sampling and Testing: The Contractor shall accomplish sampling and testing of the joint sealant for compliance with Federal specifications. Split samples of the sealant will be provided to the Government. All quality testing results will be provided to the Contracting Officer at least 10 days before starting work. The Contracting Officer representative will either approve or disapprove the source within 7 days of receipt of test data submittal.

3.2.

Submittal of Manufacturer Instructions: The manufacturer of the joint sealant shall provide an installation procedures instruction to the Contractor. The Contractor shall submit a copy of the instructions to the Government. The submittal shall be made concurrent with the results of testing and/or samples of material.

4.

ACCEPTANCE OF CONSTRUCTION PROCEDURES:

4.1.

Cleaning of Joints, Cracks, and Clean-up: Debris from the removal of existing joint sealant, crack routing, and joint facing shall be removed from the job site on a daily basis. Work shall not proceed from one area of attention to another without clean-up of the initial effort. Dust, debris, water, and fugitive materials shall be controlled at all times. Debris from the work area shall not become a nuisance in areas outside of the designated area of the work.

4.2.

Environmental Protection: Work from the cleaning and preparation of joint faces will be performed to comply with local environmental controls, policies and directives.

4.3.

Pavement Joint Seal and Crack Repair Test Section:

4.3.1. Construction Methods: The Contractor shall perform the work necessary to clean, prepare joint faces, and reseal a minimum of 61 meters (200 feet) of joint at a location designated by the Contracting Officer. The Contractor shall route and seal one full slab width crack at an area designated by the Contracting Officer. When a satisfactory test section, of either method, is accepted the work will be paid for as a part of the work. The Contractor shall use those methods, materials, and equipment used to do the test section for the remainder of the work. Quality control shall be included in the test section.

4.3.2. Test Section Acceptance: The Contracting Officer and the designated representative of the Contracting Officer will observe the test section work being performed. Corrections to the Contractors procedures, if required, will be made. If the section is rejected, the reasons shall be specifically documented. The Contractor shall remove and replace test sections which are not accepted by the Government. Test sections shall be repeated until the Contractor successfully demonstrates an acceptable construction procedure.

5.

MEASUREMENT:

5.1.

Joint Cleaning and Sealing: The quantity to be paid for will be the number of linear feet of joints that are cleaned and re-sealed approved and accepted by the Contracting Officer.

5.2.

Crack Routing and Sealing: The quantity to be paid for will be the number of linear feet of cracks which are routed and sealed and accepted by the Contracting Officer. The measurement will be the straight line dimension from the point of beginning to the point of ending of the repair on a single full slab.

6.

PAYMENT: The quantities paid for at the unit prices shall include the cost of all labor, materials, equipment, and tools required to provide a complete and functional unit.

END PART 1 - GENERAL

PART 2 - PRODUCTS

7.

MATERIALS:

7.1.

SEALANTS: Materials for sealing cracks in the paved areas of the work shall be as follows:

Silicone Sealant such as that manufactured by Dow Corning 890-SL, or equivalent.

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

TEST

METHOD

REQUIREMENTS

Weight Loss

ASTM C 792 Modified (1)

10 percent max.

Flow

ASTM C 639 (Type I)

Smooth and level

Extrusion Rate

ASTM C 603

30 sec maximum

Tack Free Time

ASTM C 679

5 hours max

Hardness(Shore 00)

ASTM C 661

30-80

(see note 2)

Tensile Stress at

ASTM D 412 (Die C)

207 kPa (30 psi) max

150% Elongation

(see note 2)

Percent Elongation

ASTM D 412 (Die C)

700 min

(see note 2)

Accelerated

ASTM C 793

Pass 5000 hours

Weathering

Bond and Movement

ASTM C 719

Pass 10 cycles at

Capability

(50% movement (no adhesion or cohesion failure)

Flame Resistant

FS-SS-S-200

Pass

NOTES:

1.

Percent weight loss of wet (uncured) sample after placing in forced down draft oven maintained at 70ºC (2ºC (158ºF (3.6ºF)for two hours.

2.

Specimen cured 21 days at 23ºC (2ºC (73ºF (3.6ºF)and 50% (5% humidity.

3.

Accelerated Weathering Factory Test Report: In lieu of testing of actual joint seal to be used on the project, a report of a factory test, performed within two years of contract award, may be submitted.

7.2 Primers: Primers, when recommended by the sealant manufacturer, shall be included in the work.

7.3.

Backer Materials: The backup material, backer rod, shall be a compressible, non-shrinking, non-staining, non-absorbing material. The backer material shall not be of a composition to react chemically with the sealant material. The backer shall have a melting temperature exceeding the application temperature of the sealant. The backer shall be 25 percent larger than the size of the reservoir in which the material is placed.

END PART 2 - PRODUCTS

PART 3 - EXECUTION

8.

PREPARATION OF JOINTS: All joints shall be thoroughly cleaned before the installation of new joint sealant. All deleterious substances shall be removed from the joint seal reservoir before the application of new sealant.

8.1.

Existing Sealant Removal: The sealant in cracks or joints shall be removed with a joint plow, or other equipment, which shall remove joint seal and back-up material. Any procedure or equipment which results in damage to the concrete shall be terminated and other methods employed. Hand tools should be used to remove bulk materials from random cracks or irregular joint faces.

8.2.

Re-facing of Joints:

Not applicable to this project 8.3.

Facing Random Cracks: Random cracks shall be routed with a vertical spindle router or a concrete saw with a small diameter blade. Rotary impact routers shall not be used. Cracks shall be pressure-washed to remove all loose debris and cement mortar. Crack routing details are provided in Figure A3e. Cracks shall be routed to a minimum width of 13 millimeters (1/2-inch) and 19 millimeters (3/4-inch) depth. When routing must be wider to match the crack width, the depth shall equal the width. When backer rod material is required the depth shall be increased to accommodate the backer rod. Guidelines for crack repair follow:

8.3.1. Low severity cracks: Hairline to 6 millimeters (1/4 inch), with no spalling shall not be repaired. Low severity cracks with spalling shall be routed and sealed.

8.3.2. Cracks from 6 millimeters (1/4-inch) to 13 millimeters (1/2-inch) wide shall be routed and sealed.

8.3.3. Cracks 9 millimeters (3/8-inch) to 19 millimeters (3/4-inch) wide with major spalling shall be repaired using rigid pavement repair procedures.

8.3.4. Cracks 19 millimeters (3/4 inch) to 38 millimeters (1-1/2 inch) with no spalling shall be routed and sealed. Backer rod material shall be used if the crack is greater than 19 millimeters (3/4-inch) wide. Cracks with major spalling shall be rebuilt as a joint using the rigid pavement repair procedures.

9.

SEALANT APPLICATION:

9.1.

Preparation of Sealants:

9.1.1. Cold-Applied Sealants: Containers shall be inspected for damage or evidence of product contamination prior to use of the material. Any materials which are found to contain water, are caked, have separated components, or otherwise appear unsatisfactory shall be wasted.

9.2.

Installation of Sealant:

9.2.1. Time of Application: Joints and cracks shall be sealed immediately following final cleaning and directly following installation of the backer material. When rain, or other adverse conditions, interrupt sealant application, the work shall stop. When work can resume, joints and cracks shall be re-cleaned and dried before resumption of the sealant application. New concrete joint faces shall be allowed to cure for a minimum time of seven days before sealant application.

9.2.2. Sealing Joints and Cracks: A final cleaning of the joints and cracks, using heated high pressure air, shall precede the application of sealant material. The application shall not be more than 15 meters (50 feet) behind the final cleaning procedure. Joints and cracks shall be filled from the bottom up to 6 millimeters (1/4-inch), plus or minus 1.5 millimeters (1/16-inch), from the top of the pavement surface. Excess sealant at overfilled joints, or spillage, shall be removed form the pavement and discarded.

10.

PROTECTION OF THE WORK: The Contractor shall protect the work from damage prior to final acceptance of the work by the Government. Traffic shall be excluded from the pavement by erecting barricades and signs. The work area shall be kept clean and any spillage of materials shall be cleaned up when the spillage occurs.

11.

CONTRACTOR QUALITY CONTROL (QC): The Contractor shall perform the minimum inspection and tests described. The results of the inspections or tests require action by the Contractor. The QC function shall be accomplished by an independent testing laboratory.

11.1.

Inspection Details and Frequency of Testing: The following is considered to be the minimum acceptable for each of the described processes.

11.1.1. Certification of Materials: When the Contractor is required to do the testing to show compliance with the appropriate Federal specification, the QC LAB shall accomplish the testing. The QC LAB shall verify that the materials used on the work are of the same lot as that tested for compliance.

11.1.2. Equipment Check: When hot-applied sealants are to be used, the temperature recording devices on the applicator reservoirs shall be calibrated at the beginning of the work. Faulty temperature indicators or gauges shall be replaced or a calibration curve shall be provided. Equipment used to mix materials and proportion components shall be calibrated to assure that a uniform mixture is supplied to the applicator.

11.1.3. Joint Cleaning: Joints shall be inspected during the cleaning process. Joints and cracks shall be inspected for residue and damage to pavement.

11.1.4. Joint Sealant Application: The application shall be checked as the sealant is applied to the joint or crack. Conformance with temperature, proportioning, and mixing shall be monitored. Any evidence of bubbling, improper installation, or failure to cure as defined by the manufacturer, shall be cause to stop the work until the causes of the deficiency are identified and corrective action is effected.

11.1.5. Joint Sealant Curing: The sealant shall be checked for proper curing, set, and bonding to the joint walls. A sample of applied material shall be extracted from the joint or crack for each 305 meters (1000 feet) of applied material, or portion thereof. Sealants exhibiting any deficiencies, or which do not perform as described in manufacturer instruction and guidelines, shall be removed from the work, wasted, and replaced. The Contractor shall repair all test locations with fresh sealant application.

11.2.

Action Required for Deficiency Correction:

11.2.1. Materials Certification: When a material is found not in compliance with Federal specifications, the lot shall be rejected and a new lot submitted for testing.

11.2.2. Equipment Checks: Equipment found to be defective shall be replaced or repaired prior to being placed on the work.

11.2.3. Joint Cleaning: Joints or cracks which have residual materials shall be cleaned and/or refaced to remove the debris. Joints or cracks which will exceed width or depth limitations for resealing shall be identified to the Government.

11.2.4. Joint Sealant Application: Sealant which is overheated, too cool, or fails to cure properly, shall be removed and replaced. Joints and cracks from which sealant has been removed shall be cleaned and refaced.

11.3.

Daily Reports: Daily progress reports shall be submitted to the Contracting Officer representative. The reports shall document any actions taken to resolve all identified discrepancies. Reports shall be submitted within a 24-hour period of the respective day; e.g., a report for activities on Wednesday is due Friday morning.

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