FULL DEPTH CLEANING AND SEALING OF JOINTS AND CRACKS TWO AND ONE HALF (2 1/2) INCHES NOMINAL WIDTH OR LESS IN PORTLAND CEMENT CONCRETE PAVEMENT

502.01 DESCRIPTION. This work shall consist of performing all operations required for cleaning and sealing cracks and joints in existing Portland cement concrete pavement of 2 1/2-inches nominal width or less at the locations indicated on the Plans or as directed by the Engineer, all in accordance with these Specifications.

502.02. MATERIALS.

a. Joint Seal. Poured joint seal material shall be hot poured asphalt rubber compound conforming to the requirements of AASHTO M173 and approved by the Engineer.

502.03 CONSTRUCTION METHODS.

502.03.1 Equipment. Equipment shall be subject to the approval of the Engineer and maintained in satisfactory working condition at all times.

a. Cutter. Equipment for reshaping cracks shall be a vertical spindle type cutter.

b. Air Compressor. Air compressors shall be portable and capable of furnishing not less than 100 cubic feet of air per minute at not less than 90 pounds per square inch pressure at the nozzle. The compressor shall be equipped with traps that will maintain the compressed air free of oil and water.

c. Self-propelled Sweeper. A small self-propelled sweeper designed especially for use in cleaning highway and airfield pavements shall be used to remove debris, dirt, and dust from joints or cracks in concrete pavement.

d. Hand Tools shall consist of brooms, wire brushes, shovels, metal bars with chisel shaped ends, and any other tools which may be used to accomplish this work.

e. Melting Kettle. The unit used to melt the joint sealing compound shall be a double boiler, indirect fired type. The space between the inner and outer shells shall be filled with a suitable heat transfer oil or substitute having a flash point of not less than 550^OF. The kettle shall be equipped with a satisfactory means of agitating the joint sealer at all times. This may be accomplished by continuous stirring with mechanically operated paddles or by a continuous circulating gear pump attached to the heating unit. The kettle must be equipped with thermostatic control calibrated between 200^OF and 550^OF.

f. Application System. The joint seal shall be placed by hot extrusion with a wand type instrument. The system shall include a flow control valve which allows all cracks to be filled to refusal.

502.03.2 Preparation of Cracks and Joints. All transverse and longitudinal joints and any cracks shall be sealed. Just prior to sealing, each joint or crack shall be thoroughly cleaned to the full depth of the concrete pavement of all foreign material by compressed air. If accessible, the sides of the joints shall be wire-brushed and cleaned of all debris. The sides of the joints shall be surface dry. Poured joint sealing material shall not be placed unless approved by the Engineer.

All material and debris removed from the joint or crack shall be immediately removed from the pavement surface by means of sweepers or hand brooms before sealing.

No joint sealing shall be allowed until the joints are thoroughly dried or where either frost, snow or ice is present.

502.03.3 Application. The joint seal shall be applied by hot extrusion. All joints or cracks are to be filled to refusal so as to eliminate all voids or entrapped air. The hot seal shall completely fill the joint or crack, such that, after cooling, the level of the sealer will be flush with the pavement surface. Any depression in the seal shall be brought up to the specified limit by the further addition of hot seal.

Care shall be taken in the sealing of the joints or cracks such that the final appearance will present a neat fine line. Overfilling of the joints will not be allowed, and spillage of the sealer should be avoided. All workmanship shall be of the highest quality, and all excess or spilled sealer must be removed from the pavement by approved methods and discarded.

502.04 METHOD OF MEASUREMENT. "Full Depth Cleaning and Sealing of Joints and Cracks Two and One-Half Inches Nominal Width or Less in Portland Cement Concrete Pavement" will be measured by the number of linear feet of sealed joints or cracks actually repaired in accordance with the Plans and/or as directed by the Engineer.

502.05 BASIS OF PAYMENT. The accepted quantity of "Full Depth Cleaning and Sealing of Joints and Cracks Two and One-Half Inches Nominal Width or Less in Portland Cement Concrete Pavement" will be paid for at the contract unit price per linear foot as listed in the Proposal. The price so-stated constitutes full and complete compensation for all labor, materials, equipment, and all other incidentals required to finish the work, complete and accepted by the Engineer.

REPAIRING DETERIORATED/DAMAGED JOINTS GREATER THAN TWO AND ONE-HALF (2 1/2) INCHES and LESS THAN OR EQUAL TO EIGHT (8) INCHES NOMINAL WIDTH IN FINISHED PORTLAND CEMENT CONCRETE PAVEMENT

503.01 DESCRIPTION. This work shall consist of performing all operations required for cleaning, saw cutting, concrete removal, rebuilding, and sealing joints in existing Portland cement concrete pavement that are greater than 2 1/2-inches and less than, or equal to 8-inches nominal width at the locations indicated on the Plans or as directed by the Engineer, all in accordance with these Specifications.

503.02. MATERIALS.

a. Joint Seal. Poured joint seal material shall be a hot poured asphalt rubber compound conforming to the requirements of AASHTO M173 and approved by the Engineer.

b. Epoxy Resin Bonding Agent. This material shall be an all-purpose, two-part epoxy resin system, conforming to AASHTO M234; Type V and be included on the Department's List of Approved Materials and Suppliers.

c. Fast Set Repair Mortar. Fast set repair mortar shall conform to the requirements of ASTM C928 and shall be included on the Department's List of Approved Materials and Suppliers. The material shall be used in strict accordance with the manufacturer's recommendations. The Department reserves the right to discontinue the use of any product it deems is not performing to the standards advertised by its manufacturer.

Should the Contractor choose an approved repair material not previously used by the Department, the Contractor shall arrange with the material's manufacturer or distributor for the services of a competent field representative at the work site prior to any mixing of components. The field representative shall instruct the work crews in the proper mixing and application procedures. The field representative shall remain at the job site after work commences and continue to instruct until he/she and the Engineer are satisfied that the crew has mastered the technique of installing the system successfully. The cost of any expense incurred for these services shall be borne by the Contractor.

d. Preformed Bituminous Joint Filler. Preformed bituminous joint filler shall conform to the requirements of AASHTO M33.

503.03 CONSTRUCTION METHODS.

503.03.1 Equipment. Equipment shall be subject to the approval of the Engineer and maintained in satisfactory working condition at all times.

a. Air Compressor. Air compressors shall be portable and capable of furnishing not less than 100 cubic feet of air per minute at not less than 90 pounds per square inch pressure at the nozzle. The compressor shall be equipped with traps that will maintain the compressed air free of oil and water.

b. Hand Tools shall consist of brooms, shovels, metal bars with chisel shaped ends, and any other tools which may be used to accomplish this work.

c. Melting Kettle. The unit shall be either oil or gas-fired, and shall be of the double walled, oil bath type with a power driven mechanical agitator and circulation pump. The kettle shall be equipped with a thermostat to maintain the sealing compound within the range of temperatures specified by the manufacturer and with a suitable mounted thermometer to indicate the temperature of the sealing compound in the kettle. The melting temperature of the sealer will be furnished by the manufacturer, and shall not be exceeded by more than 10^OF.

d. Application System. The joint seal shall be placed by hot extrusion with a wand type instrument. The system shall include a flow control valve which allows all cracks to be filed to refusal.

503.03.2 Removal of Existing Concrete.

a. Saw Cutting. A 3/4-inch deep saw cut parallel to the joint shall be made on both sides of the joint a distance of 3-inches back from the edge of the deteriorated concrete.

Care shall be taken to prevent damage to the freshly saw cut edge and the slab reinforcing during the concrete removal operations.

b. Removal. The concrete shall be removed to the full depth of the existing pavement and to a minimum width of 3-inches by a method approved by the Engineer. "Jack Hammers" heavier than the nominal 30-pound class shall not be used. "Chipping Hammers" heavier than the nominal 15-pound class shall not be used to remove concrete from beneath any reinforcing bar. Hand tools such as hammers and chisels shall be provided for removal of final particles of unsound concrete or to achieve the required depth. In no case shall pneumatic tools be placed in direct contact with reinforcing steel. Any "Load Transfer Device" encountered shall be retained, cleaned and left in place if it is still a competent part of the concrete slab. If the load transfer device has failed as determined by the Engineer, it will be removed and disposed.

503.03.3 Preparatory Work. The exposed concrete and reinforcing steel surface shall be free of rust, oil, solvent, grease, dirt, dust, bitumen, loose particles and other foreign matter just prior to the application of the epoxy bonding agent. Care shall be taken so as not to disturb the gravel subbase or undermine the existing concrete slabs. Any disturbance of the gravel subbase or undermining of the existing concrete slab shall be corrected by the Contractor, at his expense, to the satisfaction of the Engineer.

503.03.4 Joint Filler Placement. Prior to placement of the fast set repair mortar, one, 1-inch or two, 1/2-inch thick lengths of a preformed bituminous joint filler shall be installed in a straight line perpendicular to the reinforcing steel for the full width of the existing concrete slab(s). The preformed bituminous joint filler shall extend in a plumb vertical direction from the gravel subbase to the surface of the existing concrete slab.

503.03.5 Application of the Epoxy Bonding Agent. An epoxy bonding agent shall be applied to the prepared concrete surface to be repaired with a stiff-bristle broom to a thickness of approximately 20 mils or in accordance with the manufacturer's recommendations. Reinforcing steel shall not be coated with epoxy.

The Contractor shall follow the manufacturer's recommendations for curing the epoxy bonding agent prior to placing the concrete repair material. The repair material should not be placed if the bonding agent has passed the manufacturer's recommended contact time. If the bonding agent has exceeded its contact time, the Contractor shall follow the manufacturer's recommendations for re-application.

An epoxy bonding agent with an extended contact time should be used if required by the timing of concrete placement and/or weather conditions.

503.03.6 Application of Fast Setting Mortar.

a. Application, Mixing and Batching. Application, priming, curing, clean-up and protection of freshly patched areas shall be performed in accordance with applicable manufacturer's recommendations.

Mix no more material than can be placed within the specified working time recommended by the manufacturer. More than one mixing container or device may be utilized provided that enough patching area is prepared ahead and the work crews can place the materials efficiently without wasting the products.

Unless otherwise recommended by the manufacturer, coarse aggregate to be added to the system to produce concrete mix shall be clean, well graded and surface-dry. It shall conform to AASHTO M43 Size 8. Use of crushed limestone will not be permitted.

b. Weather Limitations for Application of the Epoxy Bonding Agent and Fast Setting Mortar. Concrete repair mortar shall not be applied when the ambient temperature is below 45^OF and/or in accordance with manufacturer's recommendations.

503.03.7 Sealing Joints. Upon placement and proper curing of the fast set concrete repair mortar, the top 1-inch of preformed bituminous joint filler shall be removed and replaced with a joint sealer. Each joint shall be thoroughly cleaned and dried prior to placement of the sealing compound. Any cleaning required shall be performed by blowing out all dirt, dust or deleterious matter. The hot extruded joint sealing material shall not be placed unless approved by the Engineer.

All material and debris removed from the joint shall be immediately removed from the pavement surface by means of vacuum sweepers or hand brooms before sealing.

The joint seal shall be applied by hot extrusion. All cracks are to be filled to refusal so as to eliminate all voids or entrapped air. The hot seal shall completely fill the joint, such that, after cooling, the level of the sealer will be flush with the pavement surface. Any depression in the seal shall be brought up to the specified limit by the further addition of hot seal.

Care shall be taken in the sealing of the joints such that the final appearance will present a neat fine line. Overfilling of the joints will not be allowed, and spillage of the sealer should be avoided. All workmanship shall be of the highest quality, and all excess or spilled sealer must be removed from the pavement by approved methods and discarded.

No joint sealing shall be allowed until the joints are thoroughly dried or where either frost, snow or ice is present.

Storage of materials shall be in accordance with manufacturer's recommendations.

503.04 METHOD OF MEASUREMENT. "Repairing Deteriorated/Damaged Joints Greater Than Two and One-Half Inches and Less Than or Equal to Eight Inches Nominal Width in Finished Portland Cement Concrete Pavement" will be measured by the number of cubic feet of fast set concrete repair mortar actually placed in the respective repaired joints in accordance with the Plans and/or as directed by the Engineer.

503.05 BASIS OF PAYMENT. The accepted quantity of "Repairing Deteriorated/Damaged Joints Greater Than Two and One-Half Inches and Less Than or Equal to Eight Inches Nominal Width in Finished Portland Cement Concrete Pavement" will be paid for at the contract unit price per cubic foot as listed in the Proposal. The price so-stated constitutes full and complete compensation for all labor, materials and equipment, and all other incidentals required to finish the work, complete and accepted by the Engineer.