522 PORTLAND CEMENT CONCRETE PAVEMENT REPAIRS

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522.01 DESCRIPTION.
Repair plain, conventionally reinforced, or continuously reinforced portland cement concrete pavement. Repairs are either Type I, 6 ft to less than 15 ft in length; or Type II, 15 ft and greater in length.
522.02 MATERIALS.
Refer to 520.02 except as follows.
Graded Aggregate for Base CourseThe one or more layers of specified material and thickness placed on a subbase or a subgrade to support a surface course.       901.01
Crusher Run Aggregate CR-6       901.01
Portland Cement Concrete       902.10, Mix No. 9
Nonshrink Grout       902.11(c)
Epoxy Grout       902.11(d)
Epoxy Adhesive       921.04
522.02.01 Polyester Grout. A polyester grout may be used in lieu of epoxy grout, provided the grout conforms to 902.11(d). Identify cartridge type systems by batch or lot number.
522.02.02 Epoxy Adhesives. Refer to 921.04. Use water insensitive materials classified as Type IV, Grade 3, Class B and C.
522.02.03 Reinforcement. Section 908 for reinforcement, including load transfer assemblies, tie bars, deformed steel bars, and longitudinal tie devices, except all material shall be epoxy coated.
522.03 CONSTRUCTION.
The EngineerAny person designated by the Administrator or the procurement officer, acting directly or through his duly authorized representative, such representative acting within the scope of the particular duties assigned to him or of the authority given him. will determine the areas to be repaired and the type of repair. Prior to the start of repairs, submit a proposed repair plan, including equipment, methods, and procedures. Protect the repair area against damage from all causes. Repair or replace any part of the repaired pavement that is damaged. Make repairs in only one lane at a time for each roadway.
522.03.01 EquipmentAll machinery, tools, and apparatus necessary for the proper construction and acceptable completion of the work, together with the necessary supplies for upkeep and maintenance.. Refer to 520.03.01.
522.03.02 Weather Restrictions. As specified in 520.03.02, except perform this work only during the months of April through October, unless otherwise permitted in writing. When the range in daily temperature is expected to exceed 15 F, concrete may be placed in the late afternoon after the existing pavement has achieved its maximum expansion, unless otherwise directed.
Cold weather protection shall conform to 520.03.12, except use insulated blankets when the ambient air temperature is less than 70 F.
522.03.03 Saw Cuts and Removal of Existing Pavement. Make all saw cuts perpendicular using a diamond saw blade. Remove concrete slabs by the lift out method in large sections. No other method of slab removal shall be used unless approved. Complete all repairs within the same working day on which the pavement is removed.
Repair adjacent slab damage caused by the removal operations.
Perform saw cutting and pavement removal as follows:
(a) Plain and Conventionally Reinforced Portland Cement Concrete Pavement. Make full depth sawcuts for the full slab width and at least 2 in. from and parallel to longitudinal joints. When the repair is on only one side of an existing transverse joint, extend removal into the adjacent slab a sufficient distance to remove existing dowels. Remove the concrete slab within one week after making the saw cuts. Complete the repairs in a continuous operation.
(b) Continuously Reinforced Portland Cement Concrete Pavement. Locate the boundaries of the repair at least 18 in. from the nearest transverse tight crack for normally spaced tight cracks, and at least 6 in. from the nearest transverse crack when they are closely spaced. Make at least a 2 in. depth saw cut for the full width of the lane at the boundaries of the repair. Do not cut the steel reinforcement. Make a full depth saw cut across the full width of the slab at least 22 in. inside each boundary saw cut. Make additional full depth saw cuts along all longitudinal edges not bounded by construction joints. Remove the concrete to its full depth within the boundaries of the repair area within 72 hours after making the saw cuts. Do not bend existing reinforcement bars.
Use no more than a 60 lb jackhammer and hand tools to remove concrete in the areas between each 2 in. and full depth saw cut. Trim the existing pavement edge neatly and vertical. Leave at least 22 in. of reinforcement exposed on each side of the repair. The EngineerAny person designated by the Administrator or the procurement officer, acting directly or through his duly authorized representative, such representative acting within the scope of the particular duties assigned to him or of the authority given him. will require the removal of any pavement breaking equipment from the project that could damage the adjacent concrete pavement.
When saw cuts close due to temperature, make narrowly spaced, full depth, and full width saw cuts to relieve the pressure. Remove the material between the narrowly spaced saw cuts and between the longitudinal joint and the 2 in. minimum offset longitudinal cut using the equipment specified above. Cut tie bars protruding from the longitudinal offset flush with the existing concrete. Remove all waste material immediately from the repair site. Seal any saw cuts that extend into adjacent slabs, curbs, or gutters as specified in Section 523.
522.03.04 Base and SubgradeThe top surface of a roadbed upon which the pavement structure, shoulders, and curbs are constructed. Preparation. Refer to 505.03.03, except moisten the subgrade for all types of repairs.
522.03.05 SubgradeThe top surface of a roadbed upon which the pavement structure, shoulders, and curbs are constructed. Drains. If directed, construct subgrade drains as specified in Section 306.
522.03.06 Forms. Use forms conforming to 520.03.04. Overlap existing pavement at least 1 ft on each side of the patch and securely fasten to prevent movement. Excavate the adjacent shoulder the width of the form plus 6 in. to provide space for the forms. After removing the form, repair the excavated shoulder area using the same type of material as used in the original shoulder.
522.03.07 Reinforcement. Refer to 520.03.06 and as specified herein. Place the doweled joint at the slab face closest to the original doweled joint location.
Drill holes 1/4 in. larger than the dowels, load transfer tie bars, and longitudinal tie devices into the face of the existing slab at mid depth. Blowout the holes and allow to dry. Grout or epoxy the dowels, load transfer tie bars, and longitudinal tie devices into place. Align reinforcement in the direction of the pavement and parallel to the surface.
Place a plastic grout retention disk, conforming to the Contract DocumentsThe written agreement executed between an Administration and the successful bidder, covering the performance of the work and furnishing of labor, equipment and materials, by which the Contractor is bound to perform the work and furnish the labor, equipment and materials, and by which the Administration is obligated to compensate him therefore at the mutually established and accepted rate or price. The Contract Documents shall include the Invitation for Bids, Notice to Contractors, Instructions to Bidders, Proposal, Contract Forms and Bonds, General Provisions, Specifications, Supplemental Specifications, all Special Provisions, all Technical Provisions, all Plans and Notices to Proceed, also any written Change Orders and Supplemental Agreements that are required to complete the construction of the work in an acceptable manner, including authorized extension thereof, on each dowel to prevent loss of the bonding material.
For continuously reinforced portland cement concrete pavement, use reinforcement steel bars of the same size and spacing as the existing bars. Splice the reinforcement to the existing steel by lapping, welding, or approved mechanical device. For lap splices, lap at least 22 in. and secure using tie wires. Place the longitudinal steel reinforcement bars continuous for the full length of the repair. Place an amount of steel at least equal to the amount of steel in the existing pavement. Support the reinforcement steel bars on chairs or as approved.
For plain and conventionally reinforced pavement, coat the protruding ends of the dowel bars with an approved water insoluble lubricant.
522.03.08 Joints. Refer to 520.03.14. Seal all joints as specified in Section 523.
522.03.09 Concrete Placement. Refer to 520.03.07. Prior to placing concrete, clean the adjacent vertical surfaces.
For weather requirements refer to 520.03.02. The temperature of the concrete at placement shall be 50 to 90 F.
The air temperature shall be at least 40 F and rising. When the range in daily temperature is expected to exceed 15 F, concrete may be placed in the late afternoon after the existing pavement has achieved maximum expansion, unless otherwise directed.
Construct both plain and continuously reinforced concrete pavement repairs in one full depth operation. Construct conventionally reinforced concrete pavement repairs by placing two equal lifts with the wire mesh laid on the surface of the first lift. Vibrate all concrete.
522.03.10 Finishing. Following concrete placement, strike off the surface to the finished grade using an adjustable steel or wooden template and float the surface. Screed the repair longitudinally to provide uniformity of ride to adjacent pavement. Match the contour of the existing roadway. Perform surface checks as specified in 520.03.10.
522.03.11 Curing. Cure the concrete as specified in 520.03.12, except continue curing for 12 hours after concrete placement or until the repair is put into service.
522.03.12 Emergency Filler. Have sufficient crusher run aggregate CR-6 readily available to fill the void of the repair area. Place and compact the material, and cover it with a steel plate. At the beginning of the next day’s work, completely remove the material using procedures that will not disturb the subgrade, dowels, load transfer tie bars, load transfer assemblies, or reinforcement placed previously.
522.03.13 Steel Plates. Have an ample supply of 12 x 14 ft x 1 in. thick steel plates available on the project to cover emergency filler and to protect the patch area until the concrete has developed sufficient strength to carry traffic.
522.03.14 Unacceptable Repairs. Remove and replace repairs that are not in conformance with the Contract DocumentsThe written agreement executed between an Administration and the successful bidder, covering the performance of the work and furnishing of labor, equipment and materials, by which the Contractor is bound to perform the work and furnish the labor, equipment and materials, and by which the Administration is obligated to compensate him therefore at the mutually established and accepted rate or price. The Contract Documents shall include the Invitation for Bids, Notice to Contractors, Instructions to Bidders, Proposal, Contract Forms and Bonds, General Provisions, Specifications, Supplemental Specifications, all Special Provisions, all Technical Provisions, all Plans and Notices to Proceed, also any written Change Orders and Supplemental Agreements that are required to complete the construction of the work in an acceptable manner, including authorized extension thereof and repairs damaged by traffic or other causes.
522.04 MEASUREMENT AND PAYMENT.
Portland cement concrete pavement repairs will be measured in place and paid for at the Contract unit price per square yard for the pertinent type Plain Portland Cement Concrete Pavement Repair, Conventionally Reinforced Portland Cement Concrete Pavement Repair, and Continuously Reinforced Portland Cement Concrete Pavement Repair item. The payment will be full compensation for saw cuts, furnishing, hauling, placing of all materials, removal and disposal of old concrete, grout, drilled holes, chairs, all tie devices, reinforcement, epoxy coating, steel plates, emergency filler, joint sealing, and for all material, labor, equipment, tools, and incidentals necessary to complete the work.
Emergency filler and steel plates will remain the property of the contractor at the completion of the project.
522.04.01  Removal of Unsuitable Material and Refill per cubic yard. The payment will also include excavation and disposal of unsuitable material, backfilling with aggregate, and compaction.
522.04.02  SubgradeThe top surface of a roadbed upon which the pavement structure, shoulders, and curbs are constructed. drains will be measured and paid for as specified in the applicable portions of Section 306.
522.04.03  ShoulderThe portion of the roadbed contiguous with the traveled way for accommodation of stopped vehicles, for emergency use, and for lateral support of base and surface courses. Repairs per square yard. Repairs to existing shoulders necessitated by the placement of forms are also included.