USACE / NAVFAC / AFCESA / NASA UFGS-32 01 29.61 (November 2008)
--------------------------------
Preparing Activity: USACE Superseding
UFGS-32 01 28 (April 2008)
UFGS-32 01 29.61 (January 2008)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 32 01 29.61
PARTIAL DEPTH PATCHING OF RIGID PAVING
11/08
NOTE: This guide specification covers the requirements for partial depth patching
of rigid paving.
Edit this guide specification for project specific requirements by adding, deleting,
or revising text. For bracketed items, choose applicable items(s) or insert
appropriate information.
Remove information and requirements not required in respective project, whether
or not brackets are present.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
This guide specification includes tailoring options for AFCESA, NASA, NAVFAC,
and USACE. Selection or deselection of a tailoring option (select view-tailoring
options) will include or exclude that option in the section. Specific project
editing is still required for the resulting section.
NOTE: TO DOWNLOAD UFGS GRAPHICS
Go to http://www.wbdg.org/ccb/NAVGRAPH/graphtoc.pdf.
PART 1 GENERAL
NOTE: This specification is not intended for repair of heat resistant concrete
pavements, or for rapid repair of PCC that must be returned to service in a
short time. See second note in paragraph entitled "Cement." For full depth
repairs of PCC pavements for roads and streets only, use Section 32 13 13.06
PORTLAND CEMENT CONCRETE PAVEMENT FOR ROADS AND SITE FACILITIES.
NOTE: For full-depth patches or slab removal and replacement of airfield pavements,
use Section 32 13 11 - CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY DUTY
PAVEMENTS MORE THAN 10,000 CUBIC YARDS or Section 32 13 13.03 - AIRFIELDS AND
HEAVY-DUTY CONCRETE PAVEMENT LESS THAN 10,000 CUBI YARDS.
To review UFC 3-270-03 (15 March 2001), "Concrete Crack and Partial-Depth Spall
Repair" for drawings, details and illustrations, go to http://www.wbdg.org/ccb/DOD/UFC/ufc_3_270_03.pdf
.
NOTE: As a minimum, show the following information on the drawings:
1. Plans showing layout and identification of each joint and joint type. Include
identification of joints with dowels and with tie-bars. Identify pavements
or slabs that are reinforced and the reinforcement. Include location of each
random crack where repairs are needed.
2. Show approximate location, length and width of each spall and location and
size (usually average diameter) of each popout. Dimensions of spalls and popouts
need not be to scale. Identify by legend and symbol whether spall repair needed
is approximately rectangular or pentagonal (triangular spall). Specifically
detail any special or unusual shapes or partial depth repairs.
3. If required spall repairs are extensive, provide a schedule showing scope
of work and quantities for bid purposes in addition to the location plans.
Identify feature areas where spalls or groups of spalls are located, area of
spall repairs in square meter square feet, location and number or area of popouts,
and other PCC pavement repairs which may be a part of the contract.
4. Provide details of spall and popout repairs. Refer to UFC 3-270-03 and
AASHTO SDDP-1 for suggested details to be included on project drawings. Note
that these sketches include the required 50 mm 2 inch minimum horizontal clearance
of unsound concrete in the length and width dimensions shown.
5. In conducting field surveys to locate and size spalls needing repair, each
suspect area must be sounded to determine extent of damage. Sounding may be
done with a steel hammer, steel rod, or other suitable means for locating hollows.
It is not unusual for delamination in a spall area to extend well beyond that
visually obvious. Each previous partial depth patch should also be sounded
for present condition.
[1.1 UNIT PRICES
NOTE: When lump-sum payment is used, delete this paragraph . If patching is
a separate pay item, revise the paragraph accordingly.
1.1.1 Measurement
1.1.1.1 Concrete
The quantity of concrete to be paid for is the number of square meters feet placed in the completed and accepted
patched areas.
1.1.1.2 Proprietary Cementitious Products
The quantity of proprietary cementitious product to be paid for is the number of square meters feet placed in
the completed and accepted patched areas.
1.1.2 Payment
1.1.2.1 Concrete
The quantity of concrete, measured as specified, is paid for at the contract unit price. The unit price includes
full compensation for furnishing labor; materials; and for performing work involved in patching the pavements
as specified.
1.1.2.2 Proprietary Cementitious Products
The quantity of proprietary cementitious product, measured as specified, is paid for at the contract unit price.
The unit price includes full compensation for furnishing labor; materials; and for performing work involved in
patching the pavements as specified.
]1.2 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Also use the Reference Wizard's Check Reference feature
to update the issue dates.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS (AASHTO)AASHTO M 182(2005) Standard Specification for Burlap Cloth Made from Jute or Kenaf and Cotton MatsAASHTO SDDP-1(2002) Shop Detail Drawing Presentation Guidelines][ASTM INTERNATIONAL (ASTM)ASTM C 1059/C 1059M(1999; R 2008) Standard Specification for Latex Agents for Bonding Fresh to Hardened ConcreteASTM C 1260(2007) Standard Test Method for Potential Alkali Reactivity of Aggregates (Mortar-Bar Method)ASTM C 131(2006)Standard Test Method for Resistance to Degradation of Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles MachineASTM C 136(2006) Standard Test Method for Sieve Analysis of Fine and Coarse AggregatesASTM C 143/C 143M(2008) Standard Test Method for Slump of Hydraulic-Cement ConcreteASTM C 150(2007) Standard Specification for Portland CementASTM C 1581(2004) Standard Test Method for Determining Age at Cracking and Induced Tensile Stress Characteristics of Mortar and Concrete under Restrained ShrinkageASTM C 1602/C 1602M(2006) Standard Specification for Mixing Water Used in Production of Hydraulic Cement ConcreteASTM C 171(2007) Standard Specification for Sheet Materials for Curing ConcreteASTM C 173/C 173M(2008) Standard Test Method for Air Content of Freshly Mixed Concrete by the Volumetric MethodASTM C 192/C 192M(2007) Standard Practice for Making and Curing Concrete Test Specimens in the LaboratoryASTM C 231(2008c) Standard Test Method for Air Content of Freshly Mixed Concrete by the Pressure MethodASTM C 260(2006) Standard Specification for Air-Entraining Admixtures for ConcreteASTM C 309(2007) Standard Specification for Liquid Membrane-Forming Compounds for Curing ConcreteASTM C 31/C 31M(2008a) Standard Practice for Making and Curing Concrete Test Specimens in the FieldASTM C 33(2007) Standard Specification for Concrete AggregatesASTM C 39/C 39M(2005e1e2) Standard Test Method for Compressive Strength of Cylindrical Concrete SpecimensASTM C 469(2002e1) Static Modulus of Elasticity and Poisson's Ratio of Concrete in CompressionASTM C 494/C 494M(2008a) Standard Specification for Chemical Admixtures for ConcreteASTM C 531(2000; R 2005) Linear Shrinkage and Coefficient of Thermal Expansion of Chemical-Resistant Mortars, Grouts, and Monolithic Surfacings, and Polymer ConcretesASTM C 666/C 666M(2003; R 2008) Resistance of Concrete to Rapid Freezing and ThawingASTM C 685/C 685M(2007) Concrete Made by Volumetric Batching and Continuous MixingASTM C 881/C 881M(2002) Standard Specification for Epoxy-Resin-Base Bonding Systems for ConcreteASTM C 882/C 882M(2005e1) Bond Strength of Epoxy-Resin Systems Used with Concrete by Slant ShearASTM C 94/C 94M(2007) Standard Specification for Ready-Mixed ConcreteASTM D 1751(2004; R 2008) Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)ASTM D 1752(2004a; R 2008) Standard Specification for Preformed Sponge Rubber Cork and Recycled PVC ExpansionASTM D 75(2003) Standard Practice for Sampling Aggregates][U.S. ARMY CORPS OF ENGINEERS (USACE)COE CRD-C 300(1990) Specifications for Membrane-Forming Compounds for Curing Concrete][U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)29 CFR 1910Occupational Safety and Health Standards]1.3 SUBMITTALS
NOTE: Review submittal description (SD) definitions in Section 01 33 00 SUBMITTAL
PROCEDURES and edit the following list to reflect only the submittals required
for the project. Submittals should be kept to the minimum required for adequate
quality control.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy, Air Force,
and NASA projects.
Choose the first bracketed item for Navy, Air Force and NASA projects, or choose
the second bracketed item for Army projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are for [Contractor Quality Control approval.] [information only. When used, a designation following the "G"
designation identifies the office that will review the submittal for the Government.] Submit the following in
accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-02 Shop Drawings
[Shop Drawings[; G][; G, [_____]]]
SD-03 Product Data
Mix Design[; G][; G, [_____]]
Proprietary Cementitious Products[; G] [; G, [_____]]
pigmented liquid membrane-forming compound[; G] [; G, [_____]]
SD-04 Samples
Absorbent curing material[; G][; G, [_____]]
Joint filler[; G][; G, [_____]]
[Joint sealant[; G][; G, [_____]]]
SD-05 Design Data
Concrete Mix Design[; G][; G, [_____]]
SD-06 Test Reports
Laboratory Test Results[; G][; G, [_____]]
Aggregates gradation[; G][; G, [_____]]
Cement[; G][; G, [_____]]
Concrete slump[; G][; G, [_____]]
Concrete air content[; G][; G, [_____]]
Concrete strength (cylinder)[; G][; G, [_____]]
mixer calibration and efficiency[; G][; G, [_____]]
SD-07 Certificates
Cement[; G][; G, [_____]]
Aggregate[; G][; G, [_____]]
Admixtures[; G][; G, [_____]]
Absorbent curing material[; G][; G, [_____]]
pigmented liquid membrane-forming compound[; G][; G, [_____]]
Waterproof Sheet[; G][; G, [_____]]
Joint filler[; G][; G, [_____]]
[Joint sealant[; G][; G, [_____]]]
1.4 QUALITY ASSURANCE
NOTE: Guidance for preparation of criteria to be used in inspection of laboratory
facilities is contained in ASTM E 329.
1.4.1 Preconstruction Testing Of Materials
Submit proposed concrete mix design at least [30] [_____] days prior to placement. Provide mix design evaluation
and certification by an approved engineering testing laboratory, and indicate the weight of each ingredient of
the mixture, aggregate gradation, slump, air content, water-cement ratio, and 7-day and 28-day compressive strength
test results. Include a complete list of materials including admixtures and applicable reference specifications.
Place no concrete prior to approval of the proposed mix design. No deviation from the approved mix design is
permitted without prior approval.
Within 24 hours of physical completion of laboratory testing, submit copies of test results for approval.
1.4.1.1 Cement
Test cement as prescribed in the referenced specification under which it is furnished. Cement may be accepted
on the basis of mill tests and the manufacturer's certification of compliance with the specification.
1.4.1.2 Aggregate
Take aggregate gradation samples for laboratory testing in conformance with ASTM D 75.
1.4.1.3 Proprietary Cementitious Products and Epoxy
At least 30 days before the material is used, submit certified copies of test results for the specific lots or
batches to be used on the project, not more than 6 months old prior to use in the work.
Manufacturer's certifications may be submitted rather than laboratory test results for proprietary cementitious
products. Include in the instructions details for substrate preparation, mixing, placing, finishing, curing
and testing of the material. Include a minimum of three case histories documenting the use of the product in
a similar freeze-thaw environment and airfield pavement condition. Certify compliance with the appropriate specification
referenced herein. Place no materials without prior approval from the Contracting Officer.
1.4.2 Equipment; Approval, Maintenance, and Safety
Provide and use only dependable and well maintained equipment that is appropriate to accomplish the work specified.
Allow sufficient time for assembly of equipment requiring such at the work site to permit thorough inspection,
calibration of weighing and measuring devices, adjustment of parts, and the making of any repairs that may be
required prior to the start of work.
Submit volumetric mixer calibration and efficiency test results. Results must be current within 6 months of
concrete placement.
Provide Material Safety Data Sheets (MSDS) and Personal Protection Equipment (PPE) per 29 CFR 1910.
1.4.3 Shop Detail Drawings
NOTE: Delete this paragraph if the project scope does not require detailed
shop drawings and staging plans from the Contractor.
Submit detailed Shop Drawings conforming to AASHTO SDDP-1.
1.5 DELIVERY, STORAGE, AND HANDLING
1.5.1 Cement
Deliver cement in bulk or in suitable bags used for packaging cements and store in a manner to prevent absorption
of moisture.
1.5.2 Aggregate
Deliver, handle, and store aggregate in a manner to avoid breakage, segregation, or contamination by foreign
materials.
1.5.3 Other Materials
Deliver epoxy-resin, chemical admixtures and proprietary cementitious products to the site in such manner as
to avoid damage or loss. Provide storage areas in a windowless and weatherproof, but ventilated, insulated noncombustible
building, with provision nearby for conditioning the material to 20 to 30 degrees C 70 to 85 degrees F for a
period of 48 hours prior to use. Keep the ambient temperature in the storage area no higher than 40 degrees
C 100 degrees F.
1.6 Project/Site Conditions
Do not place concrete when weather conditions detrimentally affect the quality of the finished product. Do not
place concrete when the air temperature is below 5 degrees C 40 degrees F in the shade. When air temperature
is likely to exceed 35 degrees C 90 degrees F, provide concrete having a temperature not exceeding 35 degrees
C 90 degrees F when deposited. Keep the surface of placed concrete damp with a water fog until the approved
curing medium is applied.
PART 2 PRODUCTS
2.1 MATERIALS
2.1.1 Coarse Aggregate
2.1.1.1 Composition
Provide coarse aggregate consisting of gravel, crushed gravel, crushed stone, or a combination thereof.
2.1.1.2 Quality
NOTE: Do not allow types of aggregate at locations where they have an unsatisfactory
performance record. Specify aggregate to be washed in areas where deleterious
substances or organic impurities are a problem.
Provide aggregate , as delivered to the mixers, consisting of clean, hard, unweathered, and uncoated particles.
Remove dust and other coatings from the coarse aggregate by adequate washing. Meet the requirements of ASTM C 33
, Class 4S for deleterious substances. Abrasion loss, when tested in accordance with ASTM C 131, must not exceed
40 percent; the maximum allowable percentage for clay lumps and friable particles is [1.5] [_____] percent.
Provide documentation of aggregate conforming to ASTM C 136.
2.1.1.3 Particle Shape
Provide spherical or cubical shaped coarse aggregate particles.
2.1.1.4 Gradation
NOTE: The 19 mm 3/4 inch nominal maximum dimension for coarse aggregate specified
below may be excessive for shallow spalls. If the project contains numerous
shallow depth 50 mm 2 inch spalls, the designer should specify a suitable gradation
based on locally available aggregate.
The maximum nominal size of the coarse aggregate is 13 mm 1/2 inch. Provide well graded coarse aggregate, within
the limits specified, and tested in accordance with ASTM C 136, and conforming to the following grading requirements
as delivered to the batching hoppers:
Sieve designation Percentage by weight passing
U.S. Standard individual sieves 4.75 mm to
square mesh 12.5 mm
_____________________ _________________________________
19.0 mm 100
12.5 mm 90-100
9.5 mm 40-70
4.75 mm 0-15
2.36 mm 0-5
Sieve designation Percentage by weight passing
U.S. Standard individual sieves No. 4 to
square mesh 1/2 inch
____________________ _________________________________
3/4 inch 100
1/2 inch 90-100
3/8 inch 40-70
No. 4 0-15
No. 8 0-5
2.1.1.5 Alkali Silica Reactivity
NOTE: For small quantity patching projects, include the first paragraph and
require the use of non-reactive aggregate.
For large quantity patching projects, include Section 32 13 11 CONCRETE PAVEMENT
FOR AIRFIELDS AND OTHER HEAVY DUTY PAVEMENTS MORE THAN 10,000 CUBIC YARDSand
include the second paragraph cross-referencing ASR evaluation and mitigation
testing.
[Evaluate and test coarse aggregate, to be used in all concrete, for alkali-silica reactivity in accordance with
ASTM C 1260. Measured expansion must not exceed 0.08 percent at 28 days when tested. Test data indicating an
expansion greater than 0.08 percent will be rejected.]
[Evaluate coarse aggregate in accordance with Section 32 13 11, paragraph: Alkali-Silica Reactivity, with mitigation
of reactive aggregate in accordance with the referenced paragraph.]
2.1.2 Fine Aggregate
2.1.2.1 Composition
Provide fine aggregate consisting of either natural sand, manufactured sand, or a combination of natural and
manufactured sand, and composed of clean, hard, durable particles; conforming to ASTM C 33, Table 1 for deleterious
substances..
2.1.2.2 Particle Shape and Quality
Ensure particles of the fine aggregate are generally spherical or cubical in shape.
2.1.2.3 Grading
Conform grading of the fine aggregate as delivered to the mixer to the following requirements when tested in
accordance with ASTM C 136.
Sieve designation
U.S. Standard Percentage by weight,
square mesh passing
____________________ ________________________
9.5 mm 100
4.75 mm 95-100
2.36 mm 80-90
1.18 mm 60-80
0.60 mm 30-60
0.30 mm 12-30
0.15 mm 2-10
Sieve designation
U.S. Standard Percentage by weight,
square mesh passing
____________________ ________________________
3/8 inch 100
No. 4 95-100
No. 8 80-90
No. 16 60-80
No. 30 30-60
No. 50 12-30
No. 100 2-10
In addition, provide fine aggregate, as delivered to the mixer, with a fineness modulus of not less than 2.40
nor more than 2.90, when calculated in accordance with ASTM C 136.
2.1.2.4 Alkali Silica Reactivity
Evaluate and test fine aggregate to be used in all concrete for alkali-silica reactivity using the procedures
described for coarse aggregate.
2.1.3 Admixtures
2.1.3.1 Air-Entraining Admixtures
Provide air-entraining admixtures conforming to ASTM C 260.
2.1.3.2 Chemical Admixtures
ASTM C 494/C 494M. Where not shown or specified, the use of admixtures is subject to written approval of the
Contracting Officer.
2.1.4 Cement
NOTE: Specify type of portland cement to suit project requirement and location.
Specify Type III cement only when pavements are expected to be returned to active
service in less than 7 calendar days. Specify type of cement, including low-alkali,
to suit local aggregate conditions. Types of cements other than those bracketed
may be specified provided the designer knows that they have a satisfactory service
record in partial depth repairs.
NOTE: In addition to portland cement, there are many types of cements, polymers,
blends and modifications thereto, and other cementitious materials available
for patching PCC. Some have performed very well in some cases but failed in
others. Many are unusually sensitive to moisture tolerances, temperature conditions,
mixing criteria, curing techniques, quality of workmanship, or other critical
processes. Some are suitable for use during cold weather. Many will develop
a superfluous level of strength in excess of that needed for patching PCC pavements.
Many are not as durable as PCC. Some have been introduced fairly recently and
do not have a long term performance record. For patching PCC, most are less
compatible, and more expensive than portland cement. Use of any of these materials
will depend on the knowledge of the design engineer as well as project requirements,
and may necessitate significant modifications to this guide specification and
attached details.
Provide portland cement conforming to ASTM C 150, Type [_____]. Provide low alkali cement if the proposed fine
or coarse aggregate are found to have greater than 0.04 percent expansion when tested in accordance with paragraphs:
Alkali Silica Reactivity.
2.1.4.1 Portland Cement Mix Design
NOTE: Delete the bracketed portion of the second paragraph for patching airfields.
Design the concrete mixture to produce a minimum compressive strength of [31] [35] [_____] MPa [4500] [5,000]
[_____] psi at 28 days of age, determined in conformance with ASTM C 39/C 39M and ASTM C 192/C 192M, using standard
150 by 300 mm 6 by 12 inch cylinder specimens; and providing an air content by volume of [5] [6] [_____] percent,
plus or minus 1.5 percent, based on measurements made on concrete immediately after discharge from the mixer
in conformance with ASTM C 231.
The allowable range of slump is 13 to 50 mm 1/2 to 2 inches when tested in accordance with ASTM C 143/C 143M
[except that maximum slump may be increased to 100 mm 4 inches when the Contractor has included an approved water-reducing,
high range, admixture conforming to ASTM C 494/C 494M in the mix design]. To minimize drying shrinkage, the
maximum water-cement ratio by weight is 0.45.
2.1.5 Curing Materials
2.1.5.1 Burlap
Provide burlap conforming to AASHTO M 182.
2.1.5.2 Pigmented Liquid Membrane-Forming Compound
NOTE: Retain the tailored option for COE CRD-C 300 for Air Force and Army projects,
and delete the ASTM reference.
Provide pigmented liquid membrane-forming compound conforming to COE CRD-C 300ASTM C 309.
2.1.5.3 Waterproof Sheet Materials
Provide waterproof sheet materials conforming to ASTM C 171, Type optional, color white.
2.1.6 Bonding-Agents
2.1.6.1 Epoxy-Resin
Provide two component epoxy-resin material formulated to meet the requirements of ASTM C 881/C 881M, Type III,
grade and class as approved, for use in bond coat applications and as a component of epoxy-resin concrete or
mortar.
Mix epoxy-resin grout components in the proportions recommended by the manufacturer. Condition the components
to 20 to 30 degrees C 70 to 85 degrees F for 48 hours prior to mixing. Mix the two epoxy components with a power-driven,
explosion-proof stirring device in a metal or polyethylene container having a hemispherical bottom. Add the
curing-agent component gradually to the epoxy-resin component with constant stirring until a uniform mixture
is obtained. Stir such that the rate of entrained air is a minimum.
2.1.6.2 Latex
Provide latex bonding agent meeting the requirements of ASTM C 1059/C 1059M, Type II.
2.1.7 Joint Sealant
Provide joint sealant as [indicated on the drawings.] [as specified in Section 32 01 19.61 RESEALING OF JOINTS
IN RIGID PAVING.]
2.1.8 Joint Filler
Provide joint filler material conforming to ASTM D 1751 or ASTM D 1752, Type II [ or 100% recycled material meeting
ASTM D 1752, subparagraphs 5.1 to 5.4].
2.1.9 Water
Use only clean, fresh water, free from injurious amounts of oil, acid, salt, alkali, organic matter, or other
deleterious substances. Water approved by Public Health authorities for domestic consumption may be accepted
for use without being tested. Test water that is of questionable quality, in the opinion of the Contracting
Officer, in accordance with ASTM C 1602/C 1602M and acceptance criteria of Table 1 of ASTM C 94/C 94M.
2.1.10 Proprietary Cementitious Products
NOTE: The testing protocol for Proprietary Cementitious Products is provided
in the USAF draft ETL, "Testing Protocol for Rigid Spall Repair Materials."
A proprietary cementitious product is defined as a rigid material in its hardened state with an elastic modulus
greater than 6900 MPa 1,000,000 psi. Maximum size of aggregate used to extend the product is 19 mm 3/4 inch.
Test the product in accordance with the following test series. Replicate each test on three specimens. Report
all three results for each test and use the average value for comparison with the specification requirements.
Report the curing conditions for each test type.
2.1.10.1 Compressive Strength
Cast 75 by 150 mm 3 by 6 inch cylinder specimens in accordance with ASTM C 192/C 192M and test in accordance
with ASTM C 39/C 39M, using bonded or unbonded caps, after 3 hours and 1 day curing period. A minimum compressive
strength of 20.7 MPa3500 psi is required at 3 hours and 1 day of age.
2.1.10.2 Bond Strength
Cast 75 by 150 mm 3 by 6 inch cylinder specimens and test in accordance with ASTM C 882/C 882M. Cast the candidate
material against a 30-degree wedge specimen consisting of the candidate material itself or an ordinary portland
cement mixture. Test specimens, using bonded caps, after 1 day curing period. For a bond consisting of the
candidate material bonded to OPC mortar, a minimum bond strength of 3400 kPa 500 psi is required at 1 day of
age. For a bond consisting of the candidate material bonded to itself, a minimum bond strength of 6900 kPa 1000
psi is required at 1 day of age.
2.1.10.3 Modulus of Elasticity
Cast 150 by 300 mm 6 by 12 inch cylinder specimens in accordance with ASTM C 192/C 192M and test in accordance
with ASTM C 469, using bonded caps, after 3 day curing period. A maximum chord modulus of elasticity of 27,600
MPa 4,000,000 psi is required at 3 days of age.
2.1.10.4 Coefficient of Thermal Expansion
Cast 25 by 25 by 250 mm 1 by 1 by 10-inches prismatic bar specimens and test in accordance with ASTM C 531, after
3 days curing period. A maximum coefficient of 11.6 by 10-6 mm per mm per degree C 7 by 10-6 inch per inch per
degree F is required at 3 days of age.
2.1.10.5 Shrinkage Potential
Cast 330 mm I.D. by 406 mm O.D. by 150 mm 13 inch I.D. by 16 inch O.D. by 6 inch tall restrained toroidal specimens
and test in accordance with ASTM C 1581. Start measuring strain after completion of casting. A maximum of 40
microstrain is required at 14 days of age. No cracking is permitted at 28 days of age.
2.1.10.6 Freeze-Thaw Resistance
Cast prismatic specimens in accordance with ASTM C 192/C 192M and test in accordance with ASTM C 666/C 666M,
Procedure A. Begin freeze-thaw testing after specimens have been immersed in saturated lime-water for 3 days.
Report the Durability Factor (DF) and the number of cycles to failure.
2.2 Neat Cement Grout
2.2.1 Sand-Cement Grout Bonding Course
Provide grout bonding course consisting of equal parts of Type [I or II], [III] portland cement and sand by dry
weight, thoroughly mixed with water to yield a thick, creamy mixture; with a water-cement ratio no greater than
0.62 by weight. Sand must meet the requirements of the fine aggregate specified herein, except 100 percent must
pass through a 2.36 mm No. 8 sieve.
[2.2.2 Sand-Cement Mortar for Filling Small Popouts
NOTE: Delete this paragraph for airfield projects due to insufficient durability
of sand-cement mortar.
Provide mortar consisting of one part Type [I or II], [III] portland cement and two parts sand by dry weight,
thoroughly mixed with water to yield a thick, suitable mix; with a water-cement ratio no greater than 0.45 by
weight. The sand must meet the requirements of the fine aggregate specified herein.
]2.2.3 Dowels, Tie Bars, and Reinforcement
Provide dowels, tie bars, and reinforcement as [indicated on the drawings.] [specified in Section 03 30 53 MISCELLANEOUS
CAST-IN-PLACE CONCRETE.]
PART 3 EXECUTION
3.1 PREPARATION OF EXISTING PAVEMENT
NOTE: Airfield projects require full depth repairs in accordance with Section
32 13 11 - CONCRETE PAVEMENT FOR AIRFIELDS AND OTHER HEAVY DUTY PAVEMENTS MORE
THAN 10,000 CUBIC YARDS or Section 32 13 13.03 - AIRFIELDS AND HEAVY-DUTY CONCRETE
PAVEMENT LESS THAN 10,000 CUBI YARDS.
NOTE: For projects other than airfield repairs, specify minimum depth of removal
of existing PCC. A 50 mm 2 inch minimum depth is usually satisfactory and should
be specified, except where local conditions indicate 50 mm 2 inchthick shallow
patches have an unsatisfactory service record. When required depth of repair
is known or reasonably expected to exceed one-half the pavement thickness, full
depth repairs should be required as specified in Section 32 13 13.06 [PERVIOUS]
PORTLAND CEMENT CONCRETE PAVEMENT FOR ROADS AND SITE FACILITIES.
3.1.1 Preparation of Existing Surfaces
In the area to be patched, [except popouts,] remove existing concrete to a minimum depth of [50] [_____] mm [2]
[_____] inches below the pavement surface adjacent to spalls and to such additional depth where necessary to
expose a surface of sound, unweathered concrete that is uncontaminated by sealants, oils, greases, or deicing
salts or solutions. Make a vertical saw cut at least 50 mm 2 inches deep and 50 mm 2 inches outside of the area
needing repair. Accomplish concrete removal in spalled areas with light, hand-held, high-frequency chipping
hammers weighing not more than 14 kg 30 pounds or other approved hand tools. Do not use jack hammers weighing
more than 14 kg 30 pounds and do not use pavement breaker devices mounted on or pulled by mobile equipment.
Clean the cavity surface by [sandblasting] [waterblasting], blowing with compressed air, sweeping, and vacuums.
Use [sandblasting] [waterblasting] to remove all traces of sealer, oils, grease, rust, and other contaminants.
[3.1.1.1 Joint Widening (Except Expansion Joints)
NOTE: Edit this paragraph as required. New joint groove dimensions shall be
shown on the plans.
The following information shall be shown on the project drawings:
1. Spacing, width, and type of joints in concrete pavements to be sealed.
2. Typical details of existing joints.
3. Depth of existing sealant to be removed for each type of joint, if not specified.
4. Detail of type of joint to be refaced or widened with a concrete saw. Show
extent of new width and depth of sawing to provide the proper shape factor of
the void space in the joint. For materials, other than silicone, the ratio
of the depth to width (d/w) of the sealant reservoir should generally be not
less than 1 nor greater than 1.5. For silicone sealant a depth to width ratio
of approximately 0.5 is preferred. Depending upon the width of the refaced
joint, the thickness of the sealant bead should be between 6 and 13 mm 1/4 and
1/2 inch. Following are the recommended details for silicone sealants:
Refaced Joint Width 10 mm 13 mm 19 mm 25 mm
Recess Below Surface 6 mm 6 mm 6 mm 13 mm
Thickness of Sealant 6 mm 6 mm 10 mm 13 mm
Backer Rod Diameter 13 mm 16 mm 22 mm 31 mm
Total Depth of Joint 25 mm 28 mm 38 mm 56 mm
Refaced Joint Width 3/8" 1/2" 3/4" 1"
Recess Below Surface 1/4" 1/4" 1/4" 1/2"
Thickness of Sealant 1/4" 1/4" 3/8" 1/2"
Backer Rod Diameter 1/2" 5/8" 7/8" 1 1/4"
Total Depth of Joint 1" 1 1/8" 1 1/2" 2 1/4"
5. Location and type of bond breaker or back-up.
6. Identify type of sealant based on proposed use of pavements. (See note
in paragraph entitled "Joint Sealant.")
7. For joint details see MIL-HDBK-1021/4.
Saw joints having grooves less than 10 mm 3/8 inch wide and less than 25 mm one inch deep to a minimum width
of [10] [13] [_____] mm [3/8] [1/2] [_____] inch and to the minimum depth, [of] [25 mm] [38 mm] [one inch] [1
1/2 inches] [as indicated].
]3.1.2 Dowels, Tie Bars, and Reinforcement
NOTE: For airfield projects, delete the bracketed references to torching.
Torching is not permitted on airfield projects for reinforcing steel or dowels.
Cut and remove to minimum dimensions indicated existing dowels and tie bars exposed in joints adjacent to the
spall cavity. Perform cutting by saws[, torch,] or other approved means; do not allow[ torch or] other cutting
methods to damage concrete to remain. Clean to bare metal by sandblasting any existing reinforcement or dowels
remaining exposed in the repair area. Remove any reinforcement that cannot be properly re-embedded in the new
repair concrete. Cut and remove at the joint not less than 13 mm 1/2 inch of existing exposed reinforcement
that is continuous through the repair area and is embedded in the adjacent slab.
3.1.3 Preparation of Joints Adjacent to Spalls
Remove existing joint sealing and joint filler materials. Saw as indicated and install insert, cut to appropriate
dimensions, to prevent contact between new patch material and existing concrete at existing joints. At the option
of the Contractor, a bead of approved caulking material may be installed to preclude new patching material from
getting around insert. Clean up any caulking material accidentally deposited on the prepared spall surface.
3.1.4 Disposal of Debris
NOTE: Specify location of disposal of debris.
Sweep from pavement surface to remove excess joint material, dirt, water, sand, and other debris by vacuum sweepers
or hand brooms. Remove the debris immediately [to a point off station.] [to an area designated by the Contracting
Officer.] [in accordance with Section 02 41 00 DEMOLITION.]
3.1.5 Bonding Coat
NOTE: In general a neat cement bonding coat is appropriate for all patch sizes.
Epoxy-resin bond coats should be limited to patches less than 2 feet (600 mm)
square. For proprietary cementitious patching products, prepare the substrate
in accordance with the manufacturer's recommendations.
Prior to placing concrete, wash the previously prepared surfaces with a high pressure water jet followed by an
air jet to remove free water.
3.1.5.1 Neat Cement Grout
Coat the clean and dry surface, including sawed faces, with an approximate 2 mm 1/16 inch thick coat of neat
cement grout. Place the grout just prior to concrete placement and scrub with stiff bristle brushes to fill
all voids and crevices in the spall cavity surface. Apply additional brush coats as needed to obtain the required
thickness. The concrete patch material must be placed before the grout dries or sets. Remove dried or hardened
grout by sandblasting and re-coat the cavity with fresh grout before placing concrete patch material.
3.1.5.2 Epoxy-Resin
Limit epoxy-resin bonding coat to use on patches with a surface area of less than 600 mm 2 feet square. Coat
the clean and dry surface, including sawed faces, with a 0.02 to 0.04 mm 20 to 40 mil thick film of the epoxy-resin
grout. Place the epoxy-resin grout in one application, just prior to concrete placement, with the use of mechanical
combination, mixing and spraying equipment, or two coat application with stiff brushes. Scrub the first brush
coat into the concrete surface, followed by an additional brush coat to obtain the required thickness. When
the brush method is used, the initial coat may be allowed to dry; however, apply the final coat just prior to
placement of the concrete.
3.1.5.3 Proprietary Cementitious Products
Apply in accordance with the manufacturer's written instructions.
Test as prescribed in the referenced specification under which it is furnished. Cement may be accepted on the
basis of mill tests and the manufacturer's certification of compliance with the specification, provided the cement
is the product of a mill with a record for the production of high-quality cement for the past 3 years.
3.1.6 Popout Repair
NOTE: Delete this paragraph if no popout repairs are included in the project.
Note the first sentence for definition of popouts.
Delete the bracketd statements containing "sand-cement " and "chipping" for
airfield projects, and specify overcoring surface defects in concrete.
Popouts, as used herein, are pavement surface defects caused by deterioration of unsatisfactory coarse aggregate,
decaying of organic material such as wood or roots, mechanical accidents, or other reasons. Most popouts are
indicated on the drawings by average diameter but the actual surface configuration will vary from circular to
polygonal. Repair popouts as indicated using [sand-cement mortar for small popouts (less than 50 mm 2 inches
in width or depth) and ]portland cement concrete for large popouts. Clean popout cavities of all dirt and contaminants
prior to filling. As indicated on drawings, prepare popout areas by [chipping] [overcoring surface defects in]
the concrete to eliminate feather edging of the mortar or concrete repair material.[ After preparing large popout
cavities, coat with sand-cement grout bonding course immediately prior to filling with concrete.]
3.1.7 Patch Material Selection
Fill the prepared cavity with: Portland cement concrete or latex modified concrete for cavities more than 9400
cc 600 cubic inches in volume after removal operations; portland cement mortar for cavities between 850 and 9400
cc 50 and 600 cubic inches; and epoxy resin mortar or latex modified mortar for those cavities less than 850
cc 50 cubic inches in size. Proprietary cementitious patching materials may be used, subject to approval by
the Contracting Officer.
3.2 BATCHING, MIXING AND PROPORTIONING
Provide facilities for the accurate measurement and control of each of the materials entering the concrete, mortar,
or grout. Provide free access for the Contracting Officer to the batching and mixing plant at all times. Provide
mixing equipment capable of combining the aggregate, cement, admixture, and water into a uniform mixture and
discharging this mixture without segregation.
The use of volumetric batching and continuous mixing is acceptable, provided all operations are in accordance
with ASTM C 685/C 685M.
3.2.1 Equipment
Assemble dependable and operable equipment, allowing time for thorough inspection, calibration of weighing and
measuring devices, adjustment of parts, and the making of any repairs that may be required prior to final approval
and the commencement of work. Maintain the equipment in good working condition.
3.2.2 Conveying
Convey concrete from mixer to repair area as rapidly as practicable by methods which prevent segregation or loss
of ingredients.
3.2.3 Facilities for Sampling
Provide facilities for readily obtaining representative samples of aggregate and concrete for test purposes.
Furnish necessary platforms, tools, and equipment for obtaining samples.
3.2.4 Mix Proportions
Use proportions of materials entering into the concrete mixture in accordance with the approved mix design.
Revise the mix design whenever necessary to maintain the workability, strength, and standard of quality required,
and to meet the varying conditions encountered during the construction; however, no changes shall be made without
prior approval.
3.2.5 Measurement
Provide equipment necessary to measure and control the amount of each material in each batch of concrete. Weigh
bulk cement. Cement in unopened bags as packed by the manufacturer may be used without weighing. One bag of
portland cement is considered as weighing 42.64 kg 94 pounds. Measure mixing water and air-entraining admixtures
by volume or by weight. Consider one liter one gallon of water as weighing 1 kg 8.33 pounds.
3.2.6 Workability
Maintain the slump of the concrete at the lowest practicable value, not exceeding the specified value.
3.3 PLACING
3.3.1 Portland Cement Concrete
NOTE: Specify placing time to suit concrete materials and environmental conditions.
For most projects, 90 minutes is adequate.
Place concrete within [45] [90] minutes after the introduction of the mixing water to the cement and aggregate
or the introduction of the cement to the aggregate, and before the concrete has obtained its initial set, and
before the sand-cement grout bonding course has dried or obtained its initial set. The temperature of the concrete,
as deposited in the repair area, must be not less than 10 degrees C 50 degrees F nor more than 32 degrees C 90
degrees F. Deposit concrete as to require a minimum of re-handling and in such a manner so as to least disturb
the sand-cement grout. Place concrete as indicated to maintain existing joints [and working cracks]; do not
allow new repair material to infiltrate or span existing joints [and cracks] indicated to remain. Place concrete
continuously in each spall area. Do not allow workmen to walk on the bonding course surface or in the concrete
during placing and finishing operations.
Consolidate the concrete by small spud vibrators not greater than 25 mm one inch in diameter, except that repair
areas less than 100 mm 4 inches deep or 0.093 square meter one square foot in area may be consolidated by hand
tamping or other approved means. To avoid pulling material away from patch edge and to maximize bond strength,
work the finishing screed from the center of the patch out to the patch boundary. Fill all saw kerfs extending
beyond the repair area with grout. Start finishing operations immediately after placement of the concrete.
Match finished surface grade of patched areas to the existing surface grade of the adjacent undisturbed pavement.
Keep screeding, floating, or toweling of patch material onto adjacent pavements to a minimum; remove loose or
poorly bonded patch material from adjacent surfaces. Before the concrete becomes non-plastic, finish the surface
with a [broom] [burlap drag] [_____] to approximately match the surface finish of existing adjacent concrete
pavement.
3.3.2 Epoxy-Resin Concrete and Mortar
Limit epoxy-resin bonding coat to use on patches with a surface area of less than 600 mm 2 feet square. Place
the epoxy resin materials in layers not over 50 mm 2 inches thick. Make the time interval between placement
of additional layers such that the temperature of the epoxy resin material does not exceed 60 degrees C 140 degrees
F at any time during hardening. Use mechanical vibrators and hand tampers to consolidate the concrete or mortar.
Remove any repair material on the surrounding surfaces of the existing concrete before it hardens. Use an insert
or other bond-breaking medium where the spalled area abuts a joint, to prevent bond at the joint face. Saw a
reservoir for the joint sealant to the dimensions required for other joints. Thoroughly clean and seal the reservoir
with the sealer specified for the joints. [In lieu of sawing, spalls not adjacent to joints and popouts, both
less than 150 mm 6 inches in maximum dimension, may be prepared by drilling a core 50 mm 2 inches in diameter
greater than the size of the defect, centered over the defect, and 50 mm 2 inches deep or 13 mm 1/2 inch into
sound concrete, whichever is greater. Repair the core hole as specified above for other spalls.]
3.3.3 Proprietary Cementitious Products
Perform placing, consolidating, finishing, and curing operations in accordance with the manufacturer's written
instructions.
3.3.4 Joints
Construct new joints as detailed on the drawings and align with existing joints. After curing of the concrete,
seal new joints as indicated [and specified].
3.4 FIELD QUALITY CONTROL
3.4.1 General Requirements
Furnish concrete samples, taken in the field and tested to determine the slump, air content, and strength of
the concrete. Make test cylinders for determining conformance with the strength requirements of these specifications
and, when required, for determining the time at which pavements may be placed in service. Determine air content
in conformance with ASTM C 231. Mold and cure test cylinders in conformance with ASTM C 31/C 31M and as specified
below. Furnish all materials, labor, and facilities required for molding, curing, and protecting test cylinders
at the site and under the supervision of the Contracting Officer. Include furnishing and operating water tanks
in curing facilities for test beams, equipped with temperature-control devices that will automatically maintain
the temperature of the water at 23 degrees C 73 degrees F plus or minus 3 degrees C 5 degrees F. Also furnish
and maintain at the site, boxes or other facilities suitable for storing the specimens while in the mold at a
temperature of 23 degrees C 73 degrees F plus or minus 6 degrees C 10 degrees F. Tests of the fresh concrete
and of the hardened concrete cylinders are to be made by and at the expense of the Contractor. Test Proprietary
Cementitious Products in accordance with the manufacturer's written instructions.
3.4.2 Specimens for Strength Tests
Sample concrete in the field and test to determine the slump, air content, and strength of the concrete. Make
cylinders for each shift of placed concrete. Mold each group of test cylinders from the same batch of concrete,
consisting of a sufficient number of specimens to provide two compressive-strength tests at each test age. Make
one group of specimens during the first half of each shift, and the other during the last portion of the shift.
However, at the start of paving operations and each time the aggregate source, aggregate characteristics, or
mix design is changed, make one additional set of test cylinders.
Determine the air content and slump in conformance with ASTM C 173/C 173M and ASTM C 143/C 143M, respectively.
Mold and cure test cylinders in conformance with ASTM C 31/C 31M. Furnish and maintain at the site, boxes or
other facilities suitable for storing the specimens while in the mold at a temperature of 23 degrees C 73 degrees
F plus or minus 5.5 degrees C 10 degrees F. Test cylinders in accordance with ASTM C 39/C 39M.
3.4.2.1 Test Results
Remove concrete not meeting strength, consistency, and air content requirements and provide new acceptable concrete.
The removal and replacement method or methods are subject to approval of the Contracting Officer.
3.4.2.2 Acceptance
Reject any spall repair material that cracks, or delaminates, or loses bond partly or completely, or causes spalling
of adjacent portland cement concrete, or is not separated properly from adjacent slabs at joints, or fails to
cure uniformly and completely, or is otherwise defective. Remove all unacceptable repairs, including new damaged
areas adjacent to new spall patches, and provide new repairs meeting the specifications.
3.5 FINISHING
Start finishing operations immediately after placement of the concrete. Finished surfaces of patched areas are
to approximate surface texture of the adjacent undisturbed pavements.
3.6 CURING
NOTE: A minimum curing time of 7 days isrequired when Type I or Type II cements
are used. Specify a minimum curing period of 3 days for Type III cement.
Cure the concrete by protection against loss of moisture and rapid temperature changes for a period of not less
than [_____] days from the beginning of the curing operation. Protect unhardened concrete from rain and flowing
water. Provide all equipment needed for adequate curing and protection of the concrete on hand and ready to
install before actual concrete placement begins. Cure proprietary cementitious products in accordance with manufacturer's
recommendations. Failure to comply with curing requirements will be cause for immediate suspension of concreting
operations.
3.6.1 Moist Curing
Moist-cure all portland cement concrete patches for the first 24-hours after finishing. Immediately after the
finishing operations are complete and the concrete is set sufficiently to prevent marring the surface, cover
the entire surface of the newly laid concrete with approved wetted burlap, and keep wet for a period of not less
than 24 hours. Keep the surface of the newly laid concrete moist until the burlap coverings are in place. Ensure
that moist curing is continuous 24 hours per day and that the entire surface is wet, by having an approved work
system. Continue curing the concrete for the duration of the required curing period by this method or one of
the methods specified below.
3.6.2 Waterproof-Paper Blankets or Impermeable Sheets
Immediately after removing the covering used for initial curing, moisten the exposed concrete surfaces with a
fine spray of water and cover with waterproof-paper blankets, polyethylene-coated-burlap blankets, or impermeable
sheets. Saturate polyethylene-coated burlap with water before placing. Place sheets with the light-colored
side up. Overlap sheets not less than 300 mm 12 inches with edges taped or secured to form a completely closed
joint. Weight down coverings to prevent displacement or billowing from winds. Immediately repair tears or holes
appearing during the curing by patching.
3.6.3 Membrane-Forming Curing Compound
Apply membrane -forming curing compound immediately to exposed concrete surfaces after removing burlap coverings.
Apply the curing compound with an overlapping coverage that will give a two-coat application at a coverage of
not more than 20 square m/L 200 square feet per gallon for both coats. When application is made by hand-operated
sprayers, apply the second coat in a direction approximately at right angles to the first coat.
Cure concrete properly at joints, but do not allow absorbent curing compound to enter joints that are to be
sealed with joint-sealing compounds. Provide a uniform, continuous, cohesive compound film that will not check,
crack, or peel, and that will be free from pinholes and other imperfections. Respray concrete surfaces that
are subjected to heavy rainfall within 3 hours after the curing compound has been applied at the coverage specified
above and at no additional cost to the Government. Respray areas covered with absorbent curing material that
are damaged by pedestrian and vehicular traffic or by subsequent construction operations within the specified
curing period at no additional cost to the Government.
3.7 FINISH TOLERANCE
Provide finished surfaces of patched areas meeting the grade of the adjoining pavements without deviations more
than 3 mm 1/8 inch from a true plan surface within the patched area.
3.8 PAVEMENT PROTECTION
Protect the patched areas against damage prior to final acceptance of the work by the Government. Exclude traffic
from the patched areas by erecting and maintaining barricades and signs until the completion of the curing period
of the concrete.
3.9 JOINTS
Provide jointsconforming in detail and in alignment with the existing joints. After curing of the concrete,
prepare and sealthe joints in accordance with Section 32 01 19.61 RESEALING OF JOINTS IN RIGID PAVEMENTS.