New Jersey

Department of Transportation

Standard Specifications

for Road and Bridge Construction

2007


Division 450 – Concrete Pavement Rehabilitation
       
  Section 451 – Concrete Slab Stabilization
    451.01 Description
    451.02 Materials
    451.03 Construction
      451.03.01 Pozzolan Grout
      451.03.02 High-Density Polyurethane Grout
      451.03.03 Deflection Testing
    451.04 Measurement and Payment
  Section 452 – Partial Depth Concrete Pavement Repair
    452.01 Description
    452.02 Materials
    452.03 Construction
      452.03.01 Partial Depth Concrete Pavement Repair
    452.04 Measurement and Payment
  Section 453 – Full Depth Concrete Pavement Repair
    453.01 Description
    453.02 Materials
    453.03 Construction
      453.03.01 Full Depth Repair Using Concrete
      453.03.02 Full Depth Repair Using HMA
    453.04 Measurement and Payment
  Section 454 – Retrofit Dowel Bars
    454.01 Description
    454.02 Materials
    454.03 Construction
      454.03.01 Retrofit Dowel Bars
    454.04 Measurement and Payment
  Section 455 – Diamond Grinding Existing Concrete Pavement
    455.01 Description
    455.02 Materials
    455.03 Construction
      455.03.01 Diamond Grinding Existing Concrete Pavement
    455.04 Measurement and Payment
  Section 456 – Sealing Existing Joints in Concrete Pavement
    456.01 Description
    456.02 Materials
    456.03 Construction
      456.03.01 Sealing Existing Joints in Concrete Pavement
    456.04 Measurement and Payment

Division 450 – Concrete Pavement Rehabilitation

Section 451 – Concrete Slab Stabilization

451.01 Description  back to top

This Section describes the requirements for stabilizing concrete slabs by drilling injection holes and pumping a pozzolan grout or high-density polyurethane under the slab.

451.02 Materials  back to top

451.02.01 Materials


Provide materials as specified:
  Quick-Setting Patch Material, Type 1A 903.07
  Pozzolan Grout 903.08.03.A
  High-Density Polyurethane Grout 903.08.03.B

451.02.02 Equipment


Provide equipment as specified:
  Grout Pumping Unit 1006.03
  Mixer 1006.04
  Injection Device 1006.05
  Lift Monitoring Equipment 1006.06
  Deflection Testing Equipment 1006.07
  Grinding Machine 1006.08

451.03 Construction  back to top

451.03.01 Pozzolan Grout

  1. Weather Limitation. Do not perform slab stabilization when the pavement surface temperatures are below 32 °F or if the subgrade or base course is frozen. If proper slab stabilization cannot be achieved due to excessive temperatures or direct sunlight, perform work at night.

  2. Drilling Holes. Drill the hole pattern for grout injection as noted in the plans or as determined by the RE in consultation with the Contractor. Drill a minimum of 3 holes on either side of the transverse joint. Drill holes between 1 and 2 inches in diameter, vertically and round, to a depth sufficient to penetrate the concrete pavement. Ensure that the subbase penetration does not exceed 3 inches. Clean holes with air or water to create a small cavity or remove obstructions caused during drilling, allowing initial spread of grout.

  3. Testing of Grout. The RE will perform flow cone testing of the grout at the beginning of pumping and at random times throughout pumping. Ensure that the grout is mixed so that the flow cone test result is 9 to 16 seconds.

  4. Void Filling. Ensure that the movement of the concrete slab does not exceed 0.10 inch. If the pavement has been lifted in excess of the specified amount, the RE may require removal and replacement or grinding to the correct grade.

    Pump grout into each hole until the maximum pressure is built up or material is observed flowing from hole to hole. Ensure that the maximum pressure is 58 pounds per square inch. Monitor the pressure using a gauge in the grout line. Protect the gauge from the grout slurry.

    Ensure that mixed material is not held in the mixer or pump hopper for more than 1 hour after initial mixing. Dispose of material held longer than 1 hour as specified in 201.03.09. The RE may reduce this time if the grout becomes unsuitable for use in less than 1 hour.

    Ensure that water displaced from the void structure by the grout is allowed to flow out freely. Excessive loss of the grout through cracks or joints or from back pressure in the hose or in the shoulder area will not be allowed.

    If it is determined that continued grout injection at a specific location is no longer feasible due to major voids, the RE may direct the Contractor to cease grout injection at that location.

    Upon completion of undersealing, fill drill holes full depth with a Type 1A quick-setting patch material. Ensure that the patch is flush with the surface of the pavement.

    Do not allow traffic on the slabs for 1 hour after initial set.

  5. Repairing Cracks. If transverse cracks develop between adjacent injection holes, the RE may direct repair of the cracks using retrofit dowel bars, as specified in 454.03.01, or removal and replacement of the entire panel.

    If radial cracks develop from the injecting holes, immediately cease work and correct the operation. The RE may require repair or replacement of the damaged panel.

451.03.02 High-Density Polyurethane Grout

  1. Contractor’s Experience. At the preconstruction meeting, submit the name, experience, and material manufacturer’s certification of a manufacturer’s representative to the RE. Ensure that experience includes a minimum of 5 projects on which slab stabilization operations were successfully completed using high-density polyurethane. Ensure that the manufacturer’s representative is at the work site during all high-density polyurethane slab stabilization. The Contractor may not begin the work until the RE approves the manufacturer’s representative.

  2. Weather Limitations. Do not perform slab stabilization if the underlying material is frozen.

  3. Drilling Holes. Drill the hole pattern for grout injection as noted in the plans or as determined by the RE in consultation with the Contractor. Drill a minimum of 2 holes per side of transverse joint. Ensure that the minimum horizontal distance between holes is between 2 and 4 feet. Ensure that holes do not exceed 5/8 inch in diameter, drilled vertically and round, to a depth sufficient to penetrate below the concrete pavement and into the voids, and subbase beneath the slabs. Ensure that base penetration does not exceed 3 inches. Clean holes to remove any obstructions caused during drilling to allow flow of high-density polyurethane.

  4. Slab Stabilization. During stabilization operations, ensure the upward movement of the pavement does not exceed 0.10 inch. If the pavement has been lifted in excess of the allowable amount, the RE may require removal and replacement or grinding to the correct grade.

    After drilling the holes, inject high-density polyurethane under the slabs. As the polyurethane chemically reacts, it will expand and harden to create the necessary lifting forces. Using the pumping equipment, control the amount of rise by regulating the rate of injection of the material. When the nozzle is removed from the hole, remove any excessive material from the area, and seal the holes with high-density polyurethane.

    Immediately clean up material extruded during the pumping operations as the work progresses.

    Do not allow traffic on the slabs for 1 hour after initial set.

  5. Slab Lifting. When lifting concrete pavement to correct surface defects, such as faulted and settled concrete slabs, lift the concrete slab in increments of 0.25 inch until the pavement is raised to the required elevation.

  6. Repairing Cracks. If transverse cracks develop between adjacent injection holes, the RE may direct repair of the cracks using retrofit dowel bars, as specified in 454.03.01, or removal and replacement of the entire panel.

    If radial cracks develop from the injecting holes, immediately cease work and correct the operation. The RE may require repair or replacement of the damaged panel.

451.03.03 Deflection Testing

Perform deflection testing of joints between midnight and 10 a.m. The RE may stop testing earlier if there is evidence of slab lockup due to thermal expansion of the slabs. The RE may allow testing to continue after the hour specified if the slabs are not interlocked or under compression.

Perform deflection testing after stabilization to determine the success of grouting. Use an applied load of between 7500 and 9500 pounds-force. Place the center of the loading plate within 9 inches of the slab corner. Ensure that the deflections are normalized to a 9000-pound nominal load. If joints and cracks have deflection values greater than 10 mils, regrout an additional time in an attempt to reduce the deflection to below 10 mils. The RE may require deflection testing before grouting.

451.04 Measurement and Payment  back to top


The Department will measure and make payment for Items as follows:
  Item Pay Unit
  slab stabilization, pozzolan grout bag
  slab stabilization, polyurethane grout pound
  slab stabilization, deflection testing unit
Additional Reference Material
Item Number List  
Construction Details CD-451-1

The Department will measure the quantity of Slab stabilization, POZZOLAN grout by the number of 94-pound bags of cement used in the manufacture of grout.

Section 452 – Partial Depth Concrete Pavement Repair

452.01 Description  back to top

This Section describes the requirements for constructing partial depth concrete pavement repair.

452.02 Materials  back to top

452.02.01 Materials


Provide materials as specified:
  Quick Setting Patch, Type 1A or 1B 903.07
  White Polyethylene Sheeting 903.10.03

Use aggregate with maximum size no greater than 1/2 inch in the quick setting patch.

452.02.02 Equipment


Provide equipment as specified:
  Pavement Saw 1008.04
  Mobile Mixer 1010.03
  Small-Batch Mixer 1010.04

452.03 Construction  back to top

452.03.01 Partial Depth Concrete Pavement Repair

  1. Preparation. Sawcut repair areas to a depth of 1 inch around the perimeter of each repair area before removing the deteriorated concrete. Remove loose and disintegrated concrete from the areas to expose a sound concrete surface. Remove at least 1/4 inch of sound concrete. Clean and roughen the area by sandblasting. Ensure that the remaining concrete is not damaged. Use only pneumatic or hand tools to remove the disintegrated material and to prepare and shape the areas to be repaired. Do not use hammers that exceed 30 pounds. Remove concrete adjacent to exposed reinforcement steel by hand chipping. Do not damage or debond the reinforcement steel.

    If corroded reinforcement steel is uncovered, clean the steel by sandblasting, waterblasting or wire brushing. If the concrete is debonded from the reinforcement steel or the steel is exposed, remove the concrete adjacent to the reinforcement steel to provide a 1/2-inch clearance.

    If, during removal of concrete, more than 1/3 of the slab depth is removed, cease operations at that repair and immediately notify the RE. The RE may then direct that a full depth concrete pavement repair be constructed.

  2. Concrete Placement. Place and consolidate patch materials as specified for concrete in 405.03.02.D.1.b and 405.03.02.D.1.c except that mechanical finishing is not required. Float finish and texture with a broom.

    Cover the repair with white polyethylene sheeting. Overlap sections of white polyethylene sheeting at least 18 inches. Extend the polyethylene sheeting 2 feet beyond the edges of the repair.

  3. Opening to Traffic. Do not open repair to traffic until compressive strength as measured by the average of 2 test cylinders is more than 2000 pounds per square inch. If the required compressive strength is not met by the time the roadway must be opened to traffic, open to traffic. Remove and replace the repair during the next available roadway closure.

452.04 Measurement and Payment  back to top


The Department will measure and make payment for Items as follows:
  Item Pay Unit
  partial depth concrete repair square yard
Additional Reference Material
Item Number List  
Construction Details CD-452-1

Section 453 – Full Depth Concrete Pavement Repair

453.01 Description  back to top

This Section describes the requirements for constructing full depth concrete pavement repairs with concrete or HMA.

453.02 Materials  back to top

453.02.01 Materials


Provide materials as specified:
  Coarse Aggregate (No. 8) 901.03
  Cutback Asphalt, MC-250 902.01.02
  HMA 902.02
  Concrete, Class A 903.03
  Concrete, Class V or E 903.04
  Epoxy Grout 903.08.02.B
  Curing Materials 903.10
  Reinforcement Steel 905.01
  Joint Ties (epoxy-coated) 905.03.01
  Dowel Bars 905.03.03
  Preformed Joint Filler 914.01

Use an approved 9.5 or 12.5 nominal maximum size HMA surface course mix for patching areas after form removal. Use an approved HMA 25M64 base course for full depth HMA pavement repairs.

If Class V concrete is used and the item FLEXURAL BEAM TESTING EQUIPMENT is not provided in the Contract, deliver the flexural beam test specimens for testing 1/2 hour before the scheduled testing time to the location provided in the Special Provision or to where directed by the RE.

453.02.02 Equipment


Provide equipment as specified:
  HMA Paver 1003.03
  HMA Compactor 1003.05
  Vibratory Drum Compactor 1003.06
  Sealer Application System 1003.08
  Forms 1005.01
  Spreading and Finishing Machine 1005.02
  Vibrator 1005.04
  Grinding Machine 1006.08
  Straightedge 1008.02
  Pavement Saw 1008.04
  Hot-Air Lance 1008.06
  HMA Plant 1009.01
  HMA Trucks 1009.02
  Concrete Batching Plant 1010.01
  Concrete Trucks 1010.02

For Class V, mix concrete in a concrete mobile mixer or transit mix truck.

Use a gang drill capable of maintaining vertical and horizontal alignment and drilling the group of holes in 30 seconds or less.

453.03 Construction  back to top

453.03.01 Full Depth Repair Using Concrete

  1. Preparation. Sawcut full depth at the limits of the repair. Remove existing concrete or composite pavement using the lift out method. Do not use in-place breaking to remove concrete. Ensure that spalling of the remaining concrete does not occur during the lifting. Reuse removed pavement as specified in 202.03.07.A. The Contractor may sawcut the slab and drill the lift out holes up to 5 days before the concrete removal. Only remove concrete that can be replaced during the workday. Repair any damage to remaining pavements.

    After the existing concrete has been removed, the RE will examine underlying material to determine its condition. If water or excess moisture exists in the area, remove the underlying material to the depth specified by the RE. Place and compact coarse aggregate using the directed method as specified in 203.03.02.C. Grade the underlying surface so that the thickness of the repair matches the existing slab thickness.

  2. Placing Limitations. Comply with the concrete placing limitations specified in 504.03.02.C.

    For Class V concrete, do not place concrete if the ambient temperature or the surface temperature of the underlying layer falls below 50 °F. Ensure that the temperature of the Class V concrete is at least 80 °F at the time of placement.

  3. Setting Forms, Joint Ties, and Dowels. For the sides of repair areas that are not in contact with sound concrete, set forms for the entire area of the repair before placing concrete. Set forms at grade in full contact with the underlying surface. Ensure that concrete does not seep beneath the form. Stake forms into place with at least 3 pins for each 10-foot section. Lock form sections together to prevent movement in any direction.

    Place 1/2-inch preformed joint filler along curb and around structures and other objects protruding into the slab.

    For repairs that are 15 feet or shorter, do not install longitudinal joints ties. Coat the edge of existing slabs with cutback asphalt (MC-250) before placing concrete.

    For repairs that are longer than 15 feet, install longitudinal joint ties in the abutting concrete face. Drill holes into the face of the existing concrete pavement not more than 1/4 inch in diameter greater than the maximum measured dimension of the joint tie.

    For transverse joints abutting concrete pavement to remain, drill holes into the face of the existing concrete pavement not more than 1/4 inch in diameter greater than the dowels. Use a gang drill to install the dowels in the face of the slab. Maintain vertical and horizontal alignment during drilling and do not damage existing concrete surrounding the hole.

    Before installing dowels and joint ties, clean the holes of cement dust, standing water, and materials that interfere with proper bonding of the epoxy grout.

    Mix the epoxy grout according to the manufacturer’s recommendations. Introduce the epoxy grout by low-pressure injection through a polyethylene tube, reaching to the end of the hole. Slowly withdraw the tube as the hole is filled. Fill the holes to approximately 70 percent of their depth. Install plastic grout-retention disks to prevent the escape of grout. Insert the dowel or joint tie into the hole slowly and twist 1 full revolution to evenly distribute the grout, ensuring that no bubbles are introduced within the grout. Ensure that there is sufficient epoxy grout so that it rises to the surface and overflows from the sides of the disk upon introduction of the dowel or joint tie. Spread overflow epoxy grout on the concrete face. Provide temporary support for dowels and joint ties after insertion to prevent movement and damage to the bond. Ensure that the dowels and joint ties are not disturbed before the final cure of the grout is achieved. Lightly coat the exposed end of the dowel bars with form oil or light grease. Do not coat joint ties.

    When replacing portions of slabs greater than 20 feet in length, install joint assemblies and secure in place with anchor stakes. Ensure that devices for contraction joint assemblies are capable of holding dowels firmly in place during the entire construction operation. Place dowels across joint assemblies, parallel to and level with the surface course. Set joint assemblies in line with existing, adjacent joints and perpendicular to the existing longitudinal joint. Space additional joint assemblies equidistantly between transverse joints between 13 and 20 feet apart and perpendicular to the existing longitudinal joint.

    Check the alignment and grade elevations of the forms and joint assemblies and make corrections before placing the concrete. Ensure that the forms do not deviate from the required alignment by more than 1/4 inch. Reset, or remove and replace, forms that settle or deflect under the spreading and finishing equipment. Clean the top and face of forms, and oil the face before placing concrete.

  4. Placing, Consolidating, and Finishing Concrete. Place concrete as specified in 405.03.02.D.1.b. Consolidate, strike-off, and finish concrete as specified in 405.03.02.D.1.c, except for the following:

    1. The Department will only require mechanical finishing equipment for repairs longer than 50 feet
    2. Place concrete in 2 layers with the first layer placed to such a depth that the surface of the layer is at the proper elevation to receive the reinforcement steel. Place the reinforcement steel followed by the next layer of concrete. Remove and replace the lower layer concrete if it has developed initial set or has been in place more than 30 minutes before being covered with the next layer.
    3. Texture the surface using a stiff broom.

  5. Curing. Ensure that the concrete is not exposed for more than 30 minutes after finishing. The RE will direct a suspension, as specified in 108.13, of concrete operations if the curing procedure is delayed or is not followed. Except for Class V, apply curing compound as specified in 504.03.02.F.1, or wet burlap and white polyethylene sheeting as specified in 504.03.02.F.2. Maintain the curing material for 3 days.

    For Class V, cure the concrete using wet burlap as specified in 504.03.02.F.2 and cover with an insulation blanket to retain the heat from hydration. Ensure that insulation blankets are secured to prevent lifting. When the concrete surface temperature exceeds 120 °F, remove the insulating blanket.

  6. Sawcutting and Sealing Joints. Sawcutting relief joints may begin as soon as hardened concrete can support operations without spalling, and must be completed within 18 hours of placing concrete and before opening to traffic. Sawcut transverse relief joints above joint assemblies. Sawcut 1/8-inch-wide relief joints to a depth of 1/3 of the thickness of the concrete repair.

    Sawcut 3/8 inch wide transverse and longitudinal joints to a depth of 1/2 inch at relief joints and butt joints. After sawcutting, immediately remove all sawing slurry from the sawcut cavity and surrounding pavement surface. Clean sawcuts with a minimum of 150-pounds-per-square-inch water blast to remove remaining debris in the sawcut cavity, and then blow sawcuts with a hot-air lance to provide a dry surface. Seal sawcuts immediately after blowing.

    Seal joints with joint sealer when the ambient temperature is between 50 and 80 °F. Pour joint sealer in the sawcuts, ensuring that joint sealer is not spilled on the surface of the concrete. If spillage occurs, immediately remove spilled joint sealer from the surface of the concrete. Fill joints so that the joint sealer is 1/8 to 1/4 inch below the adjacent surface. Do not allow traffic over the sealed joints until the joint sealer has hardened to resist pickup.

  7. Opening to Traffic. For Class V concrete, do not open repair to traffic until flexural strength as measured by flexural beams is more than 350 pounds per square inch. For Class A and E concrete, do not open repair to traffic until compressive strength as measured by the average of 2 cylinders is more than 3000 pounds per square inch.

    If the required strength is not met by the time the roadway must be opened to traffic, open to traffic. Remove and replace the repair during the next available roadway closure.

453.03.02 Full Depth Repair Using HMA

  1. Preparation. Prepare concrete as specified in 453.03.01.A.

  2. Weather Limitations. Comply with weather limitations as specified in 401.03.03.B.

  3. HMA Placement. Dump, spread, and screed the HMA in lifts no thicker than 6 times the nominal maximum size of the aggregate. In small areas, spread, rake, and lute HMA with hand tools. Compact using vibratory drum compactors or HMA compactors for a minimum of 4 passes.

  4. Opening to Traffic. Remove all loose material from the repair before opening to traffic. Open repairs to traffic when the surface temperatures is below 140 °F.

453.04 Measurement and Payment  back to top


The Department will measure and make payment for Items as follows:
  Item Pay Unit
  full depth concrete pavement repair, concrete class ___ square yard
  full depth concrete pavement repair, HMA square yard
Additional Reference Material
Item Number List  
Construction Details CD-453-1, CD-453-2

Section 454 – Retrofit Dowel Bars

454.01 Description  back to top

This Section describes the requirements for installing retrofit dowel bars in existing concrete pavement.

454.02 Materials  back to top

454.02.01 Materials


Provide materials as specified:
  Quick Setting Patch, Type 1, 1A, or 1B 903.07
  Dowel Bars 905.03.03

Use aggregate with maximum size no greater than 1/2 inch in the quick setting patch.

For caulk, use a silicon sealer manufactured to adhere to concrete.

Use foam core insert of rigid styrofoam material or closed cell foam, faced with poster board or plastic material.

454.02.02 Equipment


Provide equipment as specified:
  Pavement Saw 1008.04

454.03 Construction  back to top

454.03.01 Retrofit Dowel Bars

Demonstrate the method of sawcutting slots and placing the dowels or tie bars for the RE’s approval. Sawcut slots in the pavement to a depth that allows placing the center of the dowel at mid-depth in the concrete slab. Perform multiple cuts parallel to the longitudinal joint to remove material from the slot. Use small demolition hammers with a weight less than 30 pounds to break loose the concrete. Sand blast and then clean exposed surfaces in the slot to provide an acceptable bonding surface.

Immediately before placing the dowel bar, caulk the existing transverse joint or crack at the bottom and the sides of the slot. Place the caulking to provide a smooth level surface and tight fit for the foam core insert and to prevent any of the quick setting patch from entering the joint or crack.

Place dowel bar end caps on each end of the dowel to provide a 3/4 inch long void for expansion. Lightly coat the dowel bar with form oil or light grease, and place the foam core insert around the middle of the dowel.

Place the dowel bar at the mid-depth of the slab, parallel to the longitudinal joint, and parallel to the pavement surface. For cracks that are skewed more than 45 degrees, place the dowel bar perpendicular to the crack. Ensure that the foam core insert fits tightly around the dowel and to the bottom and edges of the slot. Install the filler material so that it remains in a vertical position and tight to all the edges during placement of the quick setting patch.

Place quick setting patch to the bottom of the dowel bar. Hand-tamp the quick setting patch in place. Check the position of the dowel bar to ensure that it is parallel to the pavement surface and the longitudinal joint. Place and hand-tamp quick setting patch to fill the slot. Finish the surface flush with the pavement surface.

If the foam core insert shifts during placement of the quick setting patch, remove and replace the dowel bar. Ensure that the foam core insert is cut flush to the surface.

454.04 Measurement and Payment  back to top


The Department will measure and make payment for Items as follows:
  Item Pay Unit
  retrofit dowel bar unit
Additional Reference Material
Item Number List  
Construction Details CD-454-1

Section 455 – Diamond Grinding Existing Concrete Pavement

455.01 Description  back to top

This Section describes the requirements for diamond grinding of existing concrete pavements.

455.02 Materials  back to top

455.02.01 Materials

(Intentionally Blank)

455.02.02 Equipment


Provide equipment as specified:
  Grinding Machine 1006.08
  Mechanical Sweeper 1008.03

455.03 Construction  back to top

455.03.01 Diamond Grinding Existing Concrete Pavement

Ensure that concrete pavement repairs are performed before diamond grinding. Perform joint sealing after diamond grinding.

Perform grinding operations in a longitudinal direction that is parallel to the longitudinal joint. Do not overlap longitudinal passes more than 2 inches. Continuously remove grinding slurry from the pavement surface.

Ensure that the surface of the ground pavement has a corduroy texture consisting of grooves between 1/16 and 1/8 of an inch in width. Ensure that the peaks of the ridges are between 1/32 and 1/8 of an inch in width and are approximately 1/16 of an inch higher than the bottoms of the grooves.

Do not grind to eliminate minor depressions if it lowers the overall profile of the pavement. Ensure that in any 3 × 100-foot test area at least 95 percent of the surface is ground and textured.

Test transverse joints and cracks to ensure that adjacent surfaces are in the same plane. Regrind misaligned joints and cracks in excess of 1/16 inch until the surfaces are flush.

Ensure that the surface, after grinding, meets ride quality requirements as specified in 401.03.03.J using the equations for Other Roadways.

Regrind deficient areas in the pavement surface. When regrinding to correct deficiencies is required, regrind the entire width of the lane in the area to be corrected.

Using a mechanical sweeper, clean the area before opening to traffic and before subsequent construction or resurfacing. Remove and dispose of slurry and sweepings as specified in 201.03.09.

455.04 Measurement and Payment  back to top


The Department will measure and make payment for Items as follows:
  Item Pay Unit
  diamond grinding existing concrete pavement square yard
Additional Reference Material
Item Number List

Section 456 – Sealing Existing Joints in Concrete Pavement

456.01 Description  back to top

This Section describes the requirements for cleaning and sealing transverse and longitudinal joints in existing concrete pavement.

456.02 Materials  back to top

456.02.01 Materials


Provide materials as specified:
  Joint Sealer 914.02
  Backer Rod 914.02

456.02.02 Equipment


Provide equipment as specified:
  Sealer Application System 1003.08
  Hot-Air Lance 1008.06

456.03 Construction   back to top

456.03.01 Sealing Existing Joints in Concrete Pavement

Clean joints to be sealed to a depth of at least 2 inches by use of a rectangular plow, a diamond blade saw, or other suitable equipment. Remove joint material, incompressibles, rubble, and other extraneous materials present in the joint or adhering to the face of the adjacent concrete slabs. Clean both faces of the joint by sandblasting to the depth of the proposed sealer, leaving the faces clean and free of existing joint sealer and other contaminants. Blow the joint with a hot-air lance to provide a dry surface.

Insert the backer rod only in transverse expansion joints at a depth equal to the joint width plus 1/4 inch for the recess. Install the backer rod with a doublewheeled steel roller without stretching or puncturing the backer rod. Ensure that the backer rod is firmly seated to support the joint sealer in the joint.

Melt the joint sealer according to the manufacture’s recommendations. Ensure that the application temperature of the joint sealer is approximately 295 °F, except do not exceed the manufacturer’s safe heating temperature. Seal joints when the ambient temperature is above 40 °F.

Discard the first gallon of material to flow from the applicator wand. Pour joint sealer in the joints, ensuring that joint sealer is not spilled on the surface of the concrete. If spillage occurs, immediately remove spilled joint sealer from the surface of the concrete. Fill joints so that the joint sealer is 1/8 to 1/4 inch below the adjacent surface.

Remove the joint sealer for the full slab width and full seal depth from joints that are filled to within 1/8 inch of the elevation of the adjacent concrete. Completely clean and reseal the joints the same day as the joint overfilling occurred.

Do not allow traffic over the poured joints until the joint sealer has hardened to resist pickup.

456.04 Measurement and Payment   back to top


The Department will measure and make payment for Items as follows:
  Item Pay Unit
  sealing EXISTING joints in concrete pavement linear foot
Additional Reference Material
Item Number List


Last Document Correction:
May 15, 2008