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40-2.04 PAYMENT

Not Used

40-3 RESERVED

40-4 JOINTED PLAIN CONCRETE PAVEMENT

40-4.01 GENERAL

40-4.01A Summary

Section 40-4 includes specifications for constructing jointed plain concrete pavement.

40-4.01B Definitions

Reserved

40-4.01C Submittals

At least 24 hours before each paving shift, submit the following information as an informational submittals:

1. Early age stress and strength predictions

2. Schedule of sawing and curing activities

3. Contingency plan if cracking occurs

Submit the test data for the coefficient of thermal expansion of the concrete as an informational submittal.

40-4.01D Quality Assurance

The QC plan must include a procedure for identifying the locations of transverse contraction joints relative to the dowel bars longitudinal centers and a procedure for consolidating concrete around the dowel bars.

Develop and implement a system for predicting stresses and strength during the initial 72 hours after paving. The system must include:

1. Subscription to a weather service to obtain forecasts for wind speed, ambient temperatures, humidity, and cloud cover

2. Portable weather station with an anemometer, temperature, and humidity sensors to be located at the paving site

3. Early-age concrete pavement stress and strength prediction plan

4. Methods for analyzing, monitoring, updating, and reporting predictions

Test for coefficient of thermal expansion of the concrete under AASHTO T 336. Test at field qualification and at a frequency of 1 test for each 5,000 cu yd of paving but not less than 1 test for a project with less than 5,000 cu yd of concrete.

40-4.02 MATERIALS

Not Used

40-4.03 CONSTRUCTION

40-4.03A General

Transverse contraction joints on a curve must be on a single straight line through the radius point of the curve. If transverse joints do not align in a curve, drill a full-depth 2-inch-diameter hole under ASTM C42/C42M where the joint meets the adjacent slab. Fill the hole with joint filler. If joints are not sealed, do not allow joint filler to penetrate the joint.

40-4.03B Correcting Noncompliant Pavement Work

To replace the JPCP, saw cut and remove it full depth. Saw cut full slabs at the longitudinal and transverse joints. Saw cut partial slabs at the joints and at locations determined by the Engineer. The saw cut must be vertical.

After lifting the slab, paint the cut ends of dowels and tie bars.

Construct transverse and longitudinal construction joints between the new slab and the existing concrete. If slabs are constrained at both longitudinal edges by the existing pavement, use dowel bars instead of tie bars. For longitudinal joints, offset dowel bar holes from original tie bars by 3 inches. For transverse joints, offset dowel bar holes from the original dowel bar by 3 inches.

Drill and bond bars to the existing concrete under section 41-10. Clean loose material and contaminants from the faces of joints and the underlying base. Coat the faces with a double application of pigmented curing compound under section 28-2.03F. For partial slab replacements, place preformed sponge-rubber expansion joint filler at new transverse joints under ASTM D1752. Place concrete in the area where you removed JPCP.

40-4.03C–40-4.03G Reserved

40-4.04 PAYMENT

Not Used

40-5–40-15 RESERVED
41 EXISTING CONCRETE PAVEMENT

41-1 GENERAL

41-1.01 GENERAL

41-1.01A General

Section 41-1 includes general specifications for performing work on existing concrete pavement.

Section 36-3 does not apply.

41-1.01B Definitions

Reserved

41-1.01C Submittals

At least 15 days before delivering fast-setting concrete, polyester resin binder, or bonding agent to the job site, submit the manufacturer’s instructions, SDS, and certificates of compliance. Notify the Engineer if polyester resin binder will be stored in containers over 55 gallons.

41-1.01D Quality Assurance

Before using polyester concrete:

1. Allow 14 days for sampling and testing of the polyester resin binder

2. Arrange for a representative from the manufacturer to provide training for:

2.1. Cleaning and preparing the area

2.2. Mixing and applying the bonding agent

2.3. Mixing, placing, and curing polyester concrete

Do not use polyester concrete until your personnel and the Department's personnel have been trained.

41-1.02 MATERIALS

41-1.02A General

Water for washing aggregates, mixing concrete, curing, and coring must comply with section 90-1.02D.

41-1.02B Fast-Setting Concrete

Fast-setting concrete must be one of the following:

1. Magnesium phosphate concrete that is either:

1.1. Single component water activated

1.2. Dual component with a prepackaged liquid activator

2. Modified high-alumina based concrete

3. Portland cement based concrete

Store fast-setting concrete in a cool and dry environment.

If retarders are used, add them under the manufacturer's instructions.

You may use any accelerating chemical admixtures complying with ASTM C494/C494M, Type C and section 90-1.02E.

Fast-setting concrete must comply with the requirements shown in the following table:

Fast-Setting Concrete Requirements
Quality characteristic	Test method	Requirement
Compressive strength^a (min, psi) at 3 hours at 24 hours	California Test 551 California Test 551	3,000 5,000
Flexural strength^a (min, psi, at 24 hours)	California Test 551	500
Bond strength^a (min, psi, at 24 hours) Saturated surface dry concrete Dry concrete	California Test 551 California Test 551	300 400
Water absorption (max, %)	California Test 551	10
Abrasion resistance^a (max, g, at 24 hours)	California Test 550	25
Drying shrinkage (max, %, at 4 days)	ASTM C596	0.13
Water soluble chlorides^b (max, %, by weight)	California Test 422	0.05
Water soluble sulfates^b (max, %, by weight)	California Test 417	0.25
Thermal stability (min, %)	California Test 553	90
^aPerform testing with aggregate filler if used. ^bPerform testing on a cube specimen, fabricated under California Test 551, cured at least 14 days, and then pulverized to 100% passing the no. 50 sieve.

Aggregate filler may be used to extend prepackaged concrete. Aggregate filler must:

1. Be clean and uniformly rounded.

2. Have a moisture content of 0.5-percent by weight or less when tested under California Test 226.

3. Comply with sections 90-1.02C(2) and 90-1.02C(3).

4. Not exceed 50 percent of the concrete volume or the maximum percent in the manufacturer's instructions for the fast-setting concrete, whichever is less.
Aggregate filler must comply with the gradation shown in the following table:

Aggregate Filler Gradation
Sieve size	Percentage passing
3/8 inch	100
No. 4	50–100
No. 16	0–5

41-1.02C Polyester Concrete

Polyester concrete consists of polyester resin binder and dry aggregate. The polyester resin binder must be an unsaturated isophthalic polyester-styrene copolymer.

Polyester resin binder must comply with the requirements shown in the following table:

Polyester Resin Binder Requirements
Quality characteristic	Test method	Requirement
Viscosity^a (Pa·s) RVT, No. 1 spindle, 20 RPM at 25 °C	ASTM D2196	0.075–0.200
Specific gravity^a (25 °C)	ASTM D1475	1.05–1.10
Elongation (min, %) Type I specimen, 6.3±0.76 mm (0.25 ± 0.03 inch) thick Speed of testing = 11.4 mm/min (0.45 inch/minute) Condition 18/25/50+5/70: T—23/50	ASTM D638 ASTM D618	35
Tensile strength (min, MPa) Type I specimen, 6.3±0.76 mm (0.25 ± 0.03 inch) thick Speed of testing = 11.4 mm/min (0.45 inch/minute) Condition 18/25/50+5/70: T—23/50	ASTM D638 ASTM D618	17.24 (2,500 psi)
Styrene content^a (%, by weight)	ASTM D2369	40–50
Silane coupler (min, %, by weight of polyester resin binder)	--	1.0
PCC saturated surface-dry bond strength at 24 hours and 70 ± 2 °F (min, psi)	California Test 551	500
Static volatile emissions^a (max, g/sq m)	South Coast Air Quality Management District, Method 309-91	60
^aPerform the test before adding initiator.

Silane coupler must be an organosilane ester, gamma-methacryloxypropyltrimethoxysilane. Promoter must be compatible with suitable methyl ethyl ketone peroxide and cumene hydroperoxide initiators.

Aggregate for polyester concrete must comply with sections 90-1.02C(1), 90-1.02C(2), and 90-1.02C(3).

The combined aggregate gradation must comply with one of the gradations shown in the following table:

Combined Aggregate Gradation
Sieve size	Percentage passing
Sieve size	A	B	C
1/2"	100	100	100
3/8"	83–100	100	100
No. 4	65–82	62–85	45–80
No. 8	45–64	45–67	35–67
No. 16	27–48	29–50	25–50
No. 30	12–30	16–36	15–36
No. 50	6–17	5–20	5–20
No. 100	0–7	0–7	0–9
No. 200	0–3	0–3	0–6

Aggregate retained on the no. 8 sieve must have a maximum of 45 percent crushed particles under California Test 205. Fine aggregate must be natural sand.

The weighted average absorption must not exceed 1 percent when tested under California Tests 206 and 207.

You may submit an alternative gradation or request to use manufactured sand as fine aggregate but 100 percent of the combined gradation must pass the 3/8 inch sieve. Allow 21 days for review.

Polyester concrete must have a minimum compressive strength of 1250 psi at 3 hours and 30 minutes under California Test 551 or ASTM C109.

41-1.02D Bonding Agent

Bonding agent must comply with the concrete manufacturer’s instructions.

41-1.02E Temporary Pavement Structure

Temporary pavement structure consists of RSC or HMA over AB. RSC not complying with section 41-9 may be used as temporary pavement structure if:

1. Modulus of rupture is at least 200 psi before opening to traffic

2. RSC thickness is greater than or equal to the existing concrete pavement surface layer

3. RSC is replaced during the next paving shift

AB used for temporary pavement structure must comply with the 3/4-inch maximum gradation specified in section 26-1.02B.

HMA must comply with the specifications for minor HMA in section 39.

41-1.02F Reserved

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