Engineering and Design - Standard Practice for Concrete Pavements - Mobilization Construction - EM_1110!3!135

7/29/2019 Engineering and Design - Standard Practice for Concrete Pavements - Mobilization Construction - EM_1110!3!135

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ENGINEER MANUAL EM 1110-3-135April 1984

ENGINEERING AND DESIGN

STANDARD PRACTICE FORCONCRETE PAVEMENTS

MOBILIZATION CONSTRUCTION

DEPARTMENT OF THE ARMY~~

CORPS OF ENGINEERS.

OFFICE OF THE CHIEF OF ENGINEERS


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DEPARTMENT OF THE ARMY EM1110-3-135U.S . Army Corps of Engi neersDAEN-ECE-G Washi ngton, D. C . 20314

Engi neer ManualNo . 1110-3-135

Engi neeri ng and Desi gnSTANDARD PRACTICE FOR CONCRETE PAVEMENTSMobi l i zati on Constructi on1 . Purpose . Thi s manual provi des i nformati on for the i nvesti gati on ofconcrete materi al s, proporti oni ng, and constructi on of concrete pavements atU. S . Army mobi l i zati on faci l i ti es .2 . Appl i cabi l i ty . Thi s manual i s appl i cabl e to al l fi el d operati ngacti vi ti es havi ng mobi l i zati on constructi on responsibi l i ti es .3 . Dscussi on Cri teri a and standards presented herei n appl y to constructi onconsi dered crucial to a mobi l i zati on effort . These requi rements may beal tered when necessary to sati sfy special condi ti ons on the basi s of goodengi neeri ng practi ce consi stent wth the nature of the constructi on. Desi gnand constructi on of mobi l i zati on faci l i ti es must be compl eted wthi n 180 daysf romthe date noti ce to proceed i s gi ven wth the proj ected l i f e expectancy off i ve years . Hence, rapi d constructi on of a faci l i ty shoul d be ref l ected i ni ts desi gn. Time-consumngmethods and procedures, normal l y preferred overqui cker methods for better qual i ty, shoul d be de-emphasi zed . Lesser grademateri al s shoul d be substi tuted for hi gher grade materi al s when the l essergrademateri al s woul d provi de sati sfactory servi ce and when use of hi ghergrade materi al s woul d extend constructi on time . Work i tem not i mmedi atelynecessary for the adequate functi oni ng of the faci l i ty shoul d be deferredunti l such time as they can be completed wthout del ayi ng the mobi l i zati oneffort .FOR THE COMMANDER

PAUL F , . 1CAVANAUGHCol o"i , Corps of Engi neersChi ef of Staf f

9 Apri l 1984


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Engi neer ManualNo . 1110-3-135Engi neeri ng and Desi gn

STANDARD PRACTI CE FOR CONCRETE PAVEMENTSMobi l i zati on Constructi on

DEPARTMENT OF THE ARMY EM1110-3-135U S . Army Corps of EngineersWashington, D. C. 20314

9 Apri l 1984

Paragraph PageCHAPTER 1 . GENERAL

Purpose and scope . . . . . . . . . . . . . . . . . . 1-1 1-1Strength and ai r content . . . . . . . . . . . . 1-2 1-1Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-2Admxtures . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1-2Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-3Del i very and storage ofmateri al s . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1-3Pavement protecti on . . . . . . . . . . . . . . . . . 1-7 1-3

CHAPTER 2 . AGGREGATESOpti ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-1Coarse aggregate . . . . . . . . . . . . . . . . . . . . 2-3 2-1Fi ne aggregate . . . . . . . . . . . . . . . . . . . . . . 2-4 2-3Aggregate for cal i brati onhardstands . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2-4

CHAPTER 3 . SAMPLINGAND TESTINGCement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1Aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-1Fi el d test specimens . . . . . . . . . . . . . . . . 3-3 3-1

CHAPTER 4 . PROPORTI ONNGMxture proporti oni ng. . . . . . . . . . . . . . . 4-1 4-1Mxture proporti ons . . . . . . . . . . . . . . . . . 4-2 4-1Workabi l i ty . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4-1Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4-1

CHAPTER 5 . BATCHNGAND MXING

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1Capaci ty of pl ant . . . . . . . . . . . . . . . . . . . 5-2 5-1Concrete mxers . . . . . . . . . . . . . . . . . . . . . 5-3 5-1Approval of mxers . . . . . . . . . . . . . . . . . . 5-4 5-1


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Transporti ng ready-mxParagraph Page

concrete. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5-1CHAPTER 6 . SUBGRADE, BASE, FORMS, AND STRNG LINES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1Subgrade defi ni ti on . . . . . . . . . . . . . . . 6-2 6-1Formmateri al s . . . . . . . . . . . . . . . . . . . . . . 6-3 6-1Pl acement of form and stri ngl i nes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6-1Stri ng l i ne . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-1Removal of form . . . . . . . . . . . . . . . . . . . . 6-6 6-2CHAPTER 7 . PLACNG

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7-1Pl aci ng time . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-1Sl i p-formpaving . . . . . . . . . . . . . . . . . . . . 7-3 7-1Spreadi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7-1Vi brati on . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 7-1Surface vi brators . . . . . . . . . . . . . . . . . . . 7-6 7-2Steel rei nforcement . . . . . . . . . . . . . . . . . 7-7 7-2Pl aci ng duri ng col d weather . . . . . . . . . 7-8 7-2Pl aci ng duri ng hot weather . . . . . . . . . . 7-9 7-2Pl aci ng of smal l areas . . . . . . . . . . . . . . 7-10 7-3Overl ay-pavementconstructi on . . . . . . . . . . . . . . . . . . . . . . 7-11 7-3

CHAPTER 8 . FI N SHNG AND CURNGFi ni shi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1Curi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-1

CHAPTER 9 . TOLERANCESGrade and surface-smoothnessrequi rements . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1Tol erances i n pavementthi ckness . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-1

CHAPTER 10 . J ONTSGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1Constructi on j oi nts . . . . . . . . . . . . . . . . . 10-2 10-1Expansi on j oi nts . . . . . . . . . . . . . . . . . . . . 10-3 10-2Contracti on j oi nts . . . . . . . . . . . . . . . . . . 10-4 10-2


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CHAPTER 11 .

LI ST OF TABLESTabl e 2-1 . Coarse aggregate si ze groups .

2-2 . Gradi ng of coarse aggregate .2-3. Del eteri ous substances i n coarse aggregate .2-4. Gradi ng of fi ne aggregate .2-5. Del eteri ous substances i n fi ne aggregate .9-1 . Surface smoothness - ai rfi el d and hel i portpavements .

Paragraph Page

APPENDX A

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THN BONDED RIGD OVERLAYS FORRIGD PAVEMENTSGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11-1Correcti on of defects i nexi sti ng pavement . . . . . . . . . . . . . . . . . . 11-2 11-1Fl exural strength . . . . . . . . . . . . . . . . . . . 11-3 11-1Aggregate si zes . . . . . . . . . . . . . . . . . . . . . 11-4 11-1Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 11-2Condi ti oni ng of exi sti ngpavements . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 11-2REFERENCES A-1


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J . - 1 . Purpose and scope . Thi s manual provi des i nformati on for thei nvesti gati on of concrete materi al s, proporti oni ng, and constructi on ofconcrete pavements at Army mobi l i zati on faci l i ti es .1-2. Strength and ai r content .

a . Responsi bi l i ty for mxture proporti oni ng . The responsi bi l i tyfor mxture proporti oni ng wl l be assi gned to the Contractor, and theContracti ng Of i cer w l l approve the qual i ty of al l concrete materi al sused i n the mxture . The Contractor wl l control al l proporti ons ofthe concrete mxture necessary to obtai n the strength and qual i ty ofthe concrete requi red for the pavements .

b . Fl exural strength . Ai rf i el d pavement and road pavementstructural desi gns are based on f l exural strengths that the concrete i sexpected to obtai n at the ages of 90 and 28 days, respecti vel y .However, due to the nature of the constructi on, a 7-day strength w l lbe speci f i ed for control of the concrete mxture i n the fi el d . Thi sstrength requi res that a rel i abl e correl ati on be establ i shed at theages of 7 days and 28 or 90 days for the concrete mxture to be used i nroad or ai rfi el d pavement constructi on, respecti vel y . Fl exuralstrength for al l concrete pavements wl l be a mnimumof 650 psi .

c . Test specimens . Fl exural strength tests wl l be made on mol dedbeamspeci mens of 6- by 6-i nch cross-secti onal dimensi ons i n accordancewth ASTMC 78. Standardi zati on of the test specimen i s necessarybecause of vari ati ons i n the f l exural strength obtai ned wth specimensof di f ferent si zes . I t i s essenti al that the 6- by 6-i nch mol ded beamspecimen be used for al l f l exural strength determnati ons, i n bothl aboratory and fi el d .d . Ai r content .

CHAPTER 1GENERAL

(2) Percentage of ai r content . The speci f i ed ai r content wl lbe 6 pl us or mnus 1-1/2 percent for concrete pavements l ocated i n

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(1) Effects on ai r entrai nment . Ai r-entrai ned concrete wl l berequi red for al l concrete pavements . A r entrai nment i mproves theworkabi l i ty and pl aci ng characteri sti cs of freshl y mxed concrete andi ncreases the freezi ng-and-thawng resi stance of hardened concrete .Some reducti on i n f l exural strength, however, w l l usual l y resul t,nearl y proporti onal to the percentage of ai r entrai ned i n the concrete .Proper proporti oni ng and control of the ai r-entrai ned concrete mxtureare essenti al i n order to deri ve maximumbenefi ts fromimprovement i nthe pl aceabi l i ty and durabi l i ty of concrete wth a mnimumreducti on i nf l exural strength .


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regi ons where resi stance to freezi ng and thawng i s a primeconsi derati on, and 5 pl us or mnus 1-1/2 percent for concrete pavementsl ocated i n regi ons where frost acti on i s not a factor and ai rentrainment i s used primari l y to improve the workabi l i ty andpl aceabi l i ty of freshl y mxed concrete . A r content wl l be control l edi n the fi el d at the poi nt wthi n the speci f i ed range most appropri atefor l ocal condi ti ons, depending upon the severi ty of exposure and thequal i ty and maximumsi ze of aggregate .

e . Cement content . A cement content of at l east 470 pounds percubi c yard wl l be requi red for proposed roadways and runways . Cementcontent wl l be i ncreased as necessary to achi eve the mnimum f l exuralstrength .1-3. Water . Water for mxi ng concrete wl l be free frommateri al sthat affect hydrati on of the cement . Potabl e water may be used wthouttesti ng; however, tests wl l be made i f the water source i s a streamoranother body of water of unknown qual i ty .1-4. Admxtures .

a . A r-entrai ni ng admxtures . The ai r- entrai ni ng admxtures usedwl l be based on the necessary assurance that the proposed admxturewl l have no effects on the properti es of the concrete other than thosedesi red by the ai r entrainment . The admxture wl l be prepared i n asol uti on for addi ti on at the mxer and batched wth the mxi ng water .When truck mxers are permtted, and i t i s i mpracti cal to add theai r- entrai ni ng admxture wth the water, addi ti on of the admxturesol uti on wth the f i ne aggregate i s permssibl e .

b . Other admxtures . Onl y accel erators and retarders may bespeci f i ed or approved for use i n concrete wthout pri or approval of theContracti ng Off i cer .(1) Cal ci umchl ori de . I n some i nstances, i t may be desi rabl e torequi re or permt the use of cal ci umchl ori de i n concrete pl aced duri ng

col d weather i n order to accel erate the set and thus permt thef i ni shi ng and protecti on of the concrete wthout undue del ay .(2) Retarders . The use of a retarder shoul d be consi dered whenconcrete i s to be pl aced at temperatures exceedi ng 85 degrees F . orwhen probl em i n f i ni shi ng are anti ci pated . The Contractor has theopti on of usi ng a retarder for concrete temperatures of 85 degrees F .or bel ow(3) Pozzol ans . Fl y ash or rawor cal ci ned natural pozzol an may

be used as part of the cementi ti ous materi al up to 25 percent of thesol i d vol ume of portl and cement pl us pozzol an .


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1-6 . Del i very and storage of materi al s .

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1-5 . Cement . Normal l y, portl and cement wl l be l i mted to Type I orI I , portl and bl ast- furnace sl ag cement to Type I S, andportl and-pozzol an cement to Type I P . When cements i nterground wth anai r-entrai ni ng admxture are permtted for use, the type desi gnati onsfor ai r- entrai ni ng cements wl l be i ncl uded .

a . Lowal kal i cement . When past-performance records demonstratethat the concrete aggregate to be used for a proj ect i s potenti al l yreacti ve wth al kal i es i n the cement, a l owal kal i cement wl l beused .

b . H gh-earl y-strength cement . Concrete usi ng Type I I I cementachi eves about 75 percent of i ts desi gn strength wthi n approxi matel y 3days . Thi s coul d be hi ghl y advantageous duri ng a mobi l i zati onsi tuati on . However, i ts use shoul d onl y be speci f i ed when absol utel ynecessary .

a . Cement and pozzol an . Separate storage faci l i ti es wl l beprovi ded f or each type of cementi ti ous materi al s . Storage faci l i ti eswl l be thoroughl y cl eaned before changi ng the type of cementi ti ousmateri al stored i n i t . Storage faci l i ti es must be weatherti ght and beproperl y venti l ated . Cement must be protected f romdust, debri s, andother contamnati ng substances .

b . Aggregates . Careful i nspecti on of storage and handl i ngoperati ons i s desi rabl e to assure sati sfactory control of the aggregategradi ng and contamnati on by forei gn materi al . Uni formty of f reemoi sture i n aggregate i s essenti al f or proper control of concreteconsi stency . A peri od of f ree-drai ni ng storage i s requi red for f i neaggregates and the smal l er si ze of coarse aggregate . Normal l y, 24 to48 hours wl l be suf f i ci ent .1-7 . Pavement protecti on . Al l vehi cul ar traf f i c shoul d be excl udedf romthe pavements for at l east 14 days . As a constructi on expedi ent,earl i er use of pavement i s permtted for operati ons of constructi onequi pment onl y as necessary for pavi ng i ntermedi ate l anes between newypaved l anes . Approval for use of pavements for constructi on purposespri or to 14 days may be omtted f romcontract speci f i cati ons i funnecessary or undesi rabl e for l ocal condi ti ons . Operati on ofconstructi on equi pment on the edge of previ ousl y constructed sl abs wl lbe permtted onl y when concrete i s more than 72 hours ol d and has af l exural strength of at l east 400 psi . I n al l i nstances, approval foruse of pavement wl l be based on adequate provi si ons for keepi ngpavements clean and protecti ng pavements agai nst damage .


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2-3 . Coarse aggregate .

CHAPTER 2AGGREGATES

2-1 . Opti ons . Materi al s for concrete pavi ng may be crushed oruncrushed gravel , crushed stone, crushed bl ast- furnace sl ag, orrecycled crushed PCC pavement f or coarse aggregate ; or natural ormanufactured sand for f i ne aggregate .

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2-2 . Sources . Aggregate materi al shoul d be sought i n the area orvi ci ni ty of the proj ect . Dstant sources coul d i ncur transportati onprobl em since f rei ght trai n or l ong di stance trucki ng woul d berequi red . The advi ce of l ocal suppl i ers, contractors, or engi neersshoul d be sought to eval uate the optimal source of concreteaggregates .

a . Composi ti on . The crushi ng of gravel or stone tends to improvequal i ty and bond characteri sti cs and general l y resul ts i n a hi gherf l exural strength of concrete . When mxture proporti oni ng studi es orl ocal experi ence i ndi cates that a l ow f l exural strength wl l beobtai ned wth uncrushed gravel or stone, the possi bi l i ty of obtai ni nghi gher strength by crushi ng the materi al wl l be i nvesti gated .

b . Si ze and gradi ng . The nomnal maximumsi ze of the coarseaggregate used i n pavement concrete shoul d not exceed 1/4 of thepavement thi ckness . I n no case wl l the coarse aggregate exceed a2- i nch nomnal maximumsi ze . When the nomnal maximumsi ze of coarseaggregate i s greater than 1 i nch, the aggregates wl l be furni shed i ntwo si ze groups as shown i n tabl e 2-1, wth gradi ngs wthi n theseparated si ze groups conformng to the requi rements of tabl e 2-2 .Where l ocal practi ce provi des si ze-group separati ons other than showni n tabl e 2-1, l ocal si ze gradi ngs may be speci f i ed i f approximatel y thesam si ze ranges are obtai ned and the gradi ng of coarse aggregate whencombi ned and batched for concrete i s as requi red by mxtureproporti oni ng . State speci f i cati ons for gradi ngs may be used i n pl aceof the Corps of Engi neers gradi ngs .

Tabl e 2-1 . Coarse Aggregate Si ze GroupsMaximumNomnal Si ze Si ze Groups

1-1/2 i n . No . 4 to 3/4 i n .3/4 i n . t o 1-1/2 i n .

2 i n . No . 4 to 1 i n .1 i n . t o 2 i n .


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Tabl e 2-2 . Gradi ng of Coarse AggregateSi eve Si ze Percentage by Wei ght Passing I ndi vi dual Si evesU . S . Standard No . 4 to No . 4 to 3/4 i n . t o 1 i n . t oSquare Mesh_ 3/4 i n . 1 i n . 1-1/2 i n . 2 i n .

aggregate are uni ntendedmateri al s contamnati ng the desi red aggregate .These substances wl l reduce concrete strengths, i ncrease the chancefor popouts and weatherouts, decrease workabi l i ty of the pl asti cconcrete, and l ead to abbrevi ated l i f e spans of the concrete pavements .Time wl l not al l ow extensi ve testi ng of aggregate stockpi l es, but i fdel eteri ous substances are suspected, washi ng of the aggregate shoul dbe speci f i ed . Thi s shoul d take care of mst of the obj ecti onabl emateri al . I f unwanted materi al s are sti l l present and to such a degreeas to cause consi derabl e probl em, a new source for aggregate shoul d besought . Some del eteri ous substances whi ch are possibl e i n concreteaggregates are l i sted i n tabl e 2-3 . The amunts of these substances i neach si ze group of coarse aggregate shoul d not exceed the l imts shown,determned i n accordance wth ASTMC 117, ASTM C 123, ASTM C 295appl i cabl e onl y to materi al coarser than 3/8 i nch, and ASTMC 142 .

Tabl e 2-3 . Del eteri ous Substances i n Coarse AggregateMateri al s Percentage by Wei hi t

2-2

2-1/22 i n .1-1/2

i n .

i n 10010095 + 5

10097 + 350 + 20

1 i n . 100 97+3 37+17 7+73/4 i n . 95 + 5 --- 7 + 7 ---1/t i n . --- 43 + 20 --- 3 + 33/8 i n . 37 + 17 --- 3 + 3No . 4 5+5 5+5No . 8 3+3 3+3

c . Del eteri ous substances . Del eteri ous substances i n coarse

C ay l umps 2 . 0Shal e 1 . 0Materi al f i ner than No . 2 00 sieve 1 . 0


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Tabl e 2-3 . Del eteri ous Substances i n Coarse Aggregate (conti nued)Materi al s Percentage by Wei ght

exclusi ve of materi al f i ner than No . 200 si eved . Sl ag aggregate . Before bl ast- furnace sl ag i s used i n concrete,stockpi l es of the materi al must be saturated wth water for at l east 24hours .

2-4 . Fi ne aggregate .a . Composi ti on and shape . Fi ne aggregate wl l consi st of naturalsand, manufactured sand, or a combi nati on of the two, and wl l becomposed of cl ean, hard, durabl e parti cl es . Parti cl es of the f i neaggregate shoul d be general l y spheri cal or cubi cal i n shape i nsofar' aspracti cabl e . The use of f ine aggregate contai ni ng f l at or el ongatedparti cl es shoul d be hel d to a mnimumor when no other choi ce i savai l abl e . Care must be taken to i nsure that contamnati ng substances

are not present i n f i ne aggregate stockpi l es . Such substances woul di nclude di rt, dust, mud, and constructi on debri s .b . Gradati on and uni formty . The gradi ng and uni formty speci f i ed

i n tabl e 2-4 for the f i ne aggregate are desi rabl e for concrete pavementand can general l y be met at reasonabl e cost wth mnimumtime del ay' s .However, i f these requi rements create del ays detrimental to the i ntentof the mobi l i zati on constructi on, the speci f i cati on shoul d be rel axedto provi de for conformance wth the 3/8 i nch and No . 100 si eves onl y .

Tabl e 2-4 . Gradi ng of Fi ne Aggregate

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Si eve Si ze, Cumul ati ve Percentage by Wei ghtU S . Standard Square Mesh Passi ng I ndi vi dual Si eves

2-3

Li ghtwei ght parti cl es 0 . 5C ay i ronstone 1 . 0Chert and/or cherty stone (l ess than 1 . 02 . 50 sp . gr . SSD)C aystone, mudstone, and/or si l tstone 1 . 0Shal y and/or argi l l aceous l imestone 1 . 0Other soft parti cl es 1 . 0Total of al l del eteri ous substances 3 . 0


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Note :

. 50 20 + 10

I n addi ti on, the f i ne aggregate, as del i vered to the mxer,shoul d have a f i neness modul us of not l ess than 2 . 40 nor morethan 2 . 90 . The gradi ng of the f i ne aggregate al so shoul d becontrol l ed so that the f i neness modul i of at l east ni ne oftensamples of the f i ne aggregate as del i vered to the mxer wl l notvary more than 0 . . 15 f romthe average f i neness modul i of al lsamples previ ousl y taken .

c . Del eteri ous substances i n f i ne aggregate . The amount ofdel eteri ous substances i n the f i ne aggregate shoul d not exceed thel i mts shown i n tabl e 2-5 .Tabl e 2-5 . Del eteri ous Substances i n Fi ne Aggregate

Note : The total of al l del eteri ous materi al s shoul d' not exceed3 . 0 percent of the weight of the aggregate .2-5 . Aggregate for cal i brati on hardstands . Cal i brati on hardstand' s areused by ai rcraf t techni ci ans to cal i brate f l i ght i nstruments wthregard to the earth' s magneti c f i el d and hence, metal l i c obj ects of anyki nd wl l di stort readi ngs . Thi s i ncl udes concrete pavementscontai ni ng i ron oxi des or other i ron- ri ch mneral s havi ng magneti cproperti es whi ch wl l i nterf ere wth the operati on of the faci l i ty . . Toavoi d the i ncl usi on of these substances i n the pavement materi al s, theconcrete aggregate proposed for pavi ng cal i brati on hardstands wl l be

2-4

Tabl e 2-4 .

Si eve Si ze,U S . Standard Square

Gradi ng of Fi ne Aggregate (conti nued)

Cumul ati ve Percentage by Wei ghtMesh Passing I ndi vi dual Si evesNo . 4 97 +No . 8 85 + 5No . 16 70 + 10No . 30 45+15

Materi al Per centage by Wei ghtC ay l umps and f ri abl e parti cl es 1 . 0Materi al f i ner than No . 200 si eve 3. 0Lightwei ght parti cl es 0 . 5


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subj ected to petrographi c anal yses (ASTMC 295) pri or to acceptance .Speci al attenti on wl l be gi ven to the exi stence of magneti te i ngrani tes, hi gh-i ron mneral s i n traprock, pyri te i n l imestone, and freei ron or i ron oxi de i n sl ag aggregate .

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3-3 . Fi el d test speci mens .

CHAPTER 3SAMPLING AND TESTING

EM1110-3-1359 Apr 84

3-1 . Cement . Cement for mobi l i zati on pavement proj ects may beaccepted on the basi s of the manufacturer' s cert i f i ed ml l testsreports showng compl i ance wth ci ted cement speci f i cati ons . Cementwl l be sampled and tested onl y when there i s reason to bel i eve i t doesnot meet the speci f i cati ons .3-2 . Aggregates . Aggregate sources wl l be based on an i nvesti gati onto determne the sui tabi l i ty of avai l abl e aggregates for the proposeduse . I n general , exi sti ng approved sources shoul d be used and newsources shoul d be avoi ded as much as possi bl e . Otherwse, eval uati onof the materi al wl l requi re l aboratory testi ng, i ncl udi ng petrographi cexamnati ons, physi cal tests, durabi l i ty tests, and al kal i - reacti vi tytests whi ch are time consumng . The servi ce record of the aggregateswl l be determned by i nspecti ng structures that have had exposureequi val ent to the proposed structure . Wen an aggregate source hasbeen approved previ ousl y for use on the basi s of a compl etei nvesti gati on, addi ti onal siml ar use of the source may be permtted i fthere i s no change evident i n the composi ti on and qual i ty ofaggregate .

a . General . Fi el d tests other than those cal l ed for by Contractorqual i ty control wl l be conducted by the Government to determne thesl ump and ai r content of freshl y mxed concrete, and specimens wl l bemol ded to test for f l exural strength of hardened concrete . Si nce ' theContractor wl l be requi red to furni sh concrete samples, l abor, andfaci l i ti es for moldi ng and curi ng test specimens, i t i s necessary ' thatspeci f i cati ons i ndi cate the extent of testi ng requi red . Equipment formaki ng ai r-content and sl ump tests wl l be furni shed by the Contracti ngof f i cer when the Government i s responsi bl e for testi ng and by theContractor when the Contractor i s responsi bl e for testi ng . Beammol dswl l be made of steel , ri gi d and waterti ght . Beammol ds wl l besuppl i ed by the Contracti ng off i cer, except when the Contractor i 8responsi bl e for testi ng . Wen mol ds are requi red to be furni shed' , bythe Contractor, detai l s necessary to assure that mol ds furni shed aresati sfactory wl l be i ncluded i n the contract speci f i cati ons .

b . Specimens for strength tests . Test speci mens for determni ngthe conformance wth speci f i ed strength requi rements wl l bemoi st -cured under f i el d- l aboratory condi ti ons . The si ze and number ofcuri ng tanks wl l depend on the number of speci mens taken and the agesat whi ch the tests are made . For ai rf i el d paving proj ects,f l exural -strength tests wl l be conducted at the ages of 7, 28, and 90days . For other pavements, desi gned on the basi s of 28-day f l exuralstrengths, the test ages wl l be 7 and 28 days . Were 90-day


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f l exural -strength tests are requi red, provi sions wl l be made for thecuri ng and testi ng of speci mens after the proj ect i s compl eted .


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CHAPTER 4PROPORTIONNG

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. 4- 1 . Mxture proporti oni ng. Before any concrete i s pl aced, theContractor wl l present a mx desi gn whi ch wl l gi ve the requi redf l exural strength . I n addi ti on, thi s design shoul d demonstrate thatwater-cement rati o, ai r content, and workabi l i ty are wthi n speci f i edrequi rement ranges . Based on thi s mx, 6 by 6 i nch test speci mensshoul d be mde, cured, and tested i n accordance wth standardprocedures to establ i sh the f l exural strength of thi s concrete . Enoughtest specimens shoul d be made to provi de for three tests at 7 days,three at 28 days, and three at 90 days for ai rfi el d and three tests at7 days and three tests at 28 days for roads .4-2 . Mxture proporti ons . The Contracti ng Ofi cer wl l requi re suchchanges i n the mxture proporti ons as necessary to mai ntai n theworkabi l i ty, strength, and qual i ty requi red by the contractspeci f i cati ons . The mxture proporti ons determned by i ni ti al testi ngwl l be used i n starti ng pavi ng operati ons . Adjustments wl l be madeby the Contractor as necessary to establ i sh the mxture proporti onsbest sui ted for job condi ti ons and materi al s used . Subsequent mxtureadj ustments wl l be made when necessary, but usual l y they are of amnor nature as requi red to compensate for vari ati ons i n gradi ngs andthe moi sture content of the aggregate .4-3. Workabi l i ty . The concrete sl ump wl l not exceed 2 i nches .Wthi n thi s maximuml imt, the sl ump wl l be maintained at the l owestpracti cal val ue sui tabl e for prevai l i ng weather condi ti ons and forequi pment and methods used i n placement of the concrete . For sml l ,paved areas where vi brati on i s not requi red, a sl ump i n excess of 2,i nches may be permtted, but i n no case wl l the sl ump exceed 4 i nches .Sl ump for sl i p-formpavi ng of ai rfi el d and hel i port pavements shoul d bespeci f i ed i n a range of 1/2 to 1-1/2 i nches .4-4. Strength . Control of the strength of the concrete mxture wl lbe based on tests of concrete specimens taken duri ng the pavi ngoperati ons . Pavements to be used by ai rcraft are desi gned on the basi sof the f l exural strength that the concrete i s expected to attai n at ' theage of 90 days, and specimens wl l be tested at thi s age for use i n' theeval uati on of pavements . Si nce the peri od necessary to obtai n the90-day f i el d strengths i s too great to exerci se proper control of theconcrete duri ng pavement constructi on, a 28-day strength requi rementw l l be i ncl uded i n the contract speci f i cati ons . Fl exural -strengthtests wl l be made at the age of 28 days to determne compl i ance wththe 28-day strength requi rement . I n addi ti on, 7-day strength testswl l be made to provi de an earl y i ndi cati on of the concrete strength .The average strength at the age of 28 days of any f i ve consecuti vei ndi vi dual test val ues representi ng each concrete mxture wl l be notl ess than the speci f i ed strength at the age of 28 days, and not more


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than 20 percent of the i ndi vi dual val ues w l l be l ess than thespeci f i ed strength Adj ustments of the concrete mxture proporti onsw l l be made as necessary to mai ntai n thi s strength control .


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CHAPTER 5

BATCHNG AND MXING

EM 11 10 ' ' * 3-1359 Apr 84

. 5-1 . General . Standard mnimumrequi rements for batchi ng and mxi ngof concrete cover three types of pl ants : automati c, semautomati c, andmanual . For pavi ng proj ects, ei ther automati c or semautomati c pl antswl l be acceptabl e . Speci f i cati ons wl l be prepared to al l ow ei thertype of pl ant, and the Contractor wl l have the opti on as to the typeof pl ant to be used .5-2 . Capaci ty of pl ant . The capaci ty to be speci f i ed for the batchi ngpl ant and mxi ng equi pment wl l be determned i n accordance wth theconcrete-pl acement requi rements for the proj ect . Si nce the pavementsl abs are comparati vel y smal l , the pl ant capaci ty general l y wl l not bei nf l uenced by any requi rements for mai ntai ni ng the concrete i n apl asti c condi ti on duri ng placement . The mai n consi derati ons wl l bethe requi red pl acing schedul e to meet the compl eti on date for theconstructi on or, when sl i p-f ormpavers are used, the requi red amunt ofconcrete to mai ntai n a uni f ormf orward mvement of the paver of notl ess than 2 . 5 fpm However, the placement rate speci f i ed for pavementsconstructed duri ng hot weather shoul d al so be consi dered i n determni ngpl ant capaci ty requi rements .5-3 Concrete mxers . Mxers having a capaci ty of at l east 5 cubi cyards of mxed concrete are requi red for ai rfi el d paving proj ects, ' , b u tsmal l er mxers may be permtted for smal l road proj ects and other smal lmscel l aneous constructi on .5-4 . Approval of mxers . Before truck mxers or stati onary mxers, areapproved for use, careful considerati on wl l be gi ven to the proposedpl ant and faci l i ti es for storage and handl i ng of materi al s, and f o r ' ,batchi ng, mxing, transport i ng, and handl i ng of concrete at the j o b ' ,si te to assure that adequate control of the concrete can be exerci sed .When truck mxers are used wth a l ong haul between the batchi ng pl antand the proj ect, adequate control of the concrete may be di f f i cul t dueto vari ati ons i n sl ump and ai r content caused by di f ferences i n mxi ngtime . I n such cases, i t wl l be necessary to requi re that mxi ng bedone af ter the mxer trucks arri ve on the j ob . Truck mxers wl l beequi pped wth accurate revol uti on counters .5-5 . Transporti ng ready-mx concrete . Central -mxed concrete may betransported i n a truck agi tator, i n a truck mxer operati ng atagi tati ng speed, or i n approved nonagi tati ng equi pment . Nonagi tati ngequi pment wl l have smoth, watert i ght, metal bodi es equi pped wthgates t o permt control of the di scharge of the concrete ; covers wl lbe provi ded for protecti ng concrete i n transi t, as requi red . Concretetransported i n nonagi tati ng equi pment wl l be di scharged i nto thepavement form wthi n 45 mnutes af ter the i ntroducti on of the mxi ngwater t o the cement and aggregates at the mxer . The maj or probl emi n


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using ready-mxed concrete i n pavement constructi on i s to avoi dsegregati on of the granul ar materi al s i n di schargi ng and transferri ngthe concrete f romthe transporti ng uni t to the f i nal posi ti on i n theformor on the subgrade i n f ront of the sl i p-formpaver . The use ofready-mxed concrete wl l requi re the use of sui tabl e transfer andspreadi ng equi pment capabl e of deposi ti ng and di stri buti ng the concretein an unsegregated condi ti on i n the f i nal posi ti on i n the form . Wenl ow sl ump mxed concrete i s transported, trucks equi pped wth vi bratorsare of ten requi red to di scharge the concrete and shoul d be requi redunl ess i t i s sati sfactori l y demonstrated that the concrete can bedi scharged wthout del ay .


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CHAPTER 6SUBGRADE, BASE, FORMS, AND STRING LINES

EM 1110-3-1359 Apr 84

-6-1 . General . The setti ng and protecti on of form and stri ng l i nesand the f i nal preparati on of the subgrade, base course, or fi l tercourse requi re cl ose attenti on to al l detai l s to assure that thepavement wl l have the requi red thi ckness and the surface wl l be atthe requi red grade .6-2 . Subgrade def i ni ti on. For concrete pavi ng work, the term"subgrade" general l y has been used to i ndi cate materi al di rectl yunderneath the concrete pavement regardless of type . However, i n somei nstances, subgrade has been i nterpreted to i ndi cate onl y natural earthmateri al and not other materi al s used as a base or a fi l ter course . I norder to avoi d a msunderstandi ng, proj ect pl ans and speci f i cati ons i nal l i nstances wl l i ndi cate the speci f i c type of materi al requi red,such as subgrade, subbase, base course, or f i l ter course . The l ime,cement, or asphal t-stabi l i zed materi al immedi atel y under the pavementw l l be consi dered as the base course .6-3 . Formmateri al s . Wood form general l y are unsati sfactory forpaving work, and thei r use wl l be di scouraged except for suchmscel l aneous areas as bul kheads and curved fi l l ets . To avoi d theexcessi ve cost of pavement constructi on for smal l j obs, wood form maybe al l owed for pavements l ess than 8 i nches thi ck i n noncri ti cal areas .These woul d i ncl ude open storage areas, hel i copter parki ng pads, andvehi cl e parki ng. Steel form are needed for spreadi ng and f i ni shi ngequi pment .6-4 . Pl acement of form and stri ng l i nes . Form and stri ng l i nes,shoul d be i nstal l ed wel l i n advance of concrete pavi ng operati ons sothat the requi red checks and necessary correcti ons can be made wthoutstoppi ng or hi nderi ng concrete pl acement . The same reasoni ng appl i esto the f i nal preparati on of the underl yi ng materi al , whi ch shoul d notbe l ess than 1 ful l day' s operati on of the paving equi pment ahead ofpaving .6-5 . Stri ng l i ne . The stri ng l i ne shoul d be of hi gh-strength cord' orwre . The choi ce wl l depend on the type of automati cal l y control l edf i ne grader or sl i p-formpaver used . Certai n manufacturers recommendthat hi gh tensi l e-strength wre be stretched tautl y between supports .Other manufacturers recommend a l arge di ameter cord and do not requi rethe tautness that i s recommended for wre . The use of wre requi resfi rmy anchored supports . As a resul t, wre i s l ess l i kel y to bedi sturbed than i s cord whose supports do not have to be so fi rmyanchored . Wre i s di f f i cul t to see, and f l aggi ng shoul d be attachedbetween the supports to reduce the chance that i t wl l be di sturbe'duri ng constructi on . Cord does not requi re supports to be as fi rmyanchored as for wre, and as a resul t, cord i s easi er to i nstal l and


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mai ntai n. However, the chance of saggi ng between the supports i sgreater . Cord i s easy to see, and as a resul t, the chances of i tgetti ng out of al i nement are l ess than for wre . However, cord i s moreeasi l y di sturbed than wre and shoul d be checked more f requentl y .6-6. Removal of form . Pavement form general l y may be removed 12hours after the concrete i s pl aced . A l onger peri od wl l be necessarywhen the strength gai n of the concrete i s retarded because of del ayedor i nadequate protecti on duri ng col d weather . I n some i nstances, i twl l be desi rabl e to permt earl i er removal of form so that thetransverse j oi nts may be sawed compl etel y through to the edge of theslab wthout l eavi ng a smal l fi l l et of concrete adjacent to the form


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CHAPTER 7PLACNG

EM1110' +3-1359 Apr 84

- 7-1 . General . Concrete may be pl aced between f i xed form, or i t maybe pl aced usi ng approved sl i p- formpaving equi pment . Both methodsproduce sati sfactory resul ts, and when possi bl e, the opti on shoul d, bel ef t wth the Contractor as to the method to be used . Wth sl i p- formequi pment, the rate of pl acement can be si gni f i cantl y i ncreased overthe rate wth f i xed form . I n addi ti on, the materi al for form and thel abor for setti ng form are el i mnated . As a resul t, the cost f o r 'l arge j obs wl l be l ess for sl i p- formplacement than for pl acement' ,wthf i xed form . However, on smal l j obs or l arger j obs wth speci alrequi rements, the use of f i xed form may be necessary or moreeconomcal than the use of sl i p- formequi pment . No gui del i nes can' , begi ven as to what si ze j ob wl l permt the economc use of sl i p- formpavers si nce the choi ce wl l depend on what equi pment l ocal contractorshave avai l abl e .7-2 . Pl aci ng time . Concrete wl l be pl aced before obtai ni ng i tsi ni ti al set and wthi n 45 mnutes af ter water has been added to thebatch . These provi si ons appl y to al l pavi ng proj ects regardl ess of thetype of mxi ng equi pment used . The addi ti on of water to the mxture i nexcess of that requi red by the mxture proporti ons to mai ntai n sl umpduri ng prolonged mxi ng wl l not be permtted .7-3 . Sl i p- formpavi ng. Approval of the sl i p- formpaving equi pment forai rfi el d pavement wl l be based on sati sfactory performance i n t he'f i el d. Tri al secti ons of suf f i ci ent l ength and l ocated i n l owvol umeai rcraf t traf f i c areas wll be used t o approve the pavi ng equi pment,consi deri ng both sl i p formand another for the f i l l - i n operati on whenschedul ed by the Contractor . Furthermore, approval wl l be based onthe abi l i ty of the machi ne t o consol i date the concrete and formthepavement to the desi red cross secti ons . Pl an grade and surfacesmoothness tol erances must be met . Parti cul ar attenti on shoul d be pai dto the abi l i ty of the machi ne to formthe requi red edge wthoutexcessi ve sl umpi ng or teari ng duri ng sl i p- formoperati ons and to formasui tabl e l ongi tudi nal constructi on j oi nt duri ng f i l l - i n operati ons' .The machi ne wl l not damage the surface or edge of the previ ousl ypl aced sl ab duri ng f i l l - i n operati ons . The suggested l ength of thetri al secti on i s 1, 000 to 2, 000 feet .7-4 . Spreadi ng . Hand spreadi ng of concrete wl l be permtted onl ywhen necessi tated by odd wdths or shapes of sl abs, or i n emergenci essuch as equi pment breakdown .7-5 . V brati on . V brati on requi rements are i nf l uenced by manyfactors, such as the type and si ze of aggregate, mxture proporti ons,ai r entrainment, sl ump, workabi l i ty of mxture, and pavement thi ckness .The speci f i ed maximum spaci ng for vi brator uni ts and the speci f i ed


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vi brati ng procedures are based on fi el d experi ence wth the vi brati onof pavements 12 or more i nches i n thi ckness . There has been onl yl imted use of i nternal vi brati on for thi nner sl abs . I f necessary forproper consol i dati on of the concrete, a cl oser spaci ng of vi bratoruni ts wl l be requi red . General experi ence has been that i t i s moresati sfactory to use vi brators at a cl oser spaci ng and for shorterperi ods of vi brati on than to attempt to consol i date the concrete byprol onged vi brati on at a wder spaci ng The durati on of the vi brati onwl l be l imted by the time necessary to produce a sati sfactoryconsol i dati on of the concrete, and overvi brati on wl l not be permtted .V brators must not be permtted to touch form, dowels, ti e bars, orother embedded i tem .7-6. Surface vi brators . Surface vi brators wl l not be permtted aspast experi ence wth themgeneral l y has been unsati sfactory .7-7 . Steel rei nforcement . Proj ect drawngs wl l show typi cal detai l sof al l slab rei nforcement and wl l i ndi cate the pavements requi ri ngrei nforcement and the l ocati on and amount of steel requi red i n thesl abs . Thi s i nformati on wl l supplement the speci f i cati on requi rementsfor rei nforcement, and al l requi rements wl l be careful l y checked toi nsure there are no di screpancies between drawngs and speci f i cati onrequi rements .7-8 . Pl aci ng duri ng col d weather . I t i s sel domdesi rabl e to pl acepavement concrete when the ai r temperature i s bel ow 40 degrees F . , andspecial provi si ons for pl acement and protecti on of the concrete arenecessary for such constructi on . For addi ti onal i nformati on on wnterconcreti ng, refer to AC 306R The necessary covers and other means ofprotecti ng the concrete duri ng col d weather shoul d be avai l abl e on thej ob before starti ng concrete pl acement . Cal ciumchl ori de as anadmxture may be ei ther requi red or approved t o accel erate the setti ngtime of concrete pl aced duri ng col d weather . No changes wl l be madei n the requi rements for temperature of the concrete when pl aci ng or forprotecti on of the concrete agai nst freezing when cal ci umchl ori de orany other accel erator i s used .7-9 . Pl aci ng duri ng hot weather . Duri ng hot weather, specialprecauti ons are necessary to prevent the formati on of pl asti c-shri nkagecracks, whi ch resul t f roman excessi ve l oss of moi sture f romtheconcrete before posi ti ve curi ng has begun The concrete wl l be pl acedat the cool est temperature practi cabl e, and i n no case wl l thetemperature of the concrete as pl aced exceed 90 degrees F . Mxi ng andpl aci ng of concrete wl l be so control l ed as to keep moi sture l oss at amnimum Aggregates wl l be moist when added to the mxer, and thesubgrade dampened so i t wl l not absorb water f romthe concrete . Theconcrete temperature may be reduced by usi ng cement having atemperature bel ow the maximum 150 degrees F . speci f i ed, by spri nkl i ngthe stockpi l es of aggregate to produce cool i ng by evaporati on, byprecool i ng mxi ng water, or by avoi di ng del ays i n mxi ng and pl aci ng

7-2


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concrete . The concrete wl l be pl aced and f i ni shed as rapi dl y aspracti cabl e, and the curi ng started w thout del ay . I f the appl i cati onof the curi ng medi umshoul d, for any reason, l ag pl acement for a ti mesuff i ci ent to permt surface dryi ng, the surface shoul d be kept dap.wth a fog spray and pl acement shoul d be di sconti nued unti l correcti veacti on can be taken The fog spray equi pment wl l be capabl e ofappl yi ng a very f i ne mst to the concrete to repl ace moi sture l ost' byevaporati on. I n w ndy areas, screens may be needed to protecc the'concrete f romrapi d evaporati on caused by w nd . Curi ng methods w l lassure that an evaporati on rate of 0 . 2 psf per hour as shown i n f i gure7-1 i s not exceeded .7-10 . Pl aci ng of sml l areas . For vehi cul ar parki ng and pavi ngproj ects of 1, 200 cubi c yards or l ess, machi ne spreadi ng, f i ni shi ng,and fl oati ng w l l not be requi red i f the benefi ts deri ved fromthe' useof the equi pment are not commensurate w th the cost of usi ng themachi nes . I n thi s case, hand spreadi ng, f i ni shi ng, and f l oati ng wl lbe speci f i ed .7-11 . Overl ay- pavement constructi on . Where overl ay-pavementconstructi on i s requi red, contract speci f i cati ons wl l contai nprovi si ons for preparati on and treatment of the exi sti ng surf ace beforepl aci ng concrete i n the overl ay pavement . Cri teri a herei n pertai n ' t oconstructi on of ri gi d overl ays on exi sti ng ri gi d pavement .Constructi on of ri gi d overl ays on exi sti ng f l exi bl e pavement or anexi sti ng ri gi d pavement w th a bond breaki ng course i s treated as newconstructi on .

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EM1110- 3- 1359 Apr 84

a . Bond between l ayers of pavement . Overl ay pavements general l yare desi gned on the assumpti on that a parti al bond wl l devel op betweenthe two concrete l ayers . Concrete surfaces to recei ve part i al l y bondedoverl ays wl l be thoroughl y cl eaned of di rt and other forei gn materi al ,l oose or spal l ed concrete, extrudi ng j oi nt seal , bi tumnous patches' and materi al that woul d break the bond between the concrete l ayers .D fferent areas of pavement w l l requi re di fferent treatment . Thecondi ti on of the exi sti ng pavement wl l determne the cl eanup measuresnecessary . Normal l y, sandbl asti ng or surface- abradi ng equi pment w l lbe requi red to remove materi al adheri ng to the surface, and handscal i ng of l oose or spal l ed materi al wl l be requi red . No speci altreatment, such as aci d wash of the prepared surface or the use of ggrout bondi ng course, w l l be requi red for parti al l y bonded overl ays .I n areas where oi l or grease i s present on the surface, scrubbi ng w tha detergent and a w re brush may be requi red . C eani ng of surfaces' , torecei ve the overl ay w th rotary gri ndi ng equi pment w l l be permtted,but the surface must be swept cl ean pri or to pl aci ng the concreteoverl ay .

b . Control of cracki ng i n overl ay pavement . Consi derabl edi f f i cul ty has been experi enced w th uncontrol l ed cracki ng of overl aypavements at contracti on j oi nts . Thi s cracki ng i s l i kel y to occur


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aRI

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t e rnhum2 . Movcontem

3 . Movvel4 . Mov

appeva

CURINGOF CONCRETE ( I S 155. 02T), WTH PERMSSION OF THE PORTLANDCEMENT ASSOCIATION SKOKIE, I LLINOSFIGURE 7-1 . MOSTURE LOSS FROMCONCRETE SURFACE EVAPORATION

NOWHUMDTY 100 percent----LL -1AMR NONE.T1" " /.,.

" 'JF1 / 0 , IIMINS .MN"'MEW4, 44FRMONOAZANARRIM I N M ~~N'~-Wl! - .P ad WNNE

'EMo 50 60 70 80 90 100TEMPERATURE, degr ees F WNTHS CHART : 0 8

er wth ai r t 0. 7 SENORAperature, move ' ~ soo rel ati ve cr 0. 6i di ty . so parmri ght to ~0. 5creteperature . 0 4 /e down to wndoci ty .e l ef t ; read Irox . rate of 00 2porati on . 0 1

0


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duri ng hot weather when the temperature of exi sti ng pavement i sappreciabl y hi gher than that of the concrete bei ng pl aced i n theoverl ay . Contracti on due to cool i ng of base pavement resul ts i nmovement at the exi sti ng j oi nt, whi ch may start a crack i n the bottomof the overl ay as the concrete hardens . Thi s cracki ng may occur whenthe concrete i s too green to saw Oten the crack i s not vi si bl e atthe surface of the pavement when the sawng i s done . To prevent suchcracki ng, i t may be necessary to use f i l l er-type j oi nts .

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8-1 . Fi ni shi ng .

8-2 . Curi ng .

CHAPTER 8FINSHNG AND CUR NG

a . Equi pment and methods . Types of f i ni shi ng equi pment other thanconventi onal equi pment may be used on a tri al basi s when capabl e off i ni shi ng concrete of the qual i ty and consi stency requi red .b . Surface f i ni shi ng and testi ng . Fi ni shi ng operati ons are poi ntedtoward obtai ni ng a dense, smooth surface true to the requi red grade .

Si nce the surface recei ves the greatest exposure to weatheri ng andtraf f i c, every precauti on wl l be taken t o obtai n a hi gh-qual i tyconcrete at the surface . The f i ni shi ng operati ons wl l be kept to themni mumnecessary to obtai n the requi red surface f i ni sh . Excessi vesurface mani pul ati on wl l not be permtted as i t tends to bri ng asurpl us of mortar, water, and undesi rabl e soft materi al s to thesurface, whi ch contri butes to scal i ng and surface deteri orati on .Fi ni shi ng shoul d l eave the surface at the proper grade . I f themechani cal f i ni shi ng operati ons are properl y control l ed, very l i t t l ehand fi ni shi ng wl l be necessary . Short f l oats wl l be used onl y asnecessary to correct l ocal surface unevenness . Straightedges of therequi red l ength wl l be used pri mari l y to smooth and check the surface .To avoi d l ater costl y correcti ons of hardened pavement, whi ch fai l s toconformwth speci fi c surface tol erances, the surface wl l bethoroughl y checked duri ng the mechani cal f l oati ng and necessarycorrecti ons wl l be made.

c . Hand f i ni shi ng and edgi ng . Machi ne f i ni shi ng i s requi red, buthand fi ni shi ng wl l be permtted for odd wdths and shapes of sl abs,areas adj acent to headers, and areas around outl ets i n the pavements . ,Hand- f i ni shed areas wl l have the same qual i ty and the same surfacecharacteri sti cs as those areas f i ni shed by machi ne .

d . Surface texture . The f i nal suface texture of the pavement wl lbe provi ded by means of a burl ap drag, wre comb, or broom

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a . Control of cracki ng . Shri nkage (craze) cracki ng i s caused by ecombi nati on of hi gh ambi ent ai r temperature, hi gh concrete temperature,l ow rel ati ve humdi ty, and wnd vel oci ty . These condi ti ons need to becontrol l ed when pl aci ng and protecti ng young concrete . I t i s essenti althat concrete be protected against l oss of moi sture and rapi dtemperature change f or the speci f i ed peri od of protecti on . Equi pment,materi al , and suppl i es for adequate curi ng and protecti on of theconcrete must be on hand and ready to i nstal l before actual concretepl acement begi ns . I n general , curi ng wl l be accompl i shed by usi ng a


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membrane curi ng compound . However, other methods may' be speci f i ed' i fi ndi cated by l ocal condi ti ons .b . Membrane curi ng . The curi ng compound wl l be appl i ed by meansof a power-dri ven machi ne straddl i ng the newy paved l ane and operatedso that the spray wl l cover the pavement surface compl etel y anduni formy . Spray nozzl es shoul d be surrounded by a hood to preventwnd frombl owng the curi ng-compound spray . The rate of advance ofthe sprayi ng machi ne wl l be control l ed so that a two-coat overl appi ngcoverage wl l be provided. Hand-operated pressure sprayers wl l bepermtted onl y on i ndi cated odd wdths and shapes of sl abs and onconcrete surfaces exposed by removal or form or whenmachi nes are notavai l abl e . The curi ng compound must forma conti nuous voi d-free

membrane and be mai ntai ned i n thi s condi ti on throughout the curingperi od . Unsati sfactory or damaged areas wl l be resprayed . Any damageto the membrane duri ng the sawng operati on wl l be corrected byresprayi ng .c . Substi tute curi ng provi si ons . Where i t has been establ i shedf rompast experi ence i n an area that membrane curi ng al one does notadequatel y protect pavement fromshri nkage cracki ng, a combinati on' ' ofmoi st curi ng and membrane curi ng may be speci f i ed .d . Sel ecti on of curi ng materi al for pavements to be pai nted .

sel ecti ng curi ng materi al for pavement surfaces to be pai nted,consi derati on wl l be gi ven to the necessi ty of sandbl asti ng to removecoati ngs and deposi ts that i nterfere wth the bondi ng of pai nt . Curi ngcompounds of the l owmel ti ng-poi nt wax-base type tend to penetrateconcrete and shoul d not be used i n the areas to be pai nted .


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CHAPTER 9TOLERANCES

9-1 . Grade and surface-smoothness requi rements .a . Hel i port and ai rf i el d pavements . The speci f i ed grade andsmoothness requi rements appl i cabl e to ai rfi el d and hel i port pavementsare shown i n tabl e 9-1 . The f i ni shed surfaces of ai rfi el d and hel i portpavements wl l have no abrupt change of 1/8 i nch or more and wl l notdevi ate fromthe testi ng edge of an approved 10-foot strai ghtedge morethan the tol erances shown i n tabl e 9-1 .

Tabl e 9-1 . Surface Smoothness - A rfi el d and Hel i port PavementsI tem Drecti on Tol erancesNo Pavement Category- - of Testi ng - i nches

Runwaysunways and taxiways Longi tudi nal 1/8Transverse 1/42 Cal i brati on hardstands and Longi tudi nal 1/8compass swngi ng bases Transverse 1/83 A l other ai rf i el d and hel i - Longi tudi nal 1/4copter paved areas Transverse 1/4

9-2 Tol erances i n pavement thi ckness . Pavements wl l be constructedto thi ckness i ndi cated, and pavement thi ckness wl l be checked bymeasurements of cores dri l l ed fromthe pavement as requi red by theContracti ng Ofi cer . Cores general l y wl l be taken at i nterval s of2,000 feet or a fracti on thereof fromeach pavement l ane of paved areawhere the l anes are 1,000 feet or more i n l ength and fromevery otherl ane of the paved area where the l anes are l ess than 1,000 feet i nl ength .

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b . Road, street, and open-storage concrete pavements . Pavementswl l be smooth and true to grade and cross secti on . When tested wth a10-foot strai ghtedge on l i nes 5 feet apart paral l el wth the centerl i ne of the pavement, the surface wl l not vary more than 1/4 i nch fromthe testi ng edge of the strai ghtedge .c . Requi rements for other vehi cul ar pavements . Parking-area,motor-pool - andmotor-storage area, repai r-yard, and open-storage-areapavements wl l be smooth and true to grade and cross secti on . When

tested wth a 10-foot strai ghtedge on l i nes 5 feet apart paral l el wth,and at ri ght angl es to, the center l i ne of the paved area, the surfacewl l vary not more than 3/8 i nch fromthe testi ng edge of thestrai ghtedge .


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10-2 . Constructi on j oi nts .

CHAPTER 10JONTS

10-1

EM1110-3-1359 Apr 84

rO1 . General . J oi nts are constructed i n concrete pavements to permtcontracti on and expansi on of pavement wthout i rregul ar cracki ng and asa constructi on expedi ent to separate the paved area i nto stri psnecessary for the handl i ng and pl aci ng of concrete . There are threegeneral types of j oi nts : constructi on, contracti on, and expansi on . '

a . Longi tudi nal constructi on j oi nts . These j oi nts formed betweenpavi ng l anes at the spaci ng i ndi cated wl l be ei ther thi ckened edge,keyed, keyed and ti ed, or dowel ed, as i ndi cated . The keyed j oi nt i scri ti cal i nsofar as dimensi ons are concerned . I t i s essenti al thatboth key dimensi ons and l ocati on of key i n the j oi nt conformwth thedesi gn requi rements . Key dimensi ons are based on pavement thi ckness,each thi ckness requi ri ng a di fferent key si ze . When stati onary formare used, metal mol ds for formng the keyway wl l be securel y fastenedto the concrete form so that mol ds wl l not be di spl aced by pavi ngoperati ons . When sl i p-formpavers are used to formkeyed j oi nts, thekeyway wl l be formed by means of preformed metal keyway l i ners, whi chare i nserted duri ng pavi ng . The metal l i ners may be shaped as they~arefed through the paver fromconti nuous stri ps, or they may be preformedsecti ons bol ted together before i nserti on through the paver . I t i s,recommended that the metal l i ners be l eft i n pl ace . When sl i p-formpavers are used to formkeyed and ti ed j oi nts, bent ti e bars wl l bei nserted i nto the pl asti c unconsol i dated concrete through a metalkeyway l i ner as descri bed above. The ti e bars wl l be strai ghtenedafter the concrete has hardened. The bent bars shoul d be i nspected toi nsure that the radi us of curvature at the bend i s equal to or l argerthan the speci fi ed mnimumradi us of curvature for the grade steelbei ng used . When stati onary form are used, al l dowel s wl l be pl acedby the bonded-i n-pl ace method . Ei ther one-pi ece dowel s or spl i t dowel sof the threaded type wl l be used . Dowel s wl l be hel d accuratel y andsecurel y i n pl ace by bei ng fastened to the form . When sl i p-formpavers are used, dowel s wl l be pl aced by bondi ng the dowel s i nto hol esdri l l ed i nto the hardened concrete wth rotary core-type dri l l s t h at ' ,can be maintained i n a posi ti on paral l el to the surface of the pavementand perpendi cul ar to the face of the edge of the sl ab i n a l ongi tudi naldi recti on . The diameter of the hol e shoul d not be more than 1/8 i nchl arger than the diameter of the dowel bar . The dowel s wl l be securel ybonded and proper al i nement attai ned . Conti nuous i nspecti on wl l be'requi red to i nsure that the dowel s are securel y bonded and that they'are al i ned properl y both hori zontal l y and verti cal l y. The method usedfor i nserti ng the epoxy-resi n grout i nto the hol e wl l pl ace suffi ci entgrout to compl etel y surround the dowel and prevent voi ds wthi n thegrout .


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b . Transverse constructi on j oi nts . When concrete pl acement i sstopped or i nterrupted for 30 mnutes or l onger, these j oi nts arei nstal l ed across the pavement l ane . I nsofar as practi cabl e, thesej oi nts wl l be i nstal l ed at the l ocati on of a pl anned j oi nt .10-3 Expansi on j oi nts . When expansi on j oi nts are requi red wthi n apavement, j oi nt assembl i es supporti ng both j oi nt f i l l er and dowel s wl lbe i nstal l ed bef ore pl aci ng concrete. Accurate l ocati on and al i nementof j oi nt f i l l er and dowel s are necessary for proper f uncti oni ng ofj oi nts . Si nce checki ng of embedded i tem i n j oi nts i nstal l ed wthi n apavi ng l ane i s extremel y di f f i cul t, i t i s essenti al that assembl i esused for supporti ng embedded i tem be ri gi dl y constructed and capabl eof resi sti ng al l movement and di stort i on duri ng pavi ng operati ons .Great care and conti nuous i nspecti on are requi red duri ng pl aci ng andf i ni shi ng of concrete near j oi nts to avoi d di spl acement of j oint f i l lerand dowel s . Addi ti onal hand vi brati on wl l be requi red around thej oi nt assembl i es to i nsure adequate consol i dati on . The Contractor i srequi red to provi de a templ ate for checki ng the posi ti on of dowel s .10-4 . Contracti on j oi nts .

a . General . A l contracti on j oi nts wl l be a dummy- groove typewth the l oad transf er bei ng provi ded by an i nterl ock of aggregate andconcrete i n the f racture pl ane bel ow the j oi nt groove or by anaggregate i nterl ock and dowel s . Where dowel s are requi red acrosstransverse contracti on j oi nts, sui tabl e dowel -supporti ng assembl i eswl l be used and care taken to assure proper al i nement of dowel s i n thecompl eted pavement . Requi rements for dowel supports have beendi scussed i n paragraph 10-3 . Where ti e bars are requi red i nl ongi tudi nal dummy j oi nts, sui tabl e supporti ng devices wl l be provi dedfor hol di ng ti e bars i n pl ace duri ng pavi ng operati ons, or the bars maybe i nstal l ed i n f ront of the paver by i nserti on i nto the unconsol i datedf reshl y pl aced concrete . The devi ce for i nsert i ng the bars wl l bemounted on the paver and wl l automati cal l y i nsert the bars to thespeci f i ed depth and at the requi red spaci ng .

b . J oi nt types . Contracti on j oi nts may be constructed by sawng agroove i n hardened concrete or i nstal l i ng a sui tabl e i nsert i n f reshl ypl aced concrete . Sawng of j oi nts el i mnates mani pul ati on of f reshl ypl aced concrete af ter placement and provi des the best condi ti ons forobtai ni ng a smooth surface at the j oi nt . However, sawng ti me i scri ti cal , and cracki ng wl l occur at the wrong pl ace i f the j oi nts arenot sawed at the proper ti me . The f i l l er-type j oi nt form a weakenedpl ane i n the f reshl y pl aced concrete, whi ch i nduces f racturi ng ofconcrete at the j oi nt, permts conti nuous curi ng of pavement, andprovides protecti on for the j oi nt unti l removed or depressed i npreparati on for seal i ng of j oi nts . A though sawed j oi nts have beenused successful l y on many proj ects, excessi ve cracki ng has occurred i nsome i nstances, and speci al ef fort i s requi red t o i nsure that sawng i saccompl i shed at the proper ti me . When sawng cannot be accompl i shed

10-2


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wthout undue uncontrol l ed cracki ng, provi si ons wl l be made for usi ngi nserts . Sawng of l ongi tudi nal contracti on j oi nts i s speci f i ed assawng time and i s not cri ti cal for these j oi nts . Fi l l er- type j oi nt' smay be approved for l ongi tudi nal contracti on j oi nts when i t i sdemonstrated that these j oi nts can be properl y i nstal l ed wth vi bratoryequipment . The fi l l er must be maintained i n a verti cal posi ti on and i nproper al i nement i n the f i ni shed pavement .

c . I nstal l ati on of i nsert-type j oi nts . I nsert-type j oi nts wl l ' , b ei nstal l ed immedi atel y af ter al l machi ne f i ni shi ng operati ons arecompleted . The machine for i nstal l i ng the i nsert wl l have a vi bratorybar that cuts a groove i n concrete and simul taneousl y i nstal l s ani nsert i n requi red l ocati ons . The i ntensi ty of vi brati on on the bar ' ,wl l be vari abl e as necessary to formthe groove i n the f reshl y mxedconcrete . I nserts must be the proper depth for the concrete bei ngpl aced because the l oad transfer between the slabs depends on thei nterl ock of aggregate bel ow the formed porti on of the j oint, andmateri al that i s not deep enough wl l not produce cracki ng at theproper l ocati on . I nsert materi al must be pl aced f l ush wth the surfaceto not more than 1/8 i nch bel ow the surface . The surface of thepavement wl l be f i ni shed wth a vi bratory f l oat ; hand f l oati ng shoul dnot be permtted . When f i ni shi ng concrete, af ter i nstal l ati on ofi nsert, care must be taken not to work an excessi ve amount of f i nemateri al to the surface and adj acent to the i nsert . Excessi ve f i nes'wl l cause scal i ng of the surface and spal l i ng of the j oi nt .

d . Sawng of transverse contracti on j oi nts .

EM1110-3-1359 Apr 84

(1) Method . Transverse and l ongi tudi nal contracti on j oi nts wl lbe constructed to conformwth detai l s and dimensi ons as desi gned . ' , S a wcuts wl l be made to the depth i ndi cated to i nsure that cracki ng occursas pl anned . J oi nts wl l be constructed by sawng a groove i n thehardened concrete wth a power-dri ven saw(2) Time . No def i ni te ti me for sawng j oi nts can be speci f i edbecause of the many factors that may i nf l uence the rate of hardeni ng, ofconcrete, such as ai r and concrete temperatures duri ng pl acement,ambi ent temperatures, weather condi ti ons, curi ng and protecti on, cementcontent, and mx characteri sti cs . The basic rul e for sati sfactorysawng i s : be prepared to saw as soon as the concrete i s ready forsawng regardl ess of the time of day or ni ght . Duri ng hot weather,when most pavements are constructed, the concrete usual l y wl l be readyfor sawng about 6 to 12 hours af ter pl aci ng . Si nce concrete i s pl acedmai nl y duri ng dayl i ght hours, a l arge porti on of sawng wl l have tol be

done at ni ght, and adequate l i ghti ng must be provi ded for thi s purpose .A though a cl ean, sharp cut i s desi rabl e, a smal l amount of ravel ing' atthe top of the saw cut i s not obj ecti onabl e when earl y sawng i snecessary to avoi d uncontrol l ed cracki ng. Sawng too earl y, however ' , ,wl l be guarded agai nst to prevent excessive washing and undercutti ngof concrete i n the j oi nt . The proper time for sawng the j oi nts wl l

10-3


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be determned for prevai l i ng condi ti ons on the j ob duri ng each concretepl acement . Si nce condi ti ons may change f romday to day, i t i sdesi rabl e that the saw operator be experi enced i n sawng pavementj oi nts .(3) Sawng sequence . Transverse j oi nts w l l be sawedconsecuti vel y i n the same sequence as the concrete i s pl aced i n thel ane . Sawng of al ternate j oi nts i n the pavement i s undesi rabl ebecause concrete tends t o tear ahead of the saw cut when i ntermedi atej oi nts are sawed . Thi s procedure al so reduces the uni f ormty off racturi ng of j oi nts, which may resul t i n excessi ve openi ng at somej oi nts . Before sawng each j oi nt, the concrete w l l be examnedcl osel y for cracks, and the j oi nt w l l not be sawed i f a crack hasoccurred near the j oi nt . Sawng w l l be di sconti nued i n any j oi ntwhere a crack devel ops ahead of the saw cut .


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CHAPTER 11THN BONDED RIGD OVERLAYS FOR RIGD PAVEMENTS

EM1110-3-1359 Apr 84

i l - 1 . General . Al though the vol ume of concrete requi red for a thi nbonded overl ay i s comparati vel y smal l , thi s surface l ayer i s theporti on exposed to traf f i c and weatheri ng and must be of the hi ghestpossi bl e qual i ty . A compl ete bond must be obtai ned between the ri gi dpavement and the overl ay . The thi ckness of the overl ay wl l be not ' ,l ess than 2 i nches but not more than 5 i nches . The requi red thi cknessfor unbonded or part i al l y bonded overl ays wl l be determned i naccordance wth EM1110-3-132 for strengtheni ng roads and streets andi n accordance wth EM 1110-3-142 for strengtheni ng ai rf i el ds .11-2 . Correcti on of defects i n exi sti ng pavement . The exi sti ngpavement must be i n good structural condi ti on, and any broken orotherwse defecti ve sl abs wl l be repai red or repl aced before theoverl ay i s appl i ed . The desi gner of the overl ay shoul d real i ze thatcracks i n the pavement bei ng overl ayed wl l l i kel y ref l ect through theoverl ay pavement . A condi ti on survey shoul d be made and the cause ofcracki ng of sl abs determned i n order to develop the correcti ve measureneeded for the repai r . I f cracks are l oad associ ated, i t i s l i kel ythat repai r i s needed i n the underl yi ng materi al , the enti re sl abmghtneed t o be removed, repai rs shoul d be made to the underl yi ng materi al ,and the concrete shoul d be repl aced . When cracks i n the pavement areassoci ated wth temperature or shri nkage, consi derati on shoul d be gi vento not repl acing the slab and accepti ng the fact that the underl yi ngcrack wl l ref l ect through the overl ay . I n cases where onl y parti alremoval of a slab i s requi red to correct causes of fai l ure, asuf f i ci ent number and si ze of ti e bars shoul d be i nstal l ed by dri l l i ngthe remai ni ng sl ab and epoxy grouti ng the ti e bars i n pl ace beforepl aci ng the concrete i n the areas removed . When parti al sl ab removali s used, the porti on of the sl ab remai ni ng i n pl ace shoul d be in onepi ece and not l ess than one-hal f the si ze of a singl e slab . Concreteused i n slab repl acement wl l be of the same strength and qual i ty asthe concrete used i n the ori gi nal pavement constructi on .11-3 . Flexural strength . I n general , f l exural strength for the thi nbonded overl ay wl l be the same as that obtai ned for the ori gi nalpavement constructi on at the correspondi ng age .11-4 . Aggregate si zes . A 1/2-i nch maximumcoarse-aggregate . si zeshoul d be speci f i ed for a thi n bonded overl ay of 2-i nch thi ckness . I fthe overl ay i s 3 to 5 i nches thi ck, addi ti onal coarse-aggregategradati ons wl l be speci f i ed . The maximumnomnal aggregate size usedwl l not exceed one-fourth the overl ay thi ckness . Overl ay thi cknessused i n determni ng coarse-aggregate si ze wl l not i ncl ude addi ti onalthi ckness for l evel i ng . The entrai ned ai r content wl l be i ncreasednearer the upper l imt as the mnimumcoarse-aggregate si ze i sdecreased .


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11-5 . Cement . Portl and cement i s requi red for thi n bonded overl ays .Normal l y, the Contractor' s opti on of Type I or Type I I cement wl l bespeci f i ed . Type I I I cement shoul d not be speci f i ed except where anearl y openi ng of the pavement to traf f i c i s essenti al . Natural cementsand slag cements wl l not be used .11-6. Condi ti oni ng of exi sti ng pavements . For sati sfactoryperformance of thi n bonded overl ays, the exi sti ng pavement surface mustbe thoroughl y cl eaned of al l deteri orated concrete, oi l , grease, anddi rt . I n order to accompl i sh a thoroughl y clean surface, i t i srecommended that rotary type gri nders be used to remove at l east 1/4i nch of the exi sti ng concrete, and i n areas where the concrete hasdeteri orated, the materi al shoul d be removed to sound concrete . Af tergri ndi ng wth rotary gri nders, the surface shoul d be sandbl asted toremove debri s l ef t f romgri ndi ng Before the pavement i s pl aced, thesurface of the exi sti ng pavement shoul d be cl eaned by broomng andfol l owed wth compressed ai r . I n areas where equi pment turns, such asa truck haul i ng concrete, the exi sti ng pavement shoul d be covered wthsand or some other protecti ve cover to prevent rubber f romscrubbi ngof f of ti res onto the exi sti ng concrete and formng a bond breaker .Ei ther a neat cement slurry or cement and sand grout i s sati sfactoryfor bondi ng the overl ay to the exi sti ng surface . These may be appl i edby pressure sprayi ng or by broomng over the exi sti ng surface, but theyshoul d be appl i ed t o a dry surface and appl i ed onl y 6 t o 10 feet aheadof concrete pl acing I f the grout or sl urry dri es before concrete i spl aced, i t shoul d be removed and fresh materi al appl i ed .


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Government Publ i cati ons .Department of the Arm .EM1110-3-132 Ri gi d Pavements for Roads, Streets,Wal ks and Open Storage Areas .EM1110-3-142 Ai rf i el d Ri gi d Pavement .

Nongovernment Publ i cati ons .

C 78-75 Fl exural Strength of Concrete (Usi ngSimpl e Beamwth Thi rd-Poi ntLoadi ng) .C 117-80

APPENDX AREFERENCES

Ameri can Society for Testi ng and Materi al s (ASTM, 1916 RaceStreet, Phi l adel phi a, PA 19103

Materi al s Fi ner Than 75-um(No . 200)Si eve i n Mneral Aggregates byWashi ng .

C 123-69 Lightwei ght Pi eces i n Aggregate .(R 1975)C 142-78 C ay Lumps and Fri abl e Parti cl es i nAggregates .C 295-79 Petrographi c Examnati on ofAggregates for Concrete .

Ameri can Concrete I nsti tute (ACI ), P . 0 Box 19150,Detroi t, M 48219306R-78 Recommended Practi ce for Col dWeather Concreti ng .

EM1110-31359 Apr 84

Documents

Engineering and Design - Standard Practice for Concrete Pavements - Mobilization Construction - EM_1110!3!135