Concrete Pavement Inspection

Concrete Pavement Inspection Concrete Pavement Inspection

2017 WCPA/WisDOT Concrete Pavement Inspection Workshop

2017 WisDOT Region Training

BackgroundBackground• WCPA developed course and guide for

municipalities in 2008• SE Region requested a course in 2009• “Pilot” Course given in May 2009• Well received by both Department and

Consultant staff in attendance• Now 9 years in development/revision


BackgroundBackground• Manual and PowerPoint development was

done with WCPA as the lead. • WisDOT review and approval.• Fifth generation manual updated in 2017.


CreditsCredits• Wisconsin Department of Transportation

– James Parry– Barry Paye– Chad Hayes– Wayne Chase

• Wisconsin Concrete Pavement Assoc.– Heath Schopf– Kevin McMullen


Concrete Pavement Technical Committee

Concrete Pavement Technical Committee

• WisDOT Committee Members –• Bureau of Technical Services

– Steve Krebs – Director– Barry Paye – Chief Materials and Pavement Engineer– Jim Parry – Quality Management Supervisor– Chad Hayes – Concrete Engineer– Debra Bischoff - QMP Engineer– Laura Fenley – Pavement Design Engineer– Myungook Kang – Policy and Design Engineer– Bureau of Project Development– Wayne Chase – Chief Project Development– Michael Hall – CO Specifications Section

• Bureau of Aeronautics– Tom Dewinter – Airport Construction Standards Chief

• WisDOT Regions– Southwest Region – Travis Mikshowsky– Southeast Region - Jeanne Marchant – North Central Region - Jeff Michalski – Northeast Region - Adam Johnson– Northwest Region – William Kurtz– Bruce Enke – WisDOT NE Region – Management Liaison– Anne Wallace – WisDOT SW Region – Technical Services

Liaison– Robert Schiro – WisDOT Southeast Freeways– Barb Gassen – WisDOT Interstate 39/90 Team– Brad Williams – WisDOT SW Region

• WCPA Members –– Barry Bohman – Chippewa Concrete Services– Jeff Parisi – Parisi Construction Company– Joe Culek – Raymond P. Cattell, Inc.– Tom Ptaschinski – Ptaschinski Construction

Company– David McKewin – Sommers Construction Company– Brian Oppman – Trierweiler Construction Company– Richard Lamers – Vinton Construction Company– John Zignego – Zignego Company– Andrea Breen – Lafarge Holcim– James Palmer– St. Mary’s Cement Company– Vacant - Continental Cement Company– Scott Grams – GRT Mapai– Kevin McMullen – Wisconsin Concrete Pavement

Association• FHWA Members -

– Greg Newhouse – Wisconsin Division Office• WTBA Member-

– Matt Grove – WTBA Staff• ACEC Liaison –

– Craig Treadway – JT Engineering• Other-

– Mike Debelak – Michels Paving


Concrete Pavement Inspection WorkshopConcrete Pavement

Inspection WorkshopTHIS IS A JOINT EFFORT


Concrete Paving in WisconsinConcrete Paving in Wisconsin• WisDOT and WCPA Joint Efforts• Recognized nationally as a leader• WCPA and WisDOT relationship is looked

upon with envy by other DOT’s and associations

• Our specifications, standards, industry and equipment are often recognized as the most modern and progressive

• We need to strive to continue our national leadership role.


InstructorsInstructors• WCPA

– Kevin McMullen – President– Heath Schopf – Director of Construction

Engineering• WisDOT

– James Parry – Quality Assurance Supervisor– Chad Hayes – Concrete Engineer




INTRODUCTIONINTRODUCTIONCHAPTER 1



Objective of GuideObjective of Guide

The primary objective of this guide is to educate the concrete pavement inspector for the purpose of ensuring “Good Practices” during the concrete pavement construction process.


InspectionInspection• Purpose:

– To establish that the construction process conforms to the requirements of the contract documents.

InspectionInspection• A quality concrete pavement is directly related to a

well constructed concrete pavement.• Material durability and construction quality influence

the short and long term pavement performance.• Proper inspection plays a key role in providing a well

constructed high quality pavement. • Proper inspection can influence performance quality

and the ride quality.• High quality concrete pavements provide excellent

long-term performance and ride over the design life with a low level of maintenance and rehabilitation.


InspectionInspection• Quality as defined by the American

Society of Civil Engineering (ASCE)

• “Quality is never an accident. It is always the result of high intentions, intelligent direction, and skilled execution. It represents a wise choice amongst many alternatives.”


How Important is Inspection?How Important is Inspection?• The last 8 years in WI

– 3.79 million SY per year average total statewide

– 2.91 million SY per year Average WisDOT– Average of $153 million per year

• 2016– $276,000 per lane mile of concrete pavement– $630,000 per day of paving

• Yes, inspection is important!


WORK ZONE SAFETYWORK ZONE SAFETYCHAPTER 2


The Facts on Work Zone Safety


• In 2014, 669 work zone fatalities in the US• 2% of all roadway fatalities• 119 were construction personnel• 1 out of 5 work zone fatalities are

construction personnel• 15 construction worker deaths in WI since

2003




• 40,000 work zone injuries per year• One work zone fatality every 10 hours• One work zone injury every 13 minutes


Work Zone InjuriesWork Zone Injuries• Contact with objects or equipment – 35%• Slips, trips or falls – 20%• Overexertion – 15%• Transportation incidents – 12%• Exposure to harmful substances or

environments – 5%


Work Zone FatalitiesWork Zone Fatalities• #1 cause is worker runovers/backovers

– 48% of work zone fatalities• #2 cause is worker caught in between or

struck by object– 14% of work zone fatalities

• #3 cause is vehicle collisions– 14% of work zone fatalities


Concrete SafetyConcrete SafetyWork Zone Safety is Very Important• 15% of accidents caused by unsafe mechanical or

physical conditions• 85% result of absentmindedness, negligence or

not knowing the RISK• Personnel must be able to identify potential

dangerous situations and take action if necessary• Safe construction practices need to be discussed

and implemented prior to performing an operation


Job Safety AnalysisJob Safety Analysis• Traffic control installed prior to any operation• Wear proper Personal Protective Equipment

• Eye protection• Ear protection• Hard hat• Safety vest (pants at night or flagging)• Rubber boots and gloves when working with concrete

• Keep a list of emergency numbers• Know the location of the nearest hospital first

aid kit and fire extinguisher


Personal Protection Equipment - the minimum equipment-

Personal Protection Equipment - the minimum equipment-

• Vest – Class 2 Minimum– Florescent yellow-green

preferred– ANSI/ISEA 107–2004

• Hard Hat• Safety Glasses• Ear Protection• Steel Toed Boots• OCIP Project

requirement 2017 WCPA/WisDOT Concrete Pavement Inspection Workshop

Vests - MUTCDVests - MUTCD• Standard:• 04 All workers, including emergency responders, within the

right-of-way who are exposed either to traffic (vehicles using the highway for purposes of travel) or to work vehicles and construction equipment within the TTC zone shall wear high-visibility safety apparel that meets the Performance Class 2 or 3 requirements of the ANSI/ISEA 107–2004 publication entitled “American National Standard for High-Visibility Safety Apparel and Headwear” (see Section 1A.11), or equivalent revisions, and labeled as meeting the ANSI 107-2004 standard performance for Class 2 or 3 risk exposure, except as provided in Paragraph 5. A person designated by the employer to be responsible for worker safety shall make the selection of the appropriate class of garment.


VestsVests


Class 2 -MINIMUMClass 1 -

NOT ALLOWED

Class 3 -PREFERRED and required for night work

VestsVests


Time for replacement

ApparelApparel• Long pants• Boots with steel toes• Avoid

– Loose jackets, shirts and pants

– Tennis shoes– Ties

• Moving part hazards


First Aid KitFirst Aid Kit• Availability• Restock after every

use• Gloves a necessity• Replace entire kit

biannually


Vehicle RequirementsVehicle Requirements• Public Needs to

know you are part of construction project.

• Flashing strobes– 360 degree visibility– Top Mount– Built in strobes

• Use as early warning to public when entering and exiting work zone


Traffic ControlTraffic Control


Traffic HazardsTraffic Hazards• Assume public is

– Inexperienced– unskilled– Inattentive– Or impaired

• Stay Alert• Avoid complacency


Congested WorksiteCongested Worksite


It is your job to be seenand to watch for yourself.

The truck drivers have a jobto do and may not be watching for you.

The Busy Work ZoneThe Busy Work Zone


•ALWAYS BE AWARE OF YOUR SURROUNDINGS• Be alert to traffic when working near a live roadway•Make eye contact with operators when working near heavy equipment.•Be aware of construction operations in your area.

•STAY FOCUSED•NOT THE PLACE FOR A CELL PHONE CALL TO DIVERT YOUR ATTENTION

Congested Worksite

Construction EquipmentConstruction Equipment


Two most common pieces of equipmenton a concrete paving project?

Can they see you?



Backing EquipmentBacking Equipment


Treat Equipment and Vehicles With Caution

Treat Equipment and Vehicles With Caution

• If you can not see the operator assume they can not see you.

• Stay out of blind spots• Don’t approach until you

communicate with the operator and he/she acknowledges you.

• Stay outside the safety circle

• Stay clear of vehicles• Know the traffic control plan• Use spotters when you

must have your back to equipment or traffic.


Don’t Think It Can’t Happen to You

Don’t Think It Can’t Happen to You


It can happen to you!Just ask…..

It can happen to you!Just ask…..

• John Geiger – Streu Construction– 35 years on concrete paving operations– Ran over by a dump truck– Broken legs and pelvis– Readily admits lucky to be alive

• Gene Mueller – Trierweiler Construction– 45 years on paving projects– Legs crushed between dump truck and spreader– Repeated over and over that he should have

never been there.


Other HazardsOther Hazards• Watch for unsafe

conditions• Report immediately to

your supervisor and contractor foreman

• Halt work if necessary• Resume work only

after unsafe situation is corrected


Paving EquipmentPaving Equipment• Pavers and bridges

are for the contractors• WisDOT employees

are to stay off unless doing the required probing.

• Coordinate probing with the contractor to assure safety


The Hard Hat AreaThe Hard Hat Area• The one area next to

the paver where hard hat is required.

• In general, if your hanging around this area they will ask you move and stay clear.

• Getting hit by a bundle of steel !!!


StringlineStringline• A real tripping hazard• Never locate yourself

between the string line and the paver


Between the StringsBetween the Strings• Too much activity• Main traffic area• Trucks backing long

distance• Dowel basket tripping

hazards• Contractor just does not

want you there• QC Staff must be

careful of backing trucks while sampling


FinishingFinishing


Night WorkNight Work


When working at night

Must wear vest and reflective Pants

Batch SitesBatch Sites• Multiple vehicle types• When working at the

batch site never travel so close behind a vehicle that you can’t be seen

• Park where the employees are parking


Safe Zones & ParkingSafe Zones & Parking


Look for a safe place to park at the batch sites and the construction zone.

Park where the contractor employees park or ask for instruction

Look AheadLook Ahead


Watch For Each OtherWatch For Each Other• Be alert• Keep an eye on your

coworkers• Hope they do the

same for you


Expect the Unexpected –the public makes poor

decisions at times

Expect the Unexpected –the public makes poor

decisions at times


Expect the Unexpected –even from those that should

know better

Expect the Unexpected –even from those that should

know better


Skin Contact With Portland Cement

Skin Contact With Portland Cement

• Alkaline hazard• Four types of skin problems happen most

often among cement products workers:– Dry skin or irritation (mild ICD)– Irritant contact dermatitis (ICD)– Allergic contact dermatitis (ACD)– Caustic burns (alkaline burns


Skin Protection –Best Protective Work Practices


• Keep cement products off the skin – Experienced concrete workers protect their

skin with boots, gloves, clothing and kneeboards

– Skin injury may result from clothing wet with concrete mixtures

• Don’t let skin rub against cement products– Abrasion– Rubbing increases the chances of serious

injury




• Always wash skin promptly after contact with cement products

• Keep cement and cement products out of eyes– Use safety glasses, CONCRETE SPLASHES!– Flush eyes immediately and repeatedly– Contact a physician




• Keep out of reach of children• Cement and concrete products harmful to

them• Change out of work clothes as soon as

possible and before making contact with family members

• Cover car seats • Wash cement/concrete covered clothes

separately



CONTRACT DOCUMENTSCONTRACT DOCUMENTSCHAPTER 3


CHAD

Contract DocumentsContract Documents• Hierarchy of Documents

– Contract Modification– Addenda– Special provisions– Plan– Standard Specifications


Standard SpecificationsStandard Specifications


WisDOT is an AASHTO StateWisDOT is an AASHTO State• ASTM Electronic

Portal• https://compass.astm.

org/fedlogin.php


SPECIFICATIONSSPECIFICATIONS• The only specifications that matter?

– The standard specification book referenced in your contract.

– The STSP versions in your contract– And the special provisions in your contract


SPECIFICATIONSEdition Referenced in Contract

SPECIFICATIONSEdition Referenced in Contract


STANDARD SPECIFICATIONSFOR

HIGHWAY AND STRUCTURE CONSTRUCTION

2017 Edition

Wisconsin Department of Transportation

Wisconsin Department of Transportation


2017 Standard Specifications2017 Standard Specifications• Part 1 – General Requirements and

Covenants• Part 2 – Earthwork• Part 3 – Bases and Subbases• Part 4 – Pavements• Part 5 – Structures• Part 6 – Incidental Construction• Part 7 – Quality Management Program


2017 Standard Spec Update2017 Standard Spec Update• New WisDOT Standard Specification Book

published each fall• 2017 Spec Book effective with the projects

in the December 2016 Letting.• Several minor changes in 2017 Spec

Book.


2017 Standard Spec Update2017 Standard Spec Update

Revision Affecting Concrete Pavements


Section 101General Information

Section 101General Information

• Revise 101.3(1) to add a dollar threshold to the department’s definition of major items


Section 106Control of Materials

Section 106Control of Materials

• Revise 106.1.2 to require the contractor's coordination to be HTCP certified and participate in project weekly meetings.

• Revise 106.3.4.3.2(1) to specify the department doesn't require or use non-random contractor tests for dispute resolution.

• Revise 106.3.4.3.5(2) to specify the department doesn't require or use non-random contractor tests for dispute resolution.


Section 108Prosecution and Progress

Section 108Prosecution and Progress

• Revise 108.10.2.1(3) to specify that the department will extend contract time for industry-wide material shortages.


Section 405Coloring and Stamping Concrete

Section 405Coloring and Stamping Concrete

• Retitle and revise section 405 to add bid items for custom colors and for stamping colored concrete.

• Add 405.2.1.1(5) to add a bid item for a custom color defined in STSP 405-020 Coloring Concrete Custom.

• Add 405.2.2 to provide materials requirements for stamping colored concrete.

• Add 405.3.2 to add a bid item for stamping and coloring concrete defined in STSP 405-100 Stamping Colored Concrete.

• Revise 405.5 to provide new Coloring Concrete Custom and Stamping Colored Concrete bid items to use with concrete work performed under other contract bid items. Additional costs for color and stamping can be allocated to others if state law limits department participation in coloring or stamping.


Section 416Concrete Pavement -

Appurtenant Construction

Section 416Concrete Pavement -

Appurtenant Construction • Add 416.2.3.2(5) to allow acrylic adhesive

meeting the same physical properties required for epoxy adhesives.

• Rename bid item to Concrete Truck Apron to use on roundabouts as well as truck aprons in other locations.


Section 420Diamond Grinding

Section 420Diamond Grinding

• Revise 420.1(1) to include intermittent grinding for restoring existing pavement and profile correction of new pavement.

• Revise 420.3.2 to specify intermittent grinding equipment for restoration and profile correction.


Section 440Ride QualitySection 440Ride Quality

• Revise 440.1(2) to clarify that the ride spec applies when we have a continuous stretch of new riding surface over 1500 feet long. The IRI within that 1500 feet includes measured roughness on bridges, bridge approaches, and railroad crossings but not roughness associated with roundabouts.


Section 501 Concrete

Section 501 Concrete

• Revise Section 501.2.5.4.4 to specify alkali-silica reactivity testing for coarse aggregates used in concrete

• Revise Section 501.2.5.5(1) to specify alkali-silica tests for coarse aggregates used in concrete


Section 715QMP Concrete Pavement and

Structures

Section 715QMP Concrete Pavement and

Structures• Revise 715.3.1.2.1(1) to allow fly ash

source changes without redefining concrete pavement lots to recognize systemic changes in the availability of fly ash.

• This change was implemented in ASP 6 effective with the July 2016 letting


WISDOT QUALITY MANAGEMENT PROGRAMWISDOT QUALITY MANAGEMENT PROGRAM

CHAPTER 4


JIM

Quality Management Program(QMP)

Quality Management Program(QMP)


Section 106Section 106• Under the contract QMP provisions, the

department will base approval of the covered materials on a combination of the results of the following:– Contractor Quality Control (QC) testing.– Department Quality Verification (QV) testing.– Inspections of the materials production,

storage, handling, and construction processes.

– Dispute resolution procedures.


QMP Material TestingQMP Material Testing• Quality Control or QC Test • Quality Verification or QV Test• Independent Assurance or IA Test• Process Control or PC Test

• Engineer Directed Test


• Quality Control (QC)– Testing performed by the contractor at the

specified frequency – Random sampling locations must be

computed using random numbers– Materials accepted and incentives computed

using QC test results, unless QV or IA testing shows nonconforming material

QC TestingQC Testing


• Quality Verification (QV)– Testing performed by the department’s

representative at the specified frequency– Random sampling locations are independent of

the QC sample locations and must be computed using random numbers

– QV is meant to verify the quality of the product, i.e. does the material meet the spec requirements

– If QV test result is nonconforming, department notifies contractor and investigation must take place

– QV requirements are contractual, i.e. notification of testing, timeline for reporting results to contractor

QV TestingQV Testing


• Independent Assurance (IA)– Split sample comparison testing, proficiency

observation, or calibration checks performed by a WisDOT independent assurance specialist

– Goal is to have IA performed on every active QC and QV tester at least once per year (FHWA)

– IA is meant to validate the sampling and testing proficiency of the tester

IA TestingIA Testing


PC TestingPC Testing• Process Control (PC)

– Additional testing by the contractor to help monitor the process

– We all want and encourage more testing by the contractor

– Non-random tests– At contractor discretion to control operations.– Not used for acceptance.– Contractor cannot knowingly incorporate

materials into work that is nonconforming


Engineer Directed TestEngineer Directed Test• Engineer Directed Test

– Can be directed at any time– Change of condition– Materials variation– Is not random– Typically performed by QC tester– Does not impact or replace random tests

under QMP– Must have reason and document results


• If a testing discrepancy occurs, WisDOT and the contractor will investigate possible causes and resolve the issue (review data reduction & analysis methods, review sampling & testing procedures, etc.)

• If a dispute cannot be resolved, 3rd party testing may be used. The party in error pays for the testing.

QMP Dispute ResolutionQMP Dispute Resolution


PART 7QUALITY MANAGEMENT PROGRAM

PART 7QUALITY MANAGEMENT PROGRAM

• Section 701 - General QMP Requirements• Section 710 – General Concrete QMP• Section 715 – QMP Concrete Pavement

and Structures• Section 716 – QMP Ancillary Concrete


Section 701Section 701

WHAT IS COMMON TO ALL QMP SPECIFICATIONS


Section 701 – Contractor General QMP Requirements


• Provide and maintain a quality control program– Mix and gradation design.– Control and inspection of production and placement

process– Material, sampling, testing, and correction of in-place

work• References chapter 8 of CMM for additional QMP

guidance• Submit QMP results to the Department electronically

using MRS software.• Defines quality control plan requirements




• Defines abbreviated quality control plan requirements for small quantities

• HTCP certified contractor personnel on project.• Department qualified laboratory to be used• Equipment calibration and records• Document and submit test results to WisDOT

Designated Materials Person the same day they become available.




• Enter MRS data within 5 business days.• Submit final testing records to engineer

electronically within 10 business days after all contract-required information becomes available.

• Defines required AASHTO test methods.• Notify the engineer when an individual test

exceeds a spec limit.


Section 701 – WisDOT General QMP Requirements


• Department to provide verification testing• List of names and numbers of project verification

and independent assurance personnel.• Department to provide test results within 2

business days.• Department shall notify contractor before

sampling so the contractor can observe QV sampling.




• QV tests are random and independent of QC tests at a frequency of 20% unless otherwise specified.

• If QV tests are nonconforming:– Department will notify the contractor immediately.– Engineer and contractor will jointly investigate test results.– The investigation may include additional testing as well as

review and observation of department and contractor sampling and testing procedures, equipment, and other documented test results. Both parties will document investigative work

• Defines IA testing to evaluate QC and QV sampling and testing.


Section 710Section 710

WHAT IS COMMON TO ALL CONCRETE QMP SPECIFICATIONS


SECTION 710 – General Concrete QMP Requirements


• Section 710 – General Concrete QMP Requirements– Small quantities provisions– Testing technician certification requirements– Concrete mixes– Sampling and testing– Control charts no longer required




• Concrete Classes established– Class I used in structures and pavement– Class II used in ancillary concrete that is

tested– Class III used in ancillary concrete provided

under certification




• Small Quantities– Modifies requirements for small quantity

provisions located in 715 and 716.• May submit an abbreviated QMP plan• Engineer may accept aggregate gradations based

upon satisfactory records of previous tests.

• Certifications– PCC Tech I or ACT-PCC working under a

certified technician present when placing concrete




• Concrete Mix Design – Submit mix designs 3 business days before placing concrete.– Submit modifications to a concrete mix to the engineer for

approval when changing (does not require a new lab mix design just engineer knowledge mix has changed):

• Source of materials.• Amounts of cementitious materials.• Adjustments of fine to total aggregate greater than +/- 3% by

weight.• Addition or deletion of admixtures. (Dosage adjustments do

not require engineer approval)– When HES concrete is required or allowed use type III cement or

add a minimum of 95 pounds of cement per CY to a previously accepted mix.




• Covered later in Chapter 8– Slump – Air– Temperature– Compressive testing– Aggregate testing


SECTION 715SECTION 715

QMP for Concrete Pavements and Concrete Structures


SECTION 715 - QMP Concrete Pavement and Structures


• Describes specific QMP requirement for Class I concrete used in pavement and structures.

• Builds on 701 and 710




• Class I concrete is cast-in-place concrete used in pavement or structure applications where all of the following apply:

– Mix design requires review by engineer– Contract defines spec limits for strength– The contractor may earn strength incentives

• HES and SHES concrete are not eligible for strength incentive




• Defines small quantities for class I concrete as:

– Less than 2500 CY of slip-form pavement per mix design.

– Less than 1000 CY of non-slip-form pavement per mix design.




• Requires quality control plan per 701.2.2 and includes additional mix information:– Preliminary concrete mix information including

proposed production facilities and sources of materials as well as the name, title, and phone number of the person developing the mix design.

– Proposed individual and combined aggregate gradation limits.

– Proposed methods for monitoring and recording batch weights.




• Requirements for mix designs– PCC Tech II certification required– Previously approved mix designs qualified

based on field performance– For HES and SHES concrete no separate

laboratory mix designs or compressive strength tests are required

– Submittal 3 days prior to production for review by project engineer




• Mix Requirements:– 28 day compressive strength of mix must equal or

exceed the 85 PWL criterion specified in 715.5.2. The PWL for pavements requires a lower specification limit of 3700 psi.

– Minimum cement content of 565 lb./cy except if using type I or III cement in a mix where the geologic composition of the coarse aggregate is primarily igneous or metamorphic materials, provide a minimum cement content of 660 lb./cy.

– Max target W/Cm = 0.42.– No chloride based accelerators allowed in mixes for

new construction




• Pavement lot and sublot definition– Sublots and Lots by lane feet

• Mainline slipform paving - 1000 lane feet– Sublots and Lots by cubic yard

• Intersections, roundabouts, tapers, radiuses, etc.• 250 CY minimum sublot• 2000 CY maximum lot

– 4-8 sublots per lot– Minimum 4 sublots for incentive eligibility




• Aggregate testing requirements for Class I concrete covered later in Chapter 9.


Flexural Strength SPVFlexural Strength SPV• WisDOT implementing Flexural Strength

on Certain Projects for Concrete Pavement via Special Provision.

• Similar QMP requirements as compressive strength with respect to lots, sublots, and quality verification.

• Revised Incentive pay equations.


Optimized Aggregate Gradation and Mixture Design SPV

Optimized Aggregate Gradation and Mixture Design SPV

• Defines an optimized gradation• Includes the Flexural Strength for Mix

Design or Concrete Pavement Flexural Strength SPV

• Allows minimum cement content of 520 lbs/CY

• Up to 30% replacement with fly ash, slag or combination


SECTION 716SECTION 716

QMP for Ancillary Concrete


SECTION 716 – QMP for Ancillary Concrete


• Section 716 – QMP Concrete Ancillary– Requirements for class II and class III

concrete• Class II – ancillary concrete the Department

accepts based on field testing during placement• Class III – ancillary concrete the Department

accepts by certification




QC Testing Frequency for Ancillary

Air Content, Slump and Temperature

Ancillary -1 test per 100 cubic yards,

28-day Compressive Strength

Ancillary -1 set per 200 cubic yards

Air Content, Slump, Temperature and 28-day Compressive Strength

For Deck Overlays,1 set per 50 cubic yards with grade E Concrete


716.2.1 Class II Concrete • Cast a minimum of one

set of 2 cylinders per contract for each mix grade and placement method.

• Random 28-day compressive strength cylinders are not required for HES or SHES concrete.



MINIMUM FREQUENCY PER STOCKPILE

A maximum of one test per day

A minimum of one test per 400 cubic yards of cumulative concrete placed.


716.2.1 Class II Concrete Aggregate Testing

The engineer may accept aggregate gradation based upon satisfactory records of previous testing of the material at the time of aggregate production.

Department verification testing is optional for aggregate used in class II concrete.



• Acceptance of class III concrete is based on a certificate of compliance.

• Submit the certificate of compliance at least 3 business days before producing concrete along with the initial concrete mix documentation as required under 710.4(2).


716.2.2 Class III Concrete

Key Dates for QMPKey Dates for QMPSubmittal of ECIP (WS1073) 14 days prior to Preconstruction MeetingE-Guide provided to contractor At Preconstruction MeetingReview of E-Guide by CDMP & WDMP Prior to work operations beginningContractor QC plan 10 days prior to placing concreteContractor mix designs 3 business days prior to productionEngineer response to mix designs 3 business days of receiptRecommended pavement pre-pour meeting Prior to placing concreteSubmit Certificate of Compliance for Class III 3 business days prior to productionCommercial plant inspection AnnuallyPortable plant inspection (DT1926) Initial Setup and WeeklyClass I compressive strength cylinders to lab 24-48 hours of castingClass II compressive strength cylinders to lab 72 hours of castingDocument and submit test results to WDMP Daily as they become availableElectronic submittal of MRS data Within 5 business days of resultsQV notification of test to contractor Prior to taking testsQV notification of test results Immediately to contractorQV electronic submittal of test results Within 2 business days of resultsFinal test records electronically submitted to Engr. Within 10 business days of results


Concrete Class by SectionConcrete Class by Section• To find which class applies to a particular item,

look up reference in each Standard Spec Section under Materials


Concrete Class by SectionConcrete Class by SectionSection Description Concrete Class

320 Concrete Base II390 Base Patching II415 Concrete Pavement I416 Concrete Pavement – Appurtenant Construction II502 Concrete Bridges I504 Culverts and Retaining Walls I504 Endwalls III509 Concrete Overlay and Structure Repair II510 Cast in Place Concrete Piling III514 Floor Drains, Deck Drains, and Downspouts II515 Steel Grid Floors I519 Concrete Brick and Block Footings III601 Concrete Curb and Gutter II602 Concrete Sidewalks, Loading Zones, Safety Islands, Steps II603 Concrete Barrier II604 Slope Paving III605 Ditch Checks III611 Catch Basins, Manholes and Inlets III620 Concrete Corrugated Median and Concrete Median Nose II621 Landmark Reference Monuments II636 Concrete Sign Supports II639 Drilling Wells III654 Bases III672 Intelligent Transportation System Bases III


Non-Conforming MaterialsNon-Conforming Materials• Materials that do not meet the

requirements of the specifications• Engineer has the authority to:

– Reject– Remain in place (Form DT1310 req’d)

• Consult CMM 8.10.5 and 8.10.6 for guidance


Non-Conforming MaterialsNon-Conforming Materials• Use your judgment• Consider the following:

– Long-term consequences on quality and durability.

– Implications on the project's life cycle costs, service life, serviceability, and maintenance.

– Socioeconomic, environmental, and aesthetic considerations.

– Impacts on traffic, staging, and construction timeframes.


Price Reduction Considerations:Price Reduction Considerations:• Has the contractor been conscientious to provide quality by carefully

controlling materials and construction operations?• Has the contractor been proactive and made good use of QC data to

maintain and improve quality?• Did the engineer provide the contractor with non-conforming test results

within the contractual timeframe, if specified?• If timeframes are not specified, did the engineer provide non-conforming

test results in time for the contractor to make process or materials corrections?

• Upon becoming aware of a materials quality problem, has the contractor responded quickly to correct it?

• Is the nonconforming test an isolated incident or a recurring situation?• How does the nonconforming test compare to the rest of the project data:

– Have material test results been well within specification requirements or consistently at the very limit of what is acceptable

– How many tests are nonconforming vs. how many tests have passed– How far out of spec is the non-conforming test?


Non-Performance of QMPNon-Performance of QMP• Contractor not meeting requirements of

QMP• Knowingly doing so,

– Once– Frequent problem

• Accidental and making efforts to make whole

• Use judgment• CMM 8.30.13 for additional guidance


Section 440 Ride QualitySection 440 Ride Quality


Profiling DevicesProfiling Devices


Ames Lightweight Inertial Profiler

Profiling DevicesProfiling Devices


Ride QualityRide Quality• May be used on low speed urban or high

speed rural roadways• Categories II, & III for segments with

posted speed limit of 55 mph or greater• Category IV for segments with posted

speed limit less than 55 mph


Ride QualityRide QualityCategory Description

Segments with a Posted Speed of 55 MPH or GreaterPCC II Concrete pavementPCC III Concrete Pavement segments containing any portion of a bridge,

bridge approach, railroad crossing intersection or gap. An intersection is defined as the area within the points of curvature of the intersection radii.Segments with Any Portion Having a Posted Speed Limit Less than 55 MPH

PCC IV Concrete pavement including gaps, intersections, bridges, approaches, and railroad crossings


Ride QualityRide Quality• QC Testing

– Testing is performed on mainline lanes, and includes bridges, railroads, and approaches

– Data is collected for each wheel path of each lane in 500’ segments. (Intent is to have IRI sections align with QMP Pavement sublots)

• QV Testing– The department’s quality assurance unit performs

QV testing– Contact Joe Wilson (608-516-6360) to schedule

QV testing after paving schedule is determined


Ride QualityRide Quality• Segment IRI

– Each wheel path segment IRI is analyzed and assessed a pay adjustment according to the categories in the specification

– Data should be compiled in a manner that contains 500 foot segments in station order for each wheel path. The only partial segment should be the last segment on the project. The ProVAL software does not allow combining various runs into one continuous run so these segments may be contained in several runs covering the entire project allowing for overlap for run-in and run-out lengths.

• Localized Roughness– ProVAL software is utilized to locate areas of localized

roughness as defined in the specification, and can simulate the results of proposed corrective actions

– www.roadprofile.com


Ride QualityRide Quality• Data Submittal

– Contractor downloads raw data into ProVAL software to determine localized roughness areas

– Contractor enters ride quality data into the Materials Reporting System (MRS)

– MRS computes the pay adjustments for each 500’ segment wheel path and each area of roughness

– WisDOT project representative reviews to ensure correct data, pay equation, etc. and makes necessary revisions to the approved pay adjustment


Corrective Actions for Localized RoughnessCorrective Actions for Localized Roughness


440.3.5.2 Corrective Actions for Localized Roughness(1) The engineer will assess each wheel path for areas of localized roughness within 5 business days ofbeing notified that ProVAL reports are uploaded. The engineer will document each area that exceeds 200in/mile and do one of the following:

1. Direct the contractor to correct the area to minimize the effect on the ride.2. Leave the area of localized roughness in place with no pay reduction.3. Assess a pay reduction for each area in each wheel path as follows:

Length ≤25 feet: (localized roughness in/mile - 200) dollars/foot or $250 whichever is leastLength >25 feet: (localized roughness in/mile - 200) dollars/foot or 10 dollars/foot whichever is least

The department will not reduce pay for localized roughness within HMA IV and PCC IV segments or within 25 feet of bridges, bridge approaches, or railroad crossings not constructed under the contract.

(2) The engineer will not direct corrective action or assess a pay reduction for an area of localized roughnesswithout physically riding that work.

(3) Re-profile corrected areas to verify that the localized roughness is less than 140 in/mile. Upload a revisedProVAL ride quality module report to the MRS reference documents section for corrected areas.

Corrective Actions for Excessive Segment IRICorrective Actions for Excessive Segment IRI

440.3.5.3 Corrective Actions for Excessive Segment IRI

(1) If an individual segment IRI exceeds 140 in/mile for HMA I, HMA II, and PCC II pavements after correction for localized roughness, the engineer may require the contractor to correct that segment.

Correct the segment final surface as follows:

PCC II: Correct to an IRI of 85 in/mile using whichever of the following methods the engineer approves:

- Continuous diamond grinding, conforming to 420.3.1 through 420.3.4, of the full lane width of the riding surface including adjustment of the paved shoulders.- Remove and replace the full lane width of the riding surface.

(2) Re-profile corrected segments to verify that the final segment IRI meets the above correction limits and there are no areas of localized roughness. Enter a revised ProVAL ride quality module report for the corrected areas to the reference documents section of the MRS. Segments failing these criteria after correction are non-conforming work under 105.3.


IRI Ride Pay Adjustment

IRI Ride Pay Adjustment

440.5.2 Pay Adjustment

(1) The department will pay incentive for ride under the following bid item: 440.4410 Incentive IRI Ride DOL(2) Incentive payment may be more or less than the amount the schedule of items shows.(3) The department will administer disincentives for ride under the Disincentive IRI Ride administrative item.(4) The department will not assess disincentive on HMA III or PCC III segments. Incentive pay for HMA IIIand PCC III segments will be based on the category of the adjoining segments.(5) For work placed under the contract, the department will adjust pay based on the initial segment IRI forthat segment. If corrective action is required, the department will base disincentives on the segment IRIafter correction as follows:

All Pavement: The corrective work is performed in a contiguous, full lane width section 500 feetlong, or a length as agreed with the engineer.

HMA Pavements: The corrective work is a mill and inlay or full depth replacement and the inlay orreplacement layer thickness conforms to 460.3.2.

Concrete Pavements: The corrective work is a full depth replacement and conforms to 415.


IRI Ride Incentive / Disincentive

IRI Ride Incentive / Disincentive

(6) The department will adjust pay for 500-foot long standard segments nominally one wheel path wide usingequation "ride 2.01" as follows:

For HMA II and PCC II Pavement: Initial IRI (in/mile) Pay Adjustment (dollars/500 feet)< 50 250≥ 50 to < 55 2750 - (50 x IRI)≥ 55 to < 85 0≥ 85 to < 100 (4250/3) - (50/3 x IRI)[1]≥ 100 -250[1]

[1] The department will not assess a ride disincentive for HMA pavement placed in cold weather because of a department-caused delay as specified in 450.5(5).

For HMA IV and PCC IV Pavement: Initial IRI (in/mile) Pay Adjustment (dollars/500 feet)< 35 250≥ 35 to < 45 1125 - (25xIRI)≥ 45 0

(7) The department will prorate the pay adjustment for non-standard segments based on their length.


CERTIFICATIONSCERTIFICATIONSCHAPTER 5


CHAD

CERTIFICATIONSCERTIFICATIONS• HTCP• WisDOT Lab Qualification• WisDOT Profiler Verification• ACI – not recognized by WisDOT• AASHTO Certification

• Know the certifications and people at the beginning of the project


WisDOT Highway Technician Certification Program

WisDOT Highway Technician Certification Program

• All materials testing personnel must be qualified

• Taught and administered by the University of Wisconsin Platteville

• Jodi M. Pluemer is the Director



https://www.uwplatt.edu/htcp

Certifications Required on Concrete Paving ProjectsCertifications Required on Concrete Paving Projects

• Aggregate Sampling Technician (AGGTEC-Sampling)• Aggregate Technician (AGGTEC-I)• Aggregate Testing for Transportation Systems (ATTS)• Aggregate Technician II (AGGTEC-II)• Portland Cement Concrete Technician I (PCCTEC-I)• Portland Cement Concrete Technician II (PCCTEC-II)• Concrete Strength Tester (CST)• Profiler Technician I (PROFILER)• Materials Coordinator Training - Department (MCT-D) 2017• Materials coordinator Training - Contractor (MCT-C) 2017


Are the Testers Certified by HTCP?Are the Testers Certified by HTCP?


WisDOT Laboratory Qualification ProgramWisDOT Laboratory

Qualification Program• All labs must be qualified through the

WisDOT Lab Qualification Program• Administered by WisDOT DTSD Bureau of

Technical Services Materials Management Section

• Ken Nwankwo– [email protected]– 608-246-5388

http://wisconsindot.gov/Pages/doing-bus/eng-consultants/cnslt-rsrces/tools/appr-prod/qual-lab-req.aspx


Are the Labs Qualified?Are the Labs Qualified?


Lab EquipmentLab Equipment• All testing equipment must be calibrated

according to the WisDOT Construction & Materials Manual (CMM), and have up-to-date calibration documentation

• AASHTO R-18• Air meter calibration (every 3 months)• Lab Equipment Calibration Schedule:

http://wisconsindot.gov/Documents/doing-bus/eng-consultants/cnslt-rsrces/tools/appr-prod/qual-labs/cal-scd.pdf


WisDOT Profiler Verification Program

WisDOT Profiler Verification Program

• All profilers must be verified through the WisDOT program

• Administered by WisDOT DTSD Bureau of Technical Services Materials Management Section

• Annual program for approving profilers for use• Joe Wilson – [email protected] and 608-

246-7955.


Is the Profiler Approved?Is the Profiler Approved?http://wisconsindot.gov/Documents/doing-bus/eng-consultants/cnslt-rsrces/tools/qmp/profilers.pdf


Is the Profiler Approved?Is the Profiler Approved?http://wisconsindot.gov/Documents/doing-bus/eng-consultants/cnslt-

rsrces/tools/qmp/profilers.pdf


WISDOT MATERIALS AND DATA SUBMITTALWISDOT MATERIALS AND DATA SUBMITTAL

CHAPTER 6


Materials CoordinatorsMaterials Coordinators• Required beginning with 2011 standard spec.• 2017 all project materials coordinators must

complete the HTCP online materials training course.

• Prime contractor and WisDOT required to each have a materials coordinator.

• Department provides E-Guide to contractor at the preconstruction conference

• Coordinators review and make necessary changes to E-guide before work operations.


Contractor Materials Coordinator is responsible for:

Contractor Materials Coordinator is responsible for:

• Establishing methods and work expectations with the WisDOT Materials Coordinator

• Working with WisDOT Materials Coordinator to ensure project-specific testing guide is correct before operations begin

• Submitting all required materials information from prime contractor and subcontractors

• Providing all QMP test data and control charts• Communicating materials requirements to

subcontractors• Dealing with all materials-related concerns from the

WisDOT Materials Coordinator.2017 WCPA/WisDOT Concrete Pavement Inspection Workshop

Electronic Data SubmittalElectronic Data Submittal• WisDOT Materials website known as the

“Materials Tracking System”• Covers concrete pavement:

– QMP– Thickness– Ride– Mix Designs– Aggregates


BREAK TIMEBREAK TIMETAKE 15 MINUTES


CONCRETE AND QUALITY CONTROLCONCRETE AND QUALITY CONTROL

CHAPTER 7


HEATH


ConcreteConcrete• Concrete is a manufactured product.• Concrete is basically a mixture of

aggregates and cement paste.• Aggregates in the mix are divided into two

groups, Coarse and Fine Aggregate. They act as filler and make up about 70% of the total volume of concrete.

• Cement Paste is the glue that holds concrete together and constitutes about 30% of the total volume of concrete.

The Concrete Mix9 - 15%Cement

15 - 16%Water

30 - 45%Coarse aggregate

Paste(cement + water)

Mortar(paste + fine aggregate)

Concrete(mortar + coarse aggregate)

25 - 35%Fine aggregate


Concrete Mix DesignsConcrete Mix Designs• Part 7 Requires a contractor Mix Design• Responsibility of the contractor• Reviewed and approved by the project

engineer• Mix change do not require a new lab mix

design


Quality Control TestingQuality Control Testing• QMP program goals:

– provide consistent and acceptable construction quality

– provide effective use of personnel– maintain cooperation throughout all phases of

the work being performed– Documenting test results– Communicating test results– Performing corrective action


Quality Control in ConcreteQuality Control in Concrete• Category I: Quality control related to the

placed concrete.– Slump– Air Content.– Temperature.– Compressive Strength.– Flexural Strength – when required by SPV


Quality in Concrete Quality in Concrete • Category II: Quality control related to mix

components.– Cementitious materials– Water– Aggregates– Admixtures


“Standard Battery of Tests”“Standard Battery of Tests”


• Flexural Strength of Concrete AASHTO T97

Material Quality VariabilityMaterial Quality Variability• “Differences in measured test values for a

given Quality Characteristic within a stable pattern due to chance, or outside this normal pattern due to assignable cause.”


Material Quality VariabilityMaterial Quality Variability


QUALITY CONTROL FOR PLACED CONCRETEQUALITY CONTROL FOR PLACED CONCRETE

CHAPTER 8


Quality Control Testing For Concrete

Quality Control Testing For Concrete

• Slump• Air Content• Temperature• Compressive Strength• Flexural Strength


SLUMPSLUMP

• Measure of the consistency of concrete• AASHTO T119• Slipform

– Not required per 710.5.2– Engineer/Inspector can request – slump 2.5 inches or less

• Non slip form is 4 inches or less– Done each time air test is taken



Factors Affecting SlumpFactors Affecting Slump• Water/Cement ratio.• Air content.• Air and mix temperature.• Haul time.• Aggregate gradation, angularity, and

surface texture.• Admixtures

Air ContentAir Content• Key measure of durability for freeze thaw

resistance• Types

– Entrapped – up to 2 percent– Entrained – small bubbles we want

• WisDOT requirements– Slipform – 7 +/- 1.5 percent– Non Slipform - 6 +/- 1.5 percent


Air ContentAir Content• AASHTO T152 Pressure

Method• Type B meters required• Unit weight – AASHTO T121• Hardened Air• Calibration Canister

– CMM 8.70 Appendix 1


Air Meter CalibrationAir Meter CalibrationCMM 8.70.4.3 Concrete Sampling and

Testing Standard Procedures AASHTO T 152, Air Content of Freshly Mixed Concrete by the Pressure Method.

• WisDOT allows only type B meters.• Calibrated at three points within the expected range.• Calibration be performed every three months.• Calibration records kept with the meter.• Periodic checks with a calibration canister be performed

with records available. • Comply with the air meter calibration procedure as

detailed in AASHTO T 152.


Air Meter CalibrationAir Meter Calibration


Air meter calibration every 3 months is requiredRecords must be with meter


Factors Affecting Air ContentFactors Affecting Air Content• Increase in w/cm ratio will increase air content.• Excessive mixing and/or vibration will decrease

air content.• Increase in air or concrete temperature will

decrease air content. • Increase in material passing the #100 sieve will

decrease air content. • Increase in material between the #30 and #100

sieve will increase air content.• Increase in slump will increase air content,

Non-Conforming Air TestNon-Conforming Air Test• 8.10.6.1.2 Air Content

– 0.5 % or more above specification .....10% price reduction [1] – 0.1% to 0.4% above specification ....... 5% price reduction [1] – 0.1% to 0.5% below specification .......20% price reduction – 0.6% to 1.0% below specification .......30% price reduction – More than 1.0% below specification ....Remove & replace or

50% price reduction


QC Test - Low AirQC Test - Low Air• Contractor must:

– Communicate immediately– React to the situation – Make plant adjustments if necessary

• Spec says:(2) If an individual air test is outside the spec limits, notify the engineer and test as often as practicable on subsequent loads until the air content is conforming. Document dosage rates, time of day, and air temperature whenever adjusting the air-entraining admixture dosage.


QC Test - Low AirQC Test - Low Air• If ready mix truck it is allowable to:

– add additional air entraining admixture and – revolutions to truck and retest to get into

specification– Time limits for delivery still apply


Start Up – Low AirStart Up – Low Air• WisDOT is assuming that contractor is testing at

plant prior to sending concrete out for placement• Test from first ¼ CY of load• If non-conforming do not incorporate concrete

into work• Retest• Communicate immediately with contractor on

what is happening to correct this situation


QC Test - High AirQC Test - High Air• Contractor must:

– Communicate immediately– React to the situation – Make plant adjustments if necessary

• Spec says:(2) If an individual air test is outside the spec limits, notify the engineer and test as often as practicable on subsequent loads until the air content is conforming. Document dosage rates, time of day, and air temperature whenever adjusting the air-entraining admixture dosage.


QC Test – High AirQC Test – High Air• If ready mix truck it is allowable to:

– Loss of slump usually means loss of air– Allow truck to sit and lose slump– Retest– Incorporate if within specification– Delivery times apply


QC Tests – High AirQC Tests – High Air• CMM 8.10.6.1On QMP projects, evaluate strength data. If strengths are acceptable, do not take a price reduction for high air content. Contractor is responsible to provide additional strength data, if necessary.


Start Up – High AirStart Up – High Air• WisDOT is assuming that contractor is testing at

plant prior to sending concrete out for placement• Test from first ¼ CY of load• If non-conforming do not incorporate concrete

into work• Retest• Communicate immediately with contractor on

what is happening to correct this situation


Hardened Air TestHardened Air Test• Dispute resolution tool• Additional Guidance in CMM8.70• ASTM C457 • Can be used to relieve contractor of air

penalties when QC or QV tests are in dispute


Super Air Meter (SAM)Super Air Meter (SAM)

• Modified a typical ASTM C 231 pressure meter to hold larger pressures

• Digital gauge and six clamps

• Test takes 8 - 10 minutes

• New AASHTO TP 118


www.superairmeter.com

What Does SAM Do??What Does SAM Do??• Uses an algorithm to find a SAM number.• The SAM number correlates to air void

size distribution. • A SAM number of 0.20 seems to

correspond to a spacing factor of 0.008”• The meter also measures air volume


TemperatureTemperature• ASTM C1064• Important influence on concrete properties• High temps affect shrinkage and cracking• Cold temps affect cure time and strength• WisDOT only specifies cold weather

temperature of concrete of 50 degrees.• There is no hot weather specification


Concrete Temperature and Cold Weather

Concrete Temperature and Cold Weather

• Ambient air temp below 40 degrees can require additional temp testing

• Concrete temp must be above 50 degrees• Heating aggregates and water?

– Can heat these up to 100 degrees– Concrete temp between 50 and 80 degrees


Compressive StrengthCompressive Strength• Maximum resistance

of a concrete specimen to axial loading

• Standard 6x12 inch cylinder

• AASHTO T23



Compressive StrengthCompressive Strength• Cylinders initial cure on site

– Covered– Out of direct sunlight– Kept between 60 and 80 degrees

• Following proper handling, curing, and transporting procedures of the cylinders is critical.

• It is important to understand that once the cylinder has been cast anything that happens to that cylinder will have a negative impact on compressive strength.


Factors Affecting Compressive Strength

Factors Affecting Compressive Strength

• W/C Ratio• Extent to which hydration has progressed• Curing and environmental conditions• Age of the concrete• Supplementary cementitious materials• Admixtures

Standard SpecCompressive Strength


• Cast 3 cylinders• Randomly select 2 at 28 days• Compare the strengths

– If the lower strength divided by the higher strength is 0.9 or more, average the 2 QC cylinders.

– If the lower strength divided by the higher strength is less than 0.9, break one additional cylinder and average the 2 higher strength cylinders.




(1) If a sublot strength is less than 2500 psi, the department may direct the contractor to core that sublot to determine its structural adequacy and whether to direct removal. Cut and test cores according to AASHTO T 24 as and where the engineer directs. Have an HTCP certified PCC technician I perform or observe the coring.

(2) The sublot pavement is conforming if the compressive strengths of all cores from the sublot are 2500 psi or greater or the engineer does not require coring.

(3) The sublot pavement is nonconforming if the compressive strengths of any core from the sublot is less than 2500 psi. The department may direct removal and replacement or otherwise determine the final disposition of nonconforming material as specified in 106.5.


Standard Spec Compressive Strength

Standard Spec Compressive Strength

• PWL Specification• Lower specification limit 3,700 psi

715.5.2 Pavements (1) The department will adjust pay for each lot using equation “QMP 3.01” as follows:

Percent within Limits (PWL) Pay Adjustment (dollars per square yard)≥ 95 to 100 (0.1 x PWL) - 9.5≥ 85 to < 95 0≥ 30 to < 85 (1.5/55 x PWL) - 127.5/55

< 30 -1.50

(2) The department will not pay incentive if the lot standard deviation is greater than 400 psi.


Special ProvisionFlexural StrengthSpecial ProvisionFlexural Strength

Maximum resistance of a concrete specimen to bending.• 6-inch x 6-inch x 21-inch

concrete beams• Third-point loading in

accordance with AASHTO T 97.



Flexural StrengthFlexural Strength• Beams initial cure on site

– Covered– Out of direct sunlight– Kept between 60 and 80

degrees• Following proper handling,

curing, and transporting procedures of the beams is critical.


Factors Affecting Flexural StrengthFactors Affecting Flexural Strength

• Properties of course aggegate• W/C Ratio• Curing and environmental conditions• Age of the concrete• Supplementary cementitious materials• Admixtures


• Cast 3 beams• Randomly select 2 at 28 days• Compare the strengths

– If the lower strength divided by the higher strength is 0.9 or more, average the 2 QC specimens.

– If the lower strength divided by the higher strength is less than 0.9, break one additional specimen and average the 2 higher strength specimens.



(1) If a sublot strength is less than 500 psi, the department may direct the contractor to core that sublot to determine its structural adequacy and whether to direct removal. Cut and test cores according to AASHTO T24 as and where the engineer directs. Have an HTCP-certified PCC technician I perform or observe the coring.

(2) The sublot pavement is conforming if the compressive strengths of all cores from the sublot are 2500 psi or greater or the engineer does not require coring.

(3) The sublot pavement is nonconforming if the compressive strengths of any core from the sublot is less than 2500 psi. The department may direct removal and replacement or otherwise determine the final disposition of nonconforming material as specified in 106.5.


Special Provision Flexural StrengthSpecial Provision Flexural Strength

• PWL Specification• Lower specification limit 650 psi

715.5.2 Pavements(1) The department will adjust pay for each lot using equation “QMP 6.01” as follows:

Percent within Limits (PWL) Pay adjustment (dollars per square yard)≥ 95 to 100 (0.2 x PWL) - 19≥ 85 to < 95 0≥ 50 to <85 (2.0/35 x PWL) - 170/35<50 -2

(2) The department will not pay incentive if the lot standard deviation is greater than 60 psi.


HPC Special ProvisionHPC Special Provision

HPC Concrete PavementCompressive Strength


HPC Pavement Mix Requirements

HPC Pavement Mix Requirements

• Replace standard spec 715.2.3.1(1) with the following:– Use at least 5 pairs of beams and 5 pairs of cylinders

to demonstrate the flexural strength and splitting tensile strength of a mix design. Demonstrate that the 28-day flexural strength of the proposed mix will equal or exceed 650 psi. Ensure that the average flexural strength of any one pair of beams is not less than 490 psi. The contractor need not provide separate laboratory mix designs and strength tests for high early strength concrete.


HPC Pavement Strength Evaluation

HPC Pavement Strength Evaluation

• Minimum sublot strength is 3000 psi vs 2500 psi for Standard Spec.

• PWL Specification.• Lower specification limit of 4500 psi vs

3700 psi for Standard Spec.


QUALITY CONTROL FOR MIX COMPONENTSQUALITY CONTROL FOR MIX COMPONENTS

CHAPTER 9


KEVIN

The Concrete Mix9 - 15%Cement

15 - 16%Water

30 - 45%Coarse aggregate

Paste(cement + water)

Mortar(paste + fine aggregate)

Concrete(mortar + coarse aggregate)

25 - 35%Fine aggregate


Cementitious MaterialsCementitious Materials• Portland Cement• Supplementary Cementitious Materials (SCM)

– Fly Ash– Ground Granulated Blast Furnace Slag (slag)

• SCM replacement (1:1)– Fly ash – 30 percent– Slag – 50 percent for slip form and 30 percent for

fixed form– Ternary – 30 percent


Portland CementPortland Cement• Manufactured product• Section 501.2.1• Types

– Type I – General Purpose– Type II – moderate sulfate resistance– Type III – high early strength

• Igneous aggregates use Type II


Cement TypesCement Types• Type I - Normal use (ASTM

C150)• Type II - Moderate Sulfate

Resistance (ASTM C150)• Type III - High Early Strength

(ASTM C150)

• Type 1P – Portland-Pozzolan Cement (ASTM C595)

• Type 1S – Portland blast furnace slag cement (ASTM C595)

• Type 1L – Portland-Limestone Cement (ASTM C595)

• Type 1T – Ternary Blended Cement (ASTM C595)


Portland-Limestone CementPortland-Limestone Cement• Incorporated into 2014 standard

specifications• 10% by weight of clinker is replaced with

limestone prior to grinding• First project with this material in 2012


Portland Cement AcceptancePortland Cement Acceptance501.2.1.2 Certification

(1) Obtain cement from manufacturers whose products comply with the department's certification method of acceptance for Portland cement, unless the engineer agrees to accept cement under alternate procedures allowed in the department's certification method.

(2) Provide a manufacturer's written certification for blended cements stating the source, amount, and composition of essential constituents and the composition of the final cement provided under the contract.


Fly AshFly Ash• Byproduct of coal fired electric generating

plants• Better strength and reduced permeability• Section 501.2.6• Two Types

– Class C– Class F

• Class F historically used to mitigate Alkali-Silica Reaction (ASR) when specified (Wausau area)


Class F Fly AshClass F Fly Ash• 2017 is first construction season allowed

by specification• ASP-6 Revision of 2017 Standard Spec501.2.6.3 Class F Ash(2) Furnish a class F fly ash from a source listed on the department's approved product list, and conform to ASTM C618 class F except limit the loss on ignition to a maximum of 2 percent.


Class F Fly AshClass F Fly Ash


Fly Ash MixesFly Ash Mixes• Decreased mix water demand• Increased workability• Decreased heat of hydration• Decreased air entraining ability• Decreased cementitious material costs


Fly Ash AcceptanceFly Ash Acceptance• Standard spec 501.2.6• LafargeHolcim, St. Mary’s and

Headwaters are expected to certify in 2017

(5) Prequalify any proposed fly ash source as follows: The contractor shall obtain a copy of the certified report of tests or analysis made by a qualified independent laboratory, recognized by the department under 501.2.2, showing full and complete compliance with the above specification from the fly ash manufacturer and furnish it to the engineer. Provide this report to the engineer at least 14 calendar days before using the fly ash.


SlagSlag• Byproduct of the steel production process• Better strength and reduced permeability• Section 501.2.7• Two grades

– 100* – 120

• LafargeHolcim and St. Mary’s are probable sources in 2017


Slag MixesSlag Mixes• Decreased water demand• Easier consolidation• Increased initial set time• Decreased heat of hydration• Increased opening strength time• “Sticky” and hard to finish• Increased time to apply curing compound


Slag AcceptanceSlag Acceptance• Standard spec 501.2.7(1) For grade A-S, A-T, A-S2, B-S, and C-S concrete,

provide ground granulated blast furnace slag conforming to ASTM C 989, grade 100 or 120.

• Also Standard spec 501.2.1.2(2) Provide a manufacturer's written certification for blended

cements stating the source, amount, and composition of essential constituents and the composition of the final cement provided under the contract.


WaterWater• Section 501.2.4• AASHTO T 26 as modified by Department– if

water source in doubt• Required lead time for testing• Municipal water source is exempt from testing• Water/cementitious ratio key mix property


Common Rule of Thumb:If you can drink it, you can use it in concrete

WaterWater• Advantages of reducing water content

– Increased compressive and flexural strength.– Lower permeability.– Increased resistance to weathering.– Better bond between concrete and reinforcement.– Reduced drying shrinkage and cracking. – Less volume change from wetting and drying.


WaterWater

28 Day Compressive Strength, psi

Water-Cement ratio, by weightNon-Air-entrained Concrete

Air-entrained Concrete (6%

Air)6000 0.41 0.325000 0.48 0.404000 0.57 0.483000 0.68 0.592000 0.82 0.74


General relationship of concrete compressive strength vs. water-cement ratio. Adopted from ACI 211.1 and ACI 211.3

Effects of adding 1 gallon of Water / CY

Effects of adding 1 gallon of Water / CY

• Increases slump 1 in.• Decreases compressive strength by 200

psi• Wastes the effect of 1/4 sack (23.5 lb) of

cement• Increases shrinkage by 10%• Increases permeability by up to 50%• Increases risk of air void problems


AggregatesAggregates• Section 501.2.5• Soundness, Wear and Freeze-Thaw

durability and deleterious materials testing• WI Approved Aggregate Sourceshttp://wisconsindot.gov/Pages/doing-bus/eng-consultants/cnslt-rsrces/tools/appr-prod/default.aspx


Aggregate Approved ListAggregate Approved List



Aggregate TypeAggregate Type• Basalt• Dolomite• Granite/Gneiss• Limestone• Sandstone• Siliceous Gravel• Wisconsin is blessed (or cursed?) to have

many different aggregate types


Fine AggregateNatural or manufactured

Fine AggregateNatural or manufactured


Fine AggregateFine Aggregate

501.2.5.3 Fine Aggregates(1) Fine aggregate consists of a combination of sand with fine gravel, crushed gravel, or crushed stoneconsisting of hard, strong, durable particles.

501.2.5.3.1 Deleterious Substances(1) Do not exceed the following percentages:SUBSTANCE PERCENT BY WEIGHTMaterial passing the No. 200 (75 µm) sieve .........................................................................................3.5[1]Coal.......................................................................................................................................................1.0Clay lumps.............................................................................................................................................1.0Shale .....................................................................................................................................................1.0Other local deleterious substances like alkali, mica, coated grains, soft and flaky particles .................1.0

[1] Reduce to 2.3 percent if used in grade E concrete.(2) The total percentage of coal, clay lumps, shale, and other deleterious substances shall not exceed 3.0percent by weight. There is no requirement to wash fine aggregate for portland cement concrete ifproduced otherwise to conform to all specified requirements. When used, the fine aggregate shall notcontain any of the following: frozen material, and foreign material like wood, hay, burlap, paper, or dirt.


Fine AggregateFine Aggregate501.2.5.3.2 Organic Impurities(1) Fine aggregate shall not contain harmful amounts of organic impurities.

The engineer will reject aggregates, subjected to the colorimetric test for organic impurities, producing a darker than standard color, unless they pass the mortar strength test.

501.2.5.3.3 Mortar Strength(1) Fine aggregates, if tested for the effects of organic impurities on strength

of mortar, using type I cement, must produce a relative strength at 7 days, calculated according to section 8 of AASHTO T 71, of not less than 95 percent.


Fine AggregateFine Aggregate

501.2.5.3.4 Size Requirements(1) Use well-graded fine aggregate conforming to the following gradation requirements:SIEVE SIZE PERCENT PASSING BY WEIGHT3/8 in. (9.5 mm).....................................................................................................100No. 4 (4.75 mm)................................................................................................. 90 - 100No. 16 (1.18 mm)............................................................................................... 45 - 85No. 50 (300 µm)................................................................................................... 5 - 30No. 100 (150 µm).................................................................................................0 – 10



Coarse AggregateCoarse Aggregate


501.2.5.4.1 General(1) Use clean, hard, durable gravel, crushed gravel, crushed stone or crushed concrete free of an excess of thin or elongated pieces, frozen lumps, vegetation, deleterious substances or adherent coatings considered injurious. Do not use coarse aggregates obtained from crushing concrete in concrete for bridges, culverts, or retaining walls.


Coarse AggregateCoarse Aggregate501.2.5.4.2 Deleterious Substances(1) The amount of deleterious substances shall not exceed the following percentages:

DELETERIOUS SUBSTANCE PERCENT BY WEIGHTShale .......................................................................................................................................................1.0Coal .........................................................................................................................................................1.0Clay lumps................................................................................................................................................0.3Soft fragments .........................................................................................................................................5.0Any combination of above .......................................................................................................................5.0Thin or elongated pieces based on a 3:1 ratio.......................................................................................15.0Materials passing the No. 200 (75 µm) sieve..........................................................................................1.5Chert[1] for all grades of concrete other than concrete for prestressed concrete members ..................5.0[2]Chert[1] for concrete for prestressed concrete members........................................................................2.0

[1] Material classified lithologically as chert and having a bulk specific gravity (saturated surface-dry basis) of less than 2.45. Determine the percentage of chert by dividing the weight of chert in the sample retained on a 3/8-inch (9.5 mm) sieve by the weight of the total sample.[2] The engineer may accept aggregates exceeding this value if aggregates from the same deposit or from one of similar geological origin demonstrated a satisfactory service record, or tests the engineer select indicate no inferior behavior. If using 2 sizes of coarse aggregates, the engineer will determine the percentages of harmful substances based on one of the following: a sample consisting of 50 percent of size No. 1, and 50 percent of size No. 2; or a sample consisting of the actual percent of size No. 1 and No. 2 used in the work.

(2) If using 2 sizes of coarse aggregates, the engineer will determine the percentages of harmful substancesbased on one of the following: a sample consisting of 50 percent of size No. 1, and 50 percent of size No.2; or a sample consisting of the actual percent of size No. 1 and No. 2 used in the work. (3) The engineer will not require the contractor to wash coarse aggregate produced within specified gradations, free of coatings considered injurious, and conforming to the above limits for harmful substances.


Deleterious SubstancesDeleterious Substances


Chert Shale



501.2.5.4.3 Physical Properties

(1) The percent wear shall not exceed 50, the weighted soundness loss shall not exceed 12 percent, and the weighted freeze-thaw average loss shall not exceed 18 percent.

(2) The department may prohibit using crushed stone from limestone/dolomite deposits having thinly bedded strata, or strata of a shale nature; it may also prohibit using aggregates from deposits or formations known to produce unsound material.

(3) If all coarse aggregates used are produced from the same deposit or source, ensure that testing for wear, sodium sulfate soundness, and soundness by freezing and thawing uses a composite sample. This sample will contain equal percentages of each component coarse aggregate used. If the component coarse aggregates are produced from more than one deposit or source, ensure that testing for wear, sodium sulfate soundness, and soundness by freezing and thawing uses one sample from each deposit or source.

New ASR TestingNew ASR Testing• Alkali-silica reaction• Reaction between highly alkaline cement

past and reactive non-crystalline silica found in aggregates.

• If using coarse aggregate from sources containing significant amounts:– fine-grained granitic rocks including felsic-

volcanics, felsic-metavolcanics, rhyolite, diorite, gneiss, or quartzite


New ASR TestingNew ASR Testing• ASTM C1260

– 14 day– Expansion of 0.15 or greater then

• ASTM C1567– 14 days– Expansion of 0.15 or greater

• Mitigated with Type F fly ash or slag




501.2.5.4.4 Size Requirements(1) Use well graded course aggregate conforming to the following gradation requirements:PERCENT PASSING BY WEIGHT

SIEVE SIZE SIZE NO. 1 SIZE NO. 2AASHTO No. 67[1] AASHTO No. 4[1]

2 inch (50 mm) - 1001 1/2 inch (37.5 mm) - 90-1001 inch (25.0 mm) 100 20-553/4 inch (19.0 mm) 90-100 0-153/8 inch (9.5 mm) 20-55 0-5No. 4 (4.75 mm) 0-10 -No. 8 (2.36 mm) 0-5 -

[1] Size No. according to AASHTO M 43.

(2) Furnish coarse aggregates in the separate sizes indicated, and store each size separately to prevent mixture until proportioned into each batch. The engineer will allow the contractor to combine 2 aggregate fractions to produce a gradation within the limits specified for size No. 1 or size No. 2, provided they are proportioned separately by weight into the batch in proportions the engineer approves.

(3) Except as provided below, furnish coarse aggregate conforming to size No. 1 and size No. 2, combined in the proportions specified for the pertinent grade and class of concrete under 501.3.2.2.

(4) Provide coarse aggregate consisting entirely of size No. 1 as follows:1. If the engineer approves, for grade A, A2, A3, A-FA, A-S, A-S2, A-T, A-IS, or A-IP concrete.2. Except for concrete pavement repair and if substituting grade C, C-FA, C-S, C-IS, or C-IP for grade A airentrained high early strength concrete as specified in 501.3.1.1, for grade C, C-FA, C-S, C-IS, or C-IP concrete.3. If the engineer approves, for grade D concrete.4. Except for concrete pavement repair, for grade E concrete.5. For concrete in prestressed concrete members.

QMP Combined GradationQMP Combined Gradation• One hundred percent passes the 2 inch sieve.• The percent passing the 1-inch sieve is less than or equal to 89. The

engineer may waive this requirement for one or more of the following: – Clear spacing between reinforcing bars is less than 2 inches.– The contractor provides an engineer-approved optimized gradation

analysis• The percent passing the No. 4 sieve is less than or equal to 42,

except if the coarse aggregate is completely composed of crushed stone and/or recycled concrete, up to 47 percent may pass the No. 4 sieve.

• The percent passing the No. 200 sieve is less than or equal to 2.3 percent.


Combined Gradation ExampleCombined Gradation Example• 30% coarse aggregate #1, 30% coarse aggregate #2

and 40% fine aggregate


Combined GradationCombined Gradation


Optimized Aggregate Gradation

Optimized Aggregate Gradation

• Definition of “optimized” has finally been made

• National Research• Tarantula Curve – Dr. Tyler Ley, OSU• Incorporated into the WisDOT SPV


Optimized Aggregate Gradation Graphs

Optimized Aggregate Gradation Graphs


The TARANTULA curve!!!!


Optimized Aggregate Gradation and Mix Design SPV


• Defines optimized gradation• Outlines spec and testing requirements• Contractor eligible for 3% incentive• Allows for the design of an optimized

mixture.• Can reduce cementitious content to 520

lbs/CY.• Utilizes new national design procedure




1. Utilizes mix design procedure and spreadsheet developed by the National Concrete Pavement Technology Center

2. Utilize the spreadsheet to obtain an aggregate gradation system that fits within the Tarantula Curve and is relatively close to the power 45 curve.

3. Determine the volume of voids in the selected aggregate gradation system.4. Select the paste parameters; binder type, percentages, air content, w/cm.5. Select an Initial Vpaste / Vvoids value (1.25 – 2.00). 6. Calculate the paste content utilizing the spreadsheet. WisDOT requires a

minimum cement content of 520 lbs so the Vpaste / Vvoids value may need to be adjusted to meet this minimum cement content

7. Prepare trial batches and assess fresh properties and workability.8. Prepare final trial batch and assess hardened properties.


SECTION 710GENERAL CONCRETE QMP

SECTION 710GENERAL CONCRETE QMP

• Aggregate Testing• Production or stockpiling• Concrete production• P200• Reporting of all standard sieves


Aggregate Production or Stockpiling

Aggregate Production or Stockpiling

• Testing during aggregate production– Test each component aggregate gradation– During production or stockpiling at concrete

production location• Testing during concrete production

– Aggregate stockpiled before contract– Test for combined aggregate gradation


Aggregate Testing During Production or StockpilingAggregate Testing During Production or Stockpiling


DAILY AGGREGATE PRODUCTION MINIMUM FREQUENCY PER STOCKPILE

1000 tons or less One test per cumulative total of 1000 tons

more than 1000 tons through 2000 tons Two tests per day

more than 2000 tons Three tests per day

Combined P200 TestingCombined P200 Testing• Less than 50 CY

– P200 is less than 2.3 %• Greater than 50 CY

– Once per day– Reduced to once per 5 days if:

• 5 consecutive tests• P200 is less than 1.8 %


Aggregate Testing During Concrete Production

Aggregate Testing During Concrete Production

(2) Report results for the 1 1/2", 1", 3/4", 1/2", 3/8", #4, #8, #16, #30, #50, #100, and #200 sieves.


DAILY CONCRETE PRODUCTION MINIMUM FREQUENCY PER STOCKPILE

250 cubic yards or less One test per cumulative total of 250 tons

more than 250 cubic yards through 1000 cubic yards

One tests per day

more than 1000 cubic yards Two tests per day

Chemical AdmixturesChemical Admixtures• Section 501.2.2 and 501.2.5• Admixture Types typically used for paving

– Air-entraining admixtures– Water-reducing admixtures– Retarding admixtures– Coloring admixtures

• CMM 8.70.2.1.4 Admixtures– See listing of approved admixtures at:http://wisconsindot.gov/Pages/doing-bus/eng-consultants/cnslt-rsrces/tools/appr-prod/default.aspx

• For admixture types not covered by approved lists contractor shall submit an independent lab test report conforming to ASTM C494

• Admixtures make good concrete better – not to fix bad concrete


Air Entraining AdmixturesAir Entraining Admixtures• Essential for resistance to freezing and

thawing• Improved workability, reduced water, and

reduced segregation• Reduces strength• Inexpensive• AASHTO M 154


Water ReducersWater Reducers• Reduce water required about 5% (12%)• ASTM C 494 Type A (or F)• May affect air-entrainment• May retard setting



PROJECT TEAMPROJECT TEAMCHAPTER 10


HEATH

Project TeamProject Team• Engineer – WisDOT Secretary• Project Engineer – Department’s

authorized representative for this project• Inspector – authorized representative of

the engineer to inspect the work or materials

• Contractor – Individual/company undertaking performance of the work


Project TeamProject Team• Communication• Partnering• Both of these are a two way street done

with respect and timeliness

"In any moment of decision the best thing you can do is the right thing, the next best thing is the wrong thing, and the worst thing you can do is nothing."


PLANNINGPLANNINGCHAPTER 11


HEATH

Project TeamProject Team• Engineer – WisDOT Secretary• Project Engineer – Department’s

authorized representative for this project• Inspector – authorized representative of

the engineer to inspect the work or materials

• Contractor – Individual/company undertaking performance of the work



PLANNINGPLANNING• A great deal of set up time and money are

involved to perform a paving operation that happens rather quickly.

• With concrete paving there is only one shot at getting it right, attention needs to be given to even the smallest detail.

CRITICAL DATESCRITICAL DATES• ECIP (WS 1073) – Submitted 14 days prior to

preconstruction conference• QC Plan – Submitted 10 days prior to placing concrete.• Mix Design – Submit material and mix design information

at least 3 business days before producing concrete.• QC Data to MRS – Submitted within 5 business days

after results are available.• QV Data – Department to provide test results to

contractor with 2 business days after the results are available.

• Final Testing Records – Submitted within 10 business days after all contract-required information is available.



Concrete Paving Pre-Pour Meeting


Why?• Information must be readily available in a timely

manner in order for everyone involved to perform their functions.

• Great deal of time, money, and effort involved• Paving operation happens rather quickly• One Shot at getting it right



• Pages 78-81 of the guide• Outline for the meeting• Developed by Heath Schopf of WCPA• Compilation of the issues for discussion

with contractor and how he is going to accomplish paving on your project


Concrete Paving Pre-Pour Meeting - “Pantry”

Concrete Paving Pre-Pour Meeting - “Pantry”





Purpose:• Discuss the upcoming paving operation.• Discuss Owner expectations.• Review project specifications and special provisions.• Review material and quality requirements.• Listen to Owner and Engineers concerns.• Listen to Contractors concerns.• Discuss potential problems or issues.• Establish a line of communication and chain of command.• Discuss traffic control and safety.

SUBGRADESUBGRADECHAPTER 12



SUBGRADESUBGRADEThe subgrade is foundation for the entire pavement system consisting of natural ground that is graded and compacted.

The uniformity and stability of the subgrade affect the long term performance of the pavement structure.


Subgrade UniformitySubgrade Uniformity• Uniformity is the key to constructability and

long term pavement performance• Uniformity will eliminate differential frost

heave primarily caused by varying subgrade materials.


Required Conditions forFrost Heave

Required Conditions forFrost Heave

• Frost Susceptible Soil– Susceptible to capillary action

• Freezing Temperature Penetrating Subgrade

• Supply of Water

All three conditions must be met for frost heave to occur!!!


Subgrade StabilitySubgrade Stability• Subgrade stability will provide the

necessary pavement support required.• Stability and proper compaction are one in

the same.


Typical Problem Areas for Subgrade Uniformity and Stability

Typical Problem Areas for Subgrade Uniformity and Stability• Cut-fill transition areas.• Organic soil areas such as peat.• High silt content soils.• Sewer Trenches

Soil StabilizationSoil Stabilization• Typical stabilizing additives:

– Lime– Portland Cement– Fly Ash

• WCPA member Lafarge NA actively designing and promoting and can mobilize staff to help



Do not be fooled by the term “Rigid Pavement”

Do not be fooled by the term “Rigid Pavement”

• It is true that concrete pavements are considered rigid pavements since they distribute loads over a large area, which in turn keeps the pressure on the subgrade low.

• This is not a reason to accept poor subgrade uniformity and stability.

• Non-uniformity and/or unstable subgrades may affect the long term performance of a rigid pavement.

415 Preparing the Foundation415 Preparing the Foundation• Yielding subgrades identified and

correction referred back to 301.3.5• The department will pay for engineer-

approved EBS to correct subgrade problems beyond the contractor's control as specified in 301.5.


BASEBASECHAPTER 13


BASEBASE• The base is the layer of material placed

directly below the concrete pavement and is considered part of the pavement structure.

• The base provides a working platform for the construction of the concrete pavement.

• The base can also be used as a drainage layer.



Types of BaseTypes of Base

• Primarily two types used in Wisconsin– Base Aggregates, Dense Graded– Base Aggregates, Open Graded


Base CompactionBase Compaction• Proper compaction is usually defined as

the degree of compaction necessary to preclude rutting or displacing of the material under traffic.

• Moisture is the key to proper compaction.

Base TrimmingBase Trimming• Base should be compacted to about 1 inch

higher than plan elevation to allow for future trimming operation

• Re-compact after trimming• Excess disposed outside of the track line

of paver• Excess used for shouldering


Section 211Preparing the Foundation

Section 211Preparing the Foundation

• Aggregate base course is the foundation for concrete pavement.

• Yielding subgrades after base placement are not incidental to preparing the foundation and the contractor shall be compensated accordingly

• Slip-form paving requires a machine designed for trimming base course.


SURVEY AND STAKINGSURVEY AND STAKINGCHAPTER 14



SURVEY AND STAKINGSURVEY AND STAKING• Staking and Tolerances• Paving Grades


Types of StakesTypes of Stakes• Subgrade Stakes = Blue Tops• Base Aggregate Stakes = Red Tops• Paving Stakes


Paving GradesPaving Grades• Information for calculating grades can be

found in the project plans:– Typical section sheets– Plan and profile sheets– Paving details

• Method of operation will determine staking requirements: (Communication Req’d)– Slip-formed– Hand-formed.


Paving GradesPaving Grades• Two Types:

– Offset grade is a level transfer of elevation from the edge of pavement to the offset hub. Offset grades are typically used for hand-formed paving.

– Projected grade is the extension of a line drawn through both edges of pavement.


Paving Grades Offset vs. Projected

Paving Grades Offset vs. Projected


Paving Grades, Offset vs. Projected


5 ft Offset 24 ft

Centerline

Stringline True slope projected from stringline or offset

Erroneous slope improperlyprojected using offset method





Paving StakesPaving Stakes• Placed at a maximum interval of 25 feet• Located within 0.02 feet of true horizontal• Located within 0.01 feet if true vertical• Located at high and low profile points• All changes in superelevation


Grade Stake InformationGrade Stake Information• Stationing• Offset distance• Cut or fill from adjacent top edge of slab

(offset method)• Cut or fill from plane projected through

both edges of slab (projection method)


Superelevation StakingSuperelevation Staking• Superelevated transitions will require

additional staking information:– Length of transition.– Full superelevation rate.– Transition lath located at NC, RC, and FS.– Transition lath located at even % change or at

each paving hub.– Inches of crown at even % change or at each

paving hub.

LUNCHLUNCHSee you back here

in one hour


CONCRETE BATCH PLANTSCONCRETE BATCH PLANTSCHAPTER 15


HEATH

CONCRETE BATCH PLANTSCONCRETE BATCH PLANTS



CONCRETE BATCH PLANTSCONCRETE BATCH PLANTS

• Types of Batch Plants• Concrete Batch Plant Inspection


Types of Batch PlantsTypes of Batch Plants• Central Mixed “Wet

Batch Concrete”– Batch and mixed in a

stationary mixer at the plant site

• Transit-mixed concrete – mixed completely in a

truck mixer


Central Mixed PlantsCentral Mixed Plants

Cement StorageCement Storage• Pig Side View


Cement SilosCement Silos• Most paving plants are 2 compartment split 1/3

2/3 to accommodate 2 materials.


Loading Ground HoppersLoading Ground Hoppers• Loaders feed material into Ground Hoppers


Aggregate FlowAggregate Flow• Aggregate Ground Hoppers and Conveyors

– Aggregate travels up the conveyor into the Plant’s Aggregate Bin


Bin Level Indicators Bin Level Indicators • Signal a full or empty bin or silo in order to close ground hopper gates & shut off material flow


Aggregate BinAggregate Bin• Aggregate Bin Gates Open to Discharge Bin

Contents into the Batcher


Aggregate BatcherAggregate Batcher• Base Trailer Agg Batcher is equipped with four

(4) load cells, summing box, and calibration arms for test weighing.


Agg Bin feeding an Agg Batcher

Agg Bin feeding an Agg Batcher


Up the Belt and Into the MixerUp the Belt and Into the Mixer• Aggregates, cement, water, and

admixtures are weighed and then transferred into the drum typically by belt and gravity, Liquids use pumps.


Discharging into Dump Trucks

Discharging into Dump Trucks


Control RoomControl Room



Central-Mixed ConcreteCentral-Mixed Concrete

Maintain uninterrupted flowof concrete from the plant site

to the paving operation

Plant Site Selection

Discharge on Grade DeliveryBatching & Charging


Truck-Mixed Concrete(Ready-Mix Concrete)Truck-Mixed Concrete(Ready-Mix Concrete)

Adm

ixtu

reFi

ne A

gg.

Coa

rse

Agg.

Cem

ent

Fly

Ash

To Project

Discharge on Grade Mixing & DeliveryBatching & Charging

Water

WisDOT Requirements for Ready Mix Concrete PlantsWisDOT Requirements for Ready Mix Concrete Plants

• Annual approval by on-site inspection or review of records by the region office.

• Ready Mix Producer Must submit:– Certificate of calibration for all scales and

meters– List of sources and types of materials– Mill test reports for cement, fly ash and slag


WisDOT Requirements for Portable Concrete PlantsWisDOT Requirements for Portable Concrete Plants

• Approved by engineer on each project• Contractor submits:

– Certificates of calibration for scales and meters on current project site

– Completed form DT1926 for initial checkout of plant on current site

– Weekly check out of the plant by contractor and submittal of DT1926



Batch Plant InspectionBatch Plant Inspection• Plant inspections ensure the batching and

mixing equipment has been calibrated and in good working order.

• A copy of the plant scale and water meter calibration certificate should be obtained for the project records. Scales should be inspected on a weekly basis for sensitivity.

• The actual plant inspection should be recorded in the project diary.


Batch Plant InspectionBatch Plant Inspection• Aggregate stockpiles need to be built and

maintained properly.– The main goal in aggregate stockpiling is to

maintain a uniform and consistent gradation and moisture content.

– Loader operators should take care in the proper load out technique to avoid segregation and contamination of the aggregates.


BatchingBatching


BatchingBatching• The sequence of charging ingredients into a

concrete mixer can play an important part in uniformity of the finished product.

• The mixing process must completely coat the aggregate particles and fill the voids between the particles with the cement paste.

• A concrete mixer produces a rolling, folding, and kneading action of batch materials over itself as concrete is mixed.

• The most important thing is the uniformity and consistency.

BATCH PLANT SITEBATCH PLANT SITECHAPTER 16



BATCH PLANT SITEBATCH PLANT SITE• In selecting the batch plant site the

contractor must take into account:– Project staging– Plant layout– Material delivery and storage– Utilities– Traffic flow– Agency and local requirements


Batch Plant Site Traffic FlowBatch Plant Site Traffic Flow• Traffic flow is essential to provide an uninterrupted

flow of concrete from the batch plant to the paving operation.

• Traffic flow to produce 4000CY in a 10 hours day.– 53 bulk tankers– 330 aggregate trucks– 400 round trips of haul trucks.– Equates to more than 1 vehicle per minute accessing the

plant site.

Batch Plant Site Traffic FlowBatch Plant Site Traffic Flow


DELIVERY OF MATERIALSDELIVERY OF MATERIALSCHAPTER 17



DELIVERY OF MATERIALSDELIVERY OF MATERIALS

• The delivery of concrete at a consistent and uniform rate is a key factor in producing a quality pavement.

• Concrete pavement mixtures are transported by using dump, agitator, or ready mix trucks.

• Delivery Time = Time cement was introduced into mix to the time of full discharge.

Dump Truck Dump Truck


Agitator Agitator



DeliveryDelivery

Spec Delivery TimeSpec Delivery Time• Section 501.3.5.2• Agitator trucks with paddle not constantly rotating and

Dump trucks:– Conc. temp. ≥ 85 F…………………………........= 30 minutes.– Conc. temp. < 85 ≥ 60 F…….……………........= 45 minutes– Conc. temp. < 60 F……………………………....= 60 minutes– Conc. temp. ≥ 60 F with retarding admix…….. = 60 minutes

• Agitator Trucks with paddle constantly rotating and Ready-Mix trucks:– Conc. temp. ≥ 60 F ……………………………..= 60 minutes.– Conc. temp. ≥ 60 F with retarding admix……..= 90 minutes– Conc. Temp. < 60 F ……………………………= 60 minutes



Delivery of MaterialsDelivery of Materials• Paver ride quality is related to uniform

motion.• Deposit concrete to minimize segregation• Deposit concrete across the full width of

the pavement• Horizontal movement of concrete in front

of the paver should be kept to a minimum since this may cause segregation.

SLIPFORM CONCRETE PAVEMENTSLIPFORM CONCRETE PAVEMENT

CHAPTER 18


415.3.2.1 Slip-Form Paver415.3.2.1 Slip-Form Paver


Use an engineer-approved, self-propelled slip-form paver capable of consolidating, screeding, and float-finishing freshly placed concrete in one complete pass of the machine for the required thickness. Use machines equipped to internally vibrate the concrete for the full width and depth placed in a single pass as required to produce a dense, homogeneous pavement. Equip the slip-form paver with devices that accurately space and position required tie bars and that allows for automatic or manual tie bar insertion.

THIS is a Slipform PAVERTHIS is a Slipform PAVER


This IS NOT a Slipform PaverThis IS NOT a Slipform Paver


This IS NOT a Slipform PaverThis IS NOT a Slipform Paver


Slip-Form AdvantagesSlip-Form Advantages• Uses low slump concrete• High quality concrete consistently

consolidated• Permits high production paving• Capable of producing a very smooth riding

surface


Section 415.3.6Section 415.3.6• Slip-Form Paver is required when:

– 300 or more feet in length– Minimum 10 feet in width or greater– Constant width



SLIP-FORM CONCRETE PAVEMENT

SLIP-FORM CONCRETE PAVEMENT

• Grade Control• Trimmers and Trimming• Belt Placers and Spreaders• Slip-Form Pavers and Paving


Grade ControlGrade Control• Concrete pavement is a 1 lift operation• Grade Control is essential to obtain ride

quality and pavement thickness.• Grade Control is initially established by

proper survey and layout.• Paving equipment utilizes stringlines and

sensors based on the survey and layout.


StringlineStringline• A stringline is set outside the track line and

parallel to the proposed pavement to guide the paving equipment both horizontally and vertically.

• Most paving equipment requires a stringline to be set on both sides of the pavement for maximum grade control.


Setting StringlineSetting Stringline• Rigid stakes• Quality line• Quality pin and wands.• No perceptible sagging• Eyeball for staking errors• Adjust stake spacing to

fit conditions

StringlineStringline



Checking Stringline TensionChecking Stringline Tension


Stringline ControlStringline Control

Slip-form paving equipment such as trimmers, spreaders, pavers, curing, and tining equipment utilize automatic sensors that run off the string line for elevation and alignment control.


Stringline ControlStringline Control• Alignment sensing wands are located in the front

and back of the equipment and are typically only set on one side of the equipment.

• Elevation sensing wands are typically located on all four corners of the equipment and need to be properly tensioned for sensitivity.

• Most sensing wands use a counter balance system for adjusting the tension. The inspector should check the sensing wands for proper tensioning.

Stringline ControlStringline Control


Stringless PavingStringless Paving• The technology is here• Being used across the nation• WisDOT Specification revisions pending

– Survey control– GPS automation with additional vertical

control by laser or total station– Standards for development of the surface

model


Stringless Computer

Radios

Dual-Axis SlopeSensors(On Each Side)

Machine Control Panel and Computer

360o Prisms

Common Configuration Example:Mainline Paver with 2 Total Station Control System

RTS #2(Guidance)

RTS #1 (Guidance)

RTS#3 (As-Builts & Leapfrogging)

Rover

ControlPoint Control

Point

ControlPoint


Trimmers and TrimmingTrimmers and Trimming

Trimming is the process of fine grading the base material to the required grade and cross section.


Trimmers and TrimmingTrimmers and Trimming• A trimmer utilizes a rotary

cutting head to trim the base material.

• During the trimming operation water should be added to the base to eliminate segregation of the fine particles from the larger particles.

• After trimming the disturbed base material must be recompacted.


Trimmers and TrimmingTrimmers and Trimming• Trim base to specified

tolerances:– Enhance pavement

performance– Minimize concrete

spread loss– Achieve slab design

thickness.– Enhance rideability.

• Check, Check, Check!


Trimmers and TrimmingTrimmers and Trimming• Trackline:

– Extend base 3 feet beyond the outside edge of pavement

– Construct parallel to base cross slope

– Durable for paving train

– Keep it clean


Belt Placers and SpreadersBelt Placers and Spreaders• Belt placers and

spreaders are used to provide a consistent head of concrete in front of the paver.

• Maintaining a constant head of concrete will help achieve a smooth ride.


Belt Placers and SpreadersBelt Placers and Spreaders• Advantages of use:

– Provides uniform delivery in front of the paver.– Aids in paving startup by allowing concrete to

be placed close to the paver.– Reduces risk of mix segregation.– Eliminates the risk of truck damage to the

trimmed base and/or track line.– Accommodates the presetting of dowel

baskets for non DBI paving operations.– Aids delivery process for staged construction.

Slip-form Pavers and PavingSlip-form Pavers and Paving



Slip-form Pavers and PavingSlip-form Pavers and Paving• Slip-form paving is used when large amounts of

concrete must be placed efficiently. • Slip-form pavers form and consolidate fresh

concrete while they travel.• Typical applications of slip-form paving are

mainline pavements, and airports where the paver can provide the consolidation required for deep lift concrete pavements at an accelerated production rate.


Slip-form Pavers and PavingSlip-form Pavers and Paving• Types:

– 4 track and 2 track models– Auger or plow used to

distribute concrete– Variable speed,

hydraulically controlled internal vibrators used to consolidate concrete.

– Adjustable width typically from 12-38 feet.


Slipform PaversSlipform Pavers• Consolidate• Form into a

Shape• Finish the

Surface

To Extrude:

“To shape a material by forcing it through a mold.”


Extrusion EnvelopeExtrusion Envelope

• The extrusion process utilizes vibration pressure and movement to apply energy and force the concrete through a paving mold creating a uniform shape.

Profile Pan

TamperVibratorStrike Off

Concrete Head

Profile Pan Batter -Compression-Paver Uplift

FluidizedConcrete Side Form Resistance Batter

Excess ConcreteMovement


Slip-form Paving KitsSlip-form Paving Kits

Typical Paving Kit w/ Auger Strike-Off Typical Paving Kit w/ Open Front

Typical Paving Kit w/ Dowel Bar Inserter Attachment


Slip-form Gang VibratorsSlip-form Gang Vibrators

• Types:– Horizontal tube– Multiple spud

• Purpose:– Consolidate– Fluidize


Slip-formed Concrete Placement Process

Slip-formed Concrete Placement Process


Getting StartedGetting Started• Check all equipment and tools• Verify adequate grade preparation• Communication with concrete plant• Check stringline again• Check weather forecast


Grade ControlGrade Control• Slip-form paver grade control is typically

sensors running on a stringline.• The paver actually rotates about the

sensors and not the edge of pavement.• The stringline, sensors, and grade must be

inspected prior to paving.

Grade ControlGrade Control


Given a normal crown (2%) two lane roadway (2-12 foot lanes) with a stringline offset of 5 feet horizontally and 1 foot vertically.• Slope of projected grade line = (12 feet * 2% - 12 feet * 2%) / 24 feet = 0%• The stringline elevation difference between the left and right line = 0 since the

slope of the line between the stringlines is 0%.• The inches of crown = (2% - 0% * 12 feet) = 0.24 feet• The vertical distance between the stringline and the top of slab located 5 feet off

the line = (1 foot – 5 feet * 0%), which is 1 foot left and right



Given a flat crown superelevation transition (2% on one lane and 0% on the other lane) two lane roadway (2-12 foot lanes) with a stringline offset of 5 feet horizontally and 1 foot vertically.

Slope of the projected grade line = (12 feet * 2% - 12 feet * 0%) / 24 feet = 1% The stringline elevation difference between the left and right line = (24 feet + 5 feet + 5 feet) * 1% = 0.34 feet or approximately 4 inches.

The inches of crown = (2% -1%) * 12 feet = 0.12 feet The vertical distance between the stringline and the top of slab located 5

feet off the stringline = (1 foot – 5 feet * 1%) = 0.95 feet on the left and (1 foot + 5 feet * 1%) = 1.05 feet on the right.



Given a reverse crown (2% on one lane and -2% on the other lane) two lane roadway (2-12 foot lanes) with a stringline offset of 5 feet horizontally and 1 foot vertically.

Slope of the projected grade line = (12 feet * 2% - 12 feet * -2%) / 24 feet = 2%

The stringline elevation difference between the left and right line = (24 feet + 5 feet + 5 feet) * 2% = 0.68 feet or approximately 8 inches.

The inches of crown = (2% - 2%) * 12 feet = 0. The vertical distance between the stringline and the top of slab located 5

feet off the stringline = (1 foot – 5 feet * 2%) = 0.90 feet on the left and (1 foot + 5 feet * 2%) = 1.10 feet on the right.


Initial Paving OperationsInitial Paving Operations• Check mix yield• Control workability• Probe for depth• Adjust paver speed to concrete production• Aim for minimal finishing• Communicate with plant operator


Critical FactorsCritical Factors• Sound and properly trimmed grade• Well maintained and clean equipment• Proper equipment setup and machine attitude• Proper weight & traction• Moist Base• Consistent and uniform delivery of concrete• Consistent and workable concrete mix• Proper vibration frequency• Sensor sensitivity• Quality control personnel on site


Crown and Cross SlopeCrown and Cross Slope• Check the crown and cross slope of the

pavement as soon as possible after start up.• Check the crown and cross slope by using a

string, level, paving string line, ruler, visual inspection or a combination of the above.

• When checking the crown and cross slope try to use a measurement reference point greater than 18-inches from the edge of the slab to minimize the affects of edge slump on the measurement.


Edge SlumpEdge Slump• Edge slump occurs when the

top edge of a freshly-placed, slip-formed concrete pavement sags down after the slab is extruded from behind the paver.

• Edge slump is primarily a function of the mix consistency.

Edge SlumpEdge Slump


Edge SlumpEdge Slump




Edge SlumpEdge Slump• Tolerances:

– Where an adjacent lane or ramp is not to be constructed an edge slump tolerance of 3/8 inch or less is typically acceptable.

– Where an adjacent lane or ramp is to be constructed an edge slump tolerance of 1/8 inch or less is typically acceptable.

• Edge slumps greater than contract tolerances should be corrected before the concrete hardens.

The following factors affect edge slump:

The following factors affect edge slump:

• Concrete consistency• Concrete mix compatibility with placement

technique• Paver adjustment and operation• Excessive finishing• Segregation on the belt placer


Concrete Pavement Thickness

Concrete Pavement Thickness


CHAD

Thickness TestingThickness Testing• MIT-SCAN-T2• Probing (Special Units

and Process Control)• Coring

Concrete Pavement ThicknessConcrete Pavement Thickness• Standard Spec. Section 415.3.16 and

CMM chapter 8-70.4.7• Primary method of acceptance is MIT

Scan T2 Device• Contractor develops the basic units,

special units and determines random locations.


Pavement UnitsPavement Units• Basic unit is 250 foot segments of

pavement one lane wide• Fractional units

– >100 feet is a whole basic unit– < 100 feet include as a contiguous unit

• Special Units are fillets, intersections gaps, shoulders, ramps and long segments less than 10 feet wide– Maximum size 350 square yards– No Minimum size


MIT Scan – T2MIT Scan – T2

• Developed and promoted by FHWA.

• WisDOT piloted on projects in 2014 & 2015.

• 2016 Standard Spec.


Locating Test PlatesLocating Test Plates• Department furnished test plates• CMM 8-70.4.7.2• Contractor

– Place 2 department supplied plates at random locations within each unit

– Do not place within 4 feet of joints containing steel

– Anchor to grade– Enter test place location into MRS within 5

business days


Thickness TestingThickness TestingStep 1

Step 2

Step 3

Place the target

Pave over it

Find the target

WisDOT Measurement and Acceptance

WisDOT Measurement and Acceptance

• Region IA’s measure plates• CMM 8-70.4.7.2• Locate plate placed by the contractor• If conforming, accept and document• If nonconforming, the 2nd plate within the unit is

measured, average both plates and document• Pavement thinner than I inch is unacceptable• Core at 20 foot intervals longitudinally to

determine limits of unacceptable pavement


Determining Pavement Thickness

Determining Pavement Thickness

• Special Unit – average of available measurements as agreed upon by engineer

• Can be done by probing, stringlinemeasurement or MIT Scan T2 device.


How to Probe Special UnitsHow to Probe Special Units


How to Probe Special UnitsHow to Probe Special Units


DefinitionsDefinitions• Conforming: </= 1/4-inch below plan thickness• Nonconforming: > 1/4-inch to 1-inch below plan thickness• Unacceptable: > 1-inch below plan thickness


Adjusting Pay for ThicknessAdjusting Pay for Thickness415.5.2 Adjusting Pay for Thickness

(1) The department will adjust pay for pavement thickness under the Nonconforming Thickness Concrete Pavement administrative item as follows:

FOR PAVEMENT PERCENT OF THETHINNER THAN PLAN THICKNESS BY: CONTRACT UNIT PRICE[1]

> 1/4 inch but <= 1/2 inch 80> 1/2 inch but <= 3/4 inch 60> 3/4 inch but <= 1 inch 50

[1] The department adjusts pay based on the average of 2 measurements per unit as specified in 415.3.16.4(1).

(2) If the department determines areas of pavement have unacceptable final thickness, as specified in415.3.16.4, the engineer will direct the contractor to either:

1. Remove and replace with concrete pavement of conforming thickness. The department will pay for the replaced area at the full contract price.

2. Leave the concrete in place. The department will not pay for the unacceptable area.


415 Pavement Gaps415 Pavement Gaps• 415.3.18 Pavement GapsConstruct gaps using either doweled or tied construction joints. Locate construction joints and joints within the gap ensuring that the resulting slab lengths are greater than or equal to 6 and less than or equal to 15 feet long. Alternatively, if the engineer approves, the contractor may pave continuously through the gap using concrete conforming to 415.2.5 • 415.4 MeasurementThe department will measure Concrete Pavement Gaps as each individual gap acceptably completed including eliminated gaps the engineer allows the contractor to pave through. The department will measure multiple gaps at one location as required to conform to contract staging provisions, but not solely to accommodate the contractor's means and methods.


STEEL EMBEDMENT, TIE BARS AND DOWEL BARSSTEEL EMBEDMENT, TIE BARS AND DOWEL BARS

CHAPTER 19


KEVIN


STEEL EMBEDMENT, TIE BARS, AND DOWEL BARSSTEEL EMBEDMENT, TIE

BARS, AND DOWEL BARS• Steel Embedment and Tie-Bar Placement• Dowel Bar Installation

415 Reinforcement415 Reinforcement• Section 415.3.5Reinforce the concrete if and as the plans specify. Keep reinforcement clean, free of rust and scale, and supported to prevent distortion. Store reinforcement steel, received on the job, in engineer-approved storage and distribute only as needed for placement. Protect epoxy coated steel from cumulative exposure to sunlight for more than 2 months by covering with opaque plastic sheeting or other engineer-approved material. Clear plastic shrink wrap for dowel bar bars and dowel baskets is sufficient protection for up to 4 months exposure.


STEELSTEEL

• “Buy America” Provisions 23 CFR 635.410

• Standard Spec 106.2.2

• CMM 2.28.4• Form WS4567 must

be completed by contractor


Steel “Buy America”Steel “Buy America”• Documentation/Certification of:

– Location steel was melted/cast– Location steel was rolled/drawn– Location steel was fabricated– Location steel was coated/galvanized

• Engineer’s responsibility that requirements have been adhered to and documented



Steel EmbedmentSteel Embedment• Inspect all embedded steel prior to

concrete placement.– Bar diameter, length, presence of epoxy

coatings, and steel heat numbers should be verified.

• Perform dry run of all mechanical insertion equipment prior to concrete placement.

• Embedded steel bars or mesh should be securely supported on chairs.


Tie BarsTie Bars• Located at longitudinal joints.• Mechanically inserted when paving multiple

lanes.• Bent tie bars are typically used at longitudinal

construction joints.• Verify longitudinal positioning:

– Do not place tie bars across a transverse joint. The insertion of the tie bars may conflict with the insertion of the dowel bars causing the dowel bars to become misaligned.

Mechanically Inserted Tie BarsMechanically Inserted Tie Bars


• Tie bars installed in new concrete are #4 or # 5 deformed bar, 30 or 36 inches long spaced at 36-inches center to center depending on the pavement thickness.

• Bent #4 deformed bars as noted.


Tie BarsTie Bars


Tie Bar PlacementTie Bar Placement

• WisDOT Standard Detail Drawing (SDD).


Drilled Tie BarsDrilled Tie Bars• When tie bars are

used in existing concrete they are known as drilled tie bars and are typically #6 deformed bar, 12-inches long, and spaced 30 inches center to center

What’s Wrong?What’s Wrong?


#6 bar 12” long onlyEmbedded 2”

15” min. spacing betweendowel bar and tie bar

Bent Tie BarsBent Tie Bars• Required in order to

clear paver tracks during insertion

• Uncover• Bend back to straight• Parallel with surface



Dowel Bar InstallationDowel Bar Installation• Dowels transfer loads across transverse joints.• Load transfer devices such as dowel bars help

prevent faulting.• Dowel bar position and alignment are critical.• Dowel misalignment has a significant effect on

pavement performance resulting in cracking.• Specifications typically require a dowel bar

alignment tolerance of ¼ -inch/foot or less in the vertical and horizontal plane.

• Dowel bar assemblies (dowel baskets).• Dowel bar inserter (DBI).


Dowel BarsDowel Bars• Dowel bars are 18-

inches in length and spaced 12-inches center to center across the transverse joint. The dowel bar diameter usually ranges from 1-inch to 1.5-inches depending on the slab thickness

Dowel Bar TolerancesDowel Bar Tolerances• Section 415.3.7.3 on tolerance

– Within 1 inch of the planned transverse location and depth

– Within 2 inches of the planned longitudinal location.

– Parallel to the pavement surface and centerline within a tolerance of 1/2 inches in 18 inches.

• This tolerance allows for whole inch baskets to be used for half-inch pavement thicknesses (Example: 9-inch basket used in a 9.5 inch pavement)


Dowel Bar BasketsDowel Bar Baskets




HPC Dowel BarsHPC Dowel Bars• 316L Stainless Steel Cladding• 316L Stainless Steel Tubes• Solid Stainless Steel• UNS Z41121 Zinc Alloy Cladding• CRT Bar – Conventional steel with fiber

composite outer coating


HPC Dowel BarsHPC Dowel Bars


Steel/Dowel Bars – The Future is Coming

Steel/Dowel Bars – The Future is Coming

• Non-Bendable Epoxies for Dowel Bars

• Green epoxy bar has been the standard for 30+ years.

• Need a performance standard– Fatigue– Corrosion

• Cost and competition


HPC DowelsHPC Dowels


HPC DowelsHPC Dowels



Dowel Bar BasketsDowel Bar Baskets• Dowel basket tie wires do not need to be

cut.• Check baskets from three perspectives

– Dowels parallel to center line.– Dowels are level. – Basket assemblies should be parallel to and

aligned with each other.• Verify the center of the dowel baskets are

marked for sawing.• Check for the presence of Tectyl Coating• Check for quality of anchoring



Pinned, Aligned, and Marked.Pinned, Aligned, and Marked.


Successful PracticesSuccessful Practices• Transverse spacing as specified (joint layout)• Aligned correctly• Transverse spacing as specified (joint layout)• Aligned correctly




Dowels within 12’ oflongitudinal joint.

12” Spacing



Alignment

Header ConstructionHeader Construction


Anchoring BasketsAnchoring Baskets


Successful PracticesSuccessful Practices• Firmly anchored – stakes, clips and anchors, etc.• Cut the shipping

wire?



Dowel Bar Inserters (DBI)Dowel Bar Inserters (DBI)• DBI units eliminate the need for placing dowel baskets.• Typically produce higher production rates.• DBI units are sensor controlled to insert dowel bars at

the proper joint spacing.• DBI units should have the capability of running on

automatic or manual.• Inspect DBI unit for:

– Dowel bar slot spacing.– Inserter fork alignment.– Inserter fork embedment depth.– Correct number of dowel bars loaded.– Transverse joint spacing.


Dowel Bar Inserters (DBI)Dowel Bar Inserters (DBI)

Trolley Assembly Inserter Forks


DBI OperationDBI Operation

• Dowel bars are loaded into a trolley assembly unit and lightly coated with a debonding agent.

• The trolley assembly moves transversely across the paving kit and drops the dowel bars into slots.


DBI OperationDBI Operation• When the paver is at a

transverse joint location the slots drop the bars onto the slab and a series of insertion forks vibrate the bars into location.

• As the paver tracks forward the insertion fork assembly moves at the same rate backwards to insert the bars at a fixed longitudinal location.

Key Inspection ItemsKey Inspection Items• Periodically verify dowel location behind the paver

– Expose/Probe in fresh concrete


One More Thing on DBIOne More Thing on DBI• Form oil for dowel bar release/bond breaker


Expansion JointsExpansion Joints• Bridge approach

slabs• Intersections • Railroad crossings• New language in

Section 415 allows for sawing above the expansion material


End CapsEnd Caps


Expansion JointExpansion Joint


Two recent issues:- Sealant must be

hot pour asphalt - End caps are

absolutely required for joint performance

Bridge ApproachBridge Approach


Structural ApproachesStructural Approaches


BREAK TIMEBREAK TIMETAKE 15 MINUTES


FINISHINGFINISHINGCHAPTER 20



FinishingFinishing• Finishing determines the final appearance,

smoothness, and other surface properties of concrete that affect the long-term durability of a pavement surface.

• Proper finishing primarily involves skill, knowledge, and experience, in order to deal with various concrete mixtures and field conditions.

• A large factor in the finishing operation is timing. Delays can disrupt the flow of the entire construction operation.


FinishingFinishing• Finishing is primarily

completed by the slip-form paving equipment.

• Some contractors utilize mechanical finishing equipment behind the paver such as oscillating floats or truss floats.

• If mechanical finishing is the only method to produce an acceptably “closed” surface corrections are needed for the concrete mix and/or paving equipment.


FinishingFinishing• Hand finishing efforts should be kept to a minimum.• Over finishing is detrimental to the long term durability

and smoothness of the pavement.• An acceptable concrete surface does not need to be

closed up completely and every small blemish does not need to be corrected.

• Check smoothness with straightedges• Hand tools for air-entrained concrete are made of

aluminum or magnesium alloy.• Edge pavement to a ¼ inch radius.• Do not sprinkle water on the slab surface to facilitate

finishing.• Do not work water into the surface with floats.

Wetting of Burlap DragWetting of Burlap Drag


Good PracticeQuestionable Practice

FinishingFinishing


FinishingFinishing


Some general guidelines to follow:

Some general guidelines to follow:

• Finishing efforts kept to a minimum• Does not need to be perfect prior to final

process of brooming or turf drag.• Do not add water to the surface.• Too much paste at the surface

– Too much water– Over vibration– Excessive finishing


The process of finishing:The process of finishing:• Bull float, darby or straight edge• Wait for bleed water to leave surface• Edging and forming of joints• Float one more time to remove blemishes• Steel trowel the surface – NOT FOR

EXTERIOR CONCRETE• Texture by brooming or turf drag


Additional Info. Section 415Additional Info. Section 415• Section 415.3.6.1(6)Do not add water to correct surface deficiencies except in emergency cases or with engineer authorization. • Section 415.3.2.5Use aluminum, magnesium, or wooden hand finishing tools. Do not use steel hand finishing tools.


FinishingFinishing


FinishingFinishing


FinishingFinishing


Impacts of Poor FinishingImpacts of Poor Finishing


Moderate Scaling Severe Scaling

Bull Float and Straight edgingBull Float and Straight edging


Successful PracticesSuccessful Practices


• Identify bumps and dips – overlap straightedge by 1/2

• Correct bumps and dips


Straight EdgeStraight Edge• Checking the surface with a 10-ft to 20-ft hand-

operated straightedge.• Check straightedges periodically for trueness.• Straight edging should overlap by one-half the

length of the straightedge to ensure that the tool removes high spots and fills low spots in the surface.

• Do not move concrete with a straight edge.• Check, Check, Check!

Hard Steel TrowelsHard Steel Trowels



WorkabilityWorkability• The ease of placing, consolidating, and finishing freshly

mixed concrete and the degree to which it resists segregation is called workability.

• Factors that influence the workability of concrete are: – Method and duration of transportation.– Quantity and characteristics of cementitious materials.– Concrete consistency or slump. – Gradation, shape, and surface texture of fine and coarse

aggregates.– Air entrainment.– Water content.– Temperature of the air and concrete.– Admixtures.

The Box TestThe Box Test


The Box TestThe Box Test• Add 9.5” of unconsolidated concrete to the

box• A 1” diameter stinger vibrator is inserted

into the center of the box over a three count and then removed over a three count

• The edges of the box are then removed and inspected for honey combing or edge slumping









Box Test Ranking ScaleBox Test Ranking Scale

4 3

Over 50% overall surface voids. 30‐50% overall surface voids.

2 1

10‐30% overall surface voids. Less than 10% overall surface voids.


SURFACE TEXTURESURFACE TEXTURECHAPTER 21



SURFACE TEXTURESURFACE TEXTURE• Artificial Turf Drag• Tining


Surface TexturingSurface Texturing• Apply while concrete workable• Texture types:

– Moistened burlap– Broomed finish– Artificial turf– Tining

• Each texture type is distinct in its skid resistance, friction, and noise generation.

Surface TexturingSurface Texturing• Section 415.3.8• Design speeds < 40mph – turf drag• Design speeds > 40mph – turf drag and

tine• Department required tining is longitudinal

tining



Artificial Turf DragArtificial Turf Drag• Dragged longitudinally.• When longitudinally dragging

avoid a wavy looking pattern.• The inner and outer 6 inches to

12 inches of the slab should be hand dragged to prevent edge slumping or tearing.

Artificial Turf DragArtificial Turf Drag• Molded polyethylene

with synthetic turf blades

• Approximately 0.85 inches long

• Approx. 7200 blades per sq. ft.

• 2 ft. of turf in contact with surface

• Weight as necessary to maintain contact



Tining• Check tiners for

missing, bent, or broken tines before tining.

• Tines should be clean and properly spaced,

• Machine should be guided by stringline

Longitudinal TiningLongitudinal Tining• By WisDOT Standard

– 1/8 - inch tines– 1/8 to 3/16 inch depth– 3/4 - inch spacing– Must be stringline controlled– 2-inch clear of longitudinal joint



TiningTining• Coordinate

timing of the tining operation with the turf drag operation.

• Adjust tining operation to produce a uniform depth of sharp, well defined grooves.

Longitudinal TiningLongitudinal Tining



Concurrent Longitudinal Tining and Curing

Concurrent Longitudinal Tining and Curing

Transverse TiningTransverse Tining• Transverse tining is only allowed when

matching existing transverse tining or on approval of engineer.– 5/8-inch uniform spacing is the standard– 10 foot rake


CURINGCURINGCHAPTER 22



CuringCuringCuring is the maintenance of adequate moisture and temperature in freshly placed concrete for a period of time.


Curing• ASTM C309

– Type 2, white pigmentation – required except for colored concrete.

• ASTM C1315 – Type 1, clear – for colored concrete.

• Rate according to specifications– 150 ft2/gal for tined surfaces– 200 ft2/gal for all other surfaces– Manufacturer’s recommendation


Effect of Adequate Curing on Hardened Concrete

Effect of Adequate Curing on Hardened Concrete

Increased:– Strength– Water tightness– Abrasion resistance– Freeze-thaw resistance– Volume stability


CuringCuring

Curing Application RateCuring Application RateThe curing tote interval spacing can be verified using the following equation:

Curing tote spacing (ft) = application rate (ft²/gal) x curing container volume (gal)slab width including edges (ft)

The actual application rate can be verified using the following equation:

Actual application rate (ft²/gal) = exposed pavement area including edges (ft²)actual volume applied (gal)


Curing MaterialsCuring Materials• Historical water based with wax solids

phased out only to be used when concrete pavement is being overlaid

• WisDOT specifying:– PAVEMENTS

• Poly-Alpha Methyl Styrene (PAMS)


Curing Compound - BasicsCuring Compound - Basics• Bases

– Wax– Resin

• Hydrocarbon • PAMS


General Curing GuidelinesGeneral Curing Guidelines• Gently agitated prior to and during application.• Uniform application required on all exposed

surfaces– Over application may result in runoff– Under application may result in incomplete curing

• Cure edges within 30 minutes of removing forms.

• Cure immediately upon removal of plastic used for rain protection and cold weather


Application Guidelines:Application Guidelines:• Optimum curing window is very narrow.• Apply when bleeding has stopped and no free

moisture is left on the surface– Early application will result in an incomplete film– Late application will result in water leaving the

concrete• Recommended to shy on dryer side of the curing

window.• Work together with the contractor to obtain the

correct application timing throughout the day.


Emulsified CompoundsEmulsified Compounds• Care must be taken with all emulsified

compounds to ensure the emulsion is not broken which is typically caused by dilution, over agitation, contamination, or freezing of the delivered product.

• Various types of curing compounds are not compatible with each other and all equipment must be thoroughly cleaned before switching from one base type to another.


Curing too lateCuring too late


Poor/Uneven coveragePoor/Uneven coverage


Good curingGood curing


Curing Compound: Good PracticeCuring Compound: Good Practice

Note the edge!


Curing Compound: Good PracticeCuring Compound: Good Practice


Curing Compound: OK PracticeCuring Compound: OK Practice


Curing Compound: Poor PracticeCuring Compound: Poor Practice


Curing Compound: Poor PracticeCuring Compound: Poor Practice


White Cure can Hold Heat?White Cure can Hold Heat?


FHWA SAYS:FHWA SAYS:

Definition of a good cure:

white as a piece of paper


CURING vs. SEALINGCURING vs. SEALING• The purpose of curing is to retard the loss of

water in concrete to enhance cement hydration.• Sealing retards the penetration of harmful

substances after 28 days old.


HAND-FORMED CONCRETE PAVEMENTHAND-FORMED CONCRETE PAVEMENT

CHAPTER 23


HEATH


HAND-FORMED CONCRETE PAVEMENT

HAND-FORMED CONCRETE PAVEMENT

• Forms and Forming• Hand-Formed Concrete Placement

Process

Section 415 on Hand/Fix Form Paving

Section 415 on Hand/Fix Form Paving

• Forms• Screeds• vibration


FormsForms• Section 415.3.2.4• Intent was to eliminate old language that

was written when pavers rode on forms• Steel forms with a vertical face as high or

higher than the pavement thickness minus 1 1/2 inches

• Side and base supports capable of supporting screeds and concrete pressure


ScreedsScreeds• Section 415.3.2.3• Air vibrated or mechanically vibrated truss

screeds• Roller screeds are not allowed


415.3.6.3 Formed Placement415.3.6.3 Formed Placement• Hand placement of 5-inch thickness or

greater requires additional vibration with spud vibrators

• Vibrate around all baskets , joints and forms


FormsForms• Pre 2012 spec language goes back to the

1950s• Paver rode on the forms• Needed to be functional, stable and

structural


FormsForms



Forms – Modern Day• Straight and true• Tightly lock to ends of adjacent forms• Stake with a minimum of three pins for

each 10 foot section• Stable under weight or vibration of

equipment• Clean and oil before use• Recycle or discard any bent, twisted or

broken forms


Typical Steel FormTypical Steel FormForm Lock


Typical Key LocksTypical Key Locks

Inside Wedge Outside Wedge

Iron Pin


Setting FormsSetting Forms• Form setting is critical construction step

– Uniform support– Proper maintenance

• Proper alignment and elevations contribute to smooth pavement

• Individually inspect before placement– Pin keys– Joint locks– Trueness - top and face


Setting FormsSetting Forms• Pins and key locks hold form in place• Set forms to proper grade - alignment• Eyeball horizontal and vertical alignment• Check depth between forms• Check width between forms

Hand Formed Concrete Placement Process


• Quality control personnel and testing equipment on site.

• Place concrete on a moist base.

• Check vibratory truss screed with a stringline.

• Spread concrete at a uniform depth.

• Avoid mix segregation





• Internally vibrate around all dowel basket assemblies and along all forms with a spud type vibrator ahead of the screeding operation

• A vibratory screed should be operated with a uniform forward motion.

• Keep vibrating screed moving forward• Check the slab behind the screed to verify

the proper cross slope.


Form RemovalForm Removal• Remove timely• Pull pins• Tap lightly before removal• Check edge for honeycomb• CURE EDGES !!!!!

Colored ConcreteColored Concrete


Section 405COLORING CONCRETE

Section 405COLORING CONCRETE

• NEW SECTION of Spec Book in 2012• Incorporates material and construction

requirements of widely used special provision into standard specs

• Defines WisDOT Red• To provide additional colors use SPV to

modify material requirements of 405.• New Bid Item• Payment by the CY


WisDOT RedWisDOT Red• Non-fading synthetic iron oxide• 6% or more by weight of cementitious• “Match the color in reasonably close

conformance with WisDOT red• Federal Standard 595 Color Server, FS

color 31136


6% Color Loading6% Color Loading• 5 color

manufacturer’s challenged for 6 percent loading

• Huge variation in color

• Liquid color must be adjusted to be equivalent to 6% solids


Referee SampleReferee Sample• Referee sample

available in all region offices

• WCPA members also have access to one through WCPA


Test SlabsTest Slabs• This is not the intent

of specification• “reasonably close

conformance”• Key is consistent

color across the whole roundabout


CONCRETE JOINTS AND INTERSECTION JOINTINGCONCRETE JOINTS AND INTERSECTION JOINTING

CHAPTER 24



CONCRETE JOINTS AND INTERSECTION JOINTINGCONCRETE JOINTS AND INTERSECTION JOINTING

• WisDOT changes to jointing plans• Joint Types• ACPA Jointing Methods

Construction Staking for Joint Layout

Construction Staking for Joint Layout


Joint Layout SPVJoint Layout SPV


New Jointing SDD Page 1New Jointing SDD Page 1












Important Issues for Moving Forward

Important Issues for Moving Forward

• Contractor will be responsible for joint layout

• Plan to be submitted to engineer• WCPA advising members that failure to do

correctly will make crack policy an issue


THE STANDARDTHE STANDARD• Important that a standard

be set for joint layout• ACPA Procedure outlined

in their publication IS006.• Quality measure for

WisDOT• Having a standard allows

the crack spec to remain in place



JointingJointing

• Concrete cracks• Joints force the concrete

to crack where we want

Why are joints necessary?


• Concrete drying shrinkage• Changes in temperature and moisture

– Ambient (contraction)– Gradient (curling)

• Subbase restraint (friction or bond)• First applied loads

Why Does Concrete Crack After Placement?

Why Does Concrete Crack After Placement?


Natural Crack DevelopmentNatural Crack Development

• Volume loss• Thermal Contraction

Usually within first 12-24 hours



• Temperature Gradients• Moisture Gradients• Thermal Cycles• Loading

Usually occurs sometime after12 hours and may take months


Proper jointing provides a series of saw cuts (joints) spaced to control crack formation



Main FactorsMain Factors• Joint Types and Purpose• Joint Saw Depth• Joint Spacing• Intersection Orientation


Joint Types and PurposeJoint Types and Purpose• Contraction Joints

– Transverse – Longitudinal

• Expansion Joints– Transverse

• Construction Joints– Transverse– Longitudinal


Contraction JointsContraction Joints

• Temperature stress

• Moisture stress• Loading stress


Longitudinal Contraction Joints

Longitudinal Contraction Joints

• New Concrete (Tie Bars)– #4 bar, 30 inches long for < 10.5 inch

pavements and #5 bar, 36 inches long for >/= to 10.5 inch thick, Spacing is 36 inches

• Existing Concrete (Drilled Tie Bars formerly referred to as Pavement Ties)– #6 bar, 12 inches long, spaced 30 inches C-C


Transverse Contraction JointTransverse Contraction Joint• New Concrete (18 inch Dowel Bars)


Expansion JointsExpansion Joints

• Expansion and contraction of concrete

• Failure history• Current use


Construction JointsConstruction Joints

• Joints formed during construction

• Paver limitations


Construction JointsConstruction Joints• Joints formed during construction or by

paver limitations.• Headers:

– Located a minimum of 4 feet from the nearest contraction joint.

– Dowel bars only used for headers since 2014


Joint DepthJoint Depth• T/3• Tape Inserts not recommended• Sawing preferred


Joint SpacingJoint Spacing• 2 x T (Granular Sub-base)• 1.5 x T (Stabilized Sub-base)• Wisconsin empirical performance governs

15 feet• Random not allowed• Skew not allowed

Keep it Short!

Keep it Simple!

Keep it Practical!


Joint Load Transfer and Tie Bars

Joint Load Transfer and Tie Bars

• Aggregate Interlock• Doweled Transverse joints• Tie Longitudinal and Construction Joints


Things to EnsureThings to Ensure• Match existing joints or cracks• Place Joints to meet in-pavement structures• Reduce/eliminate crack risks

– Develop a jointing plan– Watch timing– Error on the short side– Exact spacing not important

• Consider non-obvious factors– Avoid acute angles– Meet in-pavement structures– Meet pavement width changes


Things to AvoidThings to Avoid• Slabs < 2 foot wide• Slabs > 15 feet wide• Angles < 60º (<90º is better)• Interior corners (L-shaped slabs)• Odd shapes (keep slabs square or pie-

shaped)


Intersection JointingIntersection Jointing• Develop a

Jointing Plan– Bird’s eye view

• Follow ACPA’smethod

• Be practical!

ACPA’S 10 STEP METHODACPA’S 10 STEP METHOD


Step 1

2 feet2 feet

Circumference Return

Taper Return

Step 2Step 3

?

?

? ?

Step 4Step 5Step 6Step 7Step 8Step 9Step 10

A

BA

C

Telescopingmanhole


Edge of laneBack of curb

2 feet

Width change and dogleg in gutter near point of curvatureA2017 WCPA/WisDOT Concrete Pavement Inspection Workshop

BWidth change and dogleg in gutter near start of a taperB

2 feet



Width change and dogleg in paving slab for hand-pour areaC

2 feet



An abbreviated look at jointing a skewed

intersection

An abbreviated look at jointing a skewed

intersection


Step 1Draw all pavement edge and back-of-curb lines in the plan view.


Cross-road Return

2 feet1/2 nominal lane width

Step 2Lightly draw circumference-return, taper-return, and crossroad-return linesas offsets of 2 ft.


Step 7

Isolation Joint

Define intersection box by extending lane lines from both intersecting roadways.


A

AB

AStep 10

Extend lines from center of curb return radii to corners of intersection box panels. Draw joints along these “diagonal” lines.Make adjustments to eliminate doglegs in pavement edges.


Optional joint usedwhere slab widthexceeds 15 feet


24 F

t.30

Ft.

36 F

t.

OpposingDual-LeftTurn Lanes


RoundaboutsRoundabouts• Isolated Circle Method• Pin Wheel Method

• Pave Through Method not allowed by WisDOT


Isolated Circle Jointing ExampleIsolated Circle Jointing Example


Pinwheel Jointing ExamplePinwheel Jointing Example



Expansion / Isolation Joint Required

Expansion / Isolation Joint Required


It’s not nice to fool with mother

nature

It’s not nice to fool with mother

nature


It’s not nice to fool with

mother nature

It’s not nice to fool with

mother nature


Follow the Radius Return…Follow the Radius Return…


Follow the Radius Return…Follow the Radius Return…


If it gets too Wide…If it gets too Wide…


Matching Joints…Matching Joints…


Matching Cracks…Matching Cracks…


You can kill yourself trying,

just be practical!!

You can kill yourself trying,

just be practical!!


Joint through or Perimeter

Isolation?

Joint through or Perimeter

Isolation?


Good PracticeGood Practice

SAWINGSAWINGCHAPTER 25


KEVIN

SawingSawing• 415.3.2.6 Concrete SawsUse saws light enough to operate on and capable of sawing new concrete with minimal raveling, chipping, spalling, or otherwise damaging the pavement. Ensure that saws have diamond blades with functioning blade guards and are equipped with guides or other devices to control cut alignment and depth.



SAWINGSAWING• Types of Saws

– Conventional saws– Early entry saws– Span saws

Conventional Wet SawingConventional Wet Sawing



Early Entry Dry SawEarly Entry Dry Saw


Span SawSpan Saw

Span SawSpan Saw


HEM Magna Cut Sawing System

HEM Magna Cut Sawing System



Sawing WindowSawing Window• Dependent on:

– Mix proportions– Weather conditions– Type of aggregate– Hardness of aggregate

• Urgency of the operation• Skip sawing• Hand tooling of joints allowed, but must be

later sawed to plan depth


SawingSawing• D/3 for assured prevention of uncontrolled

cracking using conventional sawing methods

• D/5 possible for early entry saws (not WisDOT spec or standard)

• Locations of joints must be positively and accurately marked during the paving process


Time

Con

cret

e St

reng

thToo Late:Cracking

SawingWindow

Too Early:Raveling

Restraint Stress EqualsConcrete Strength

Minimum Strength to AvertExcessive Saw Cut Raveling

Sawing WindowSawing Window


Joint Sawing Joint Sawing (IMCP—pages 233–236)





RAINFALL PROTECTIONRAINFALL PROTECTIONCHAPTER 26



RAINFALL PROTECTIONRAINFALL PROTECTION• Preparation• Rain and preventing damage• Correcting damage• More severe distress

Standard Spec. 415Standard Spec. 415• 415.3.14 (3) Protecting ConcreteArrange to have available materials for protecting the unhardened concrete against rain damage. If rain is imminent, cover unhardened concrete immediately with plastic or other engineer-approved material secured along pavement edges. Provide drainage as required to protect the work.

• 415.3.8.2 (3) Surface FinishingRestore pavement texture damaged by rain by re-dragging the concrete while still plastic.


CMM GuidanceCMM Guidance• 4-24.8 Rain Damaged PavementAreas damaged by rain may be re-dragged and/or re-tined if the concrete is still plastic. It is even better, if rain is suspected or forecast, to have plastic ready for covering the pavement and to halt paving operations if rain is prolonged. If all else fails, the damaged area must be ground by machine to avoid accidents caused by slick pavement. Grinding should be parallel to the centerline, and the finished areas should be rectangular, neat and not distracting to motorists.



PreparationPreparation• Knowledgeable of

weather forecast• Plastic sheeting on site• Steel forms or wooden

boards available on site



Rain and Preventing DamageRain and Preventing Damage• Begin covering at first signs of rain• Stop production and paving and begin protecting

work.• Cover back to the point where rain is not

indenting surface, starting at paver and working backwards.

• Rain may wash curing compound off and not damage surface (re-cure when rain stops).

• Some marring of the surface may occur with plastic sheeting (That is OK).


Marring of the pavement surface due to plastic sheeting. Does not require remediation unless ride or skid resistance is unduly affected.



Edge erosion of freshly-placed slab due to rain


Rain and Preventing DamageRain and Preventing Damage• Slip form concrete is low slump stiff

concrete that has been consolidated. This prevents water from soaking into the concrete.

• Do not attempt to remove surface water, texture or cure prior to covering.


Correcting DamageCorrecting Damage• Do not finish rain water into the concrete surface

this will reduce the durability of the surface.• After rain has stopped covers can be removed

and texturing and curing can be continued.• Severe damage with loss of mortar at the

surface can be corrected by diamond grinding to expose good concrete and provide texture.

• Caution: Be aware of rapid cooling of the surface after removal of the covering this can cause cracking.

HOT AND COLD WEATHER PROTECTIONHOT AND COLD WEATHER PROTECTION

CHAPTER 27


HOT WEATHER CONCRETINGHOT WEATHER CONCRETING• Current Specification – Nothing• HPC Specification

– Written temperature control plan– Temp exceeds 80 degrees F– Asphalt base moisture– 90 degrees – stop placement– Ice is in the spec, but not practical for paving



COLD WEATHER PROTECTIONCOLD WEATHER PROTECTION


QUESTION:QUESTION:

All things being equal, at what temperature does concrete cure to produce the strongest

and most durable concrete?


ANSWER:ANSWER:

42 °F

Crystalline structure grows slowly and completely


Cold Weather Concrete Paving Construction

Cold Weather Concrete Paving Construction

• Theoretical• WisDOT Specifications


Cold Weather - AggregatesCold Weather - Aggregates• Must not be frozen• Assures clumps of aggregate are not

incorporated


Cold Weather - SubgradeCold Weather - Subgrade• Issue boiled down:

– If the subgrade or base is frozen don’t pave.

• Steals heat from the hydration process• Can freeze the concrete at the interface


WisDOT Cold Weather HighlightsWisDOT Cold Weather Highlights• Suspend if a descending air temperature falls below 35 F• Resume if ascending air temperature reaches 30 F• If air temperature falls below 40 F contractor may be

required to measure temp at point of placement• Concrete temperature must be 50 F or greater at time of

placement• Contractor may heat water, aggregates or both• Once paving has started temperature of mix must be

between 50 F and 80 F• Can not:

– Heat cement– Add salt– Add chemical admixtures to prevent freezing

• Do not place on frozen base or subgrade


Cold Weather ProtectionCold Weather Protection• At any time of the year, if national weather service forecast of the

construction area predicts freezing temperatures within the next 24 hours, or when freezing temperatures actually occur, provide the minimum level of thermal protection specified below for concrete that has yet to conform to the opening criteria specified in 415.3.17 (3,000 psi compressive strength).

PREDICTED OR ACTUAL AIR TEMPERATURE

MINIMUM EQUIVALENT LEVEL OF PROTECTION

22 to <28 F Single layer of polyethylene17 to <22 F Double layer of polyethylene

<17 F 6” of loose, dry straw or hay between 2 layers of

polyethylene


Cold Weather ProtectionCold Weather Protection• HEART OF THE ISSUE - Contractor is

responsible for frozen concrete.

OPENING TO SERVICEOPENING TO SERVICECHAPTER 28



OPENING TO SERVICEOPENING TO SERVICE• Opening Cylinders• Equivalent Curing Days• Maturity


Opening Strength CylindersOpening Strength Cylinders• Field cured• Tested by the contractor• 3,000 PSI opening strength for concrete

pavement to construction or public traffic.• 2,500 PSI opening strength for gaps.• 2,000 PSI opening strength for concrete base

and concrete base patching if edge loading is greater than 6-inches from a free edge.

• If cylinders are lost, damaged or unavailable go to equivalent curing days concept.


Equivalent Curing DaysEquivalent Curing DaysMix Type Equivalent Curing DaysHigh early strength concrete 3General purpose concrete (grades A, A2, and A3) 4General purpose concrete (grades A-FA and A-IP) 5General purpose concrete (grades A-S, A-S2, A-IS, and A-T) 7

If the daily average temperature falls below 60 F, accumulate the equivalent curing days at a reduced rate. When the average ambient air temperature is 60 F or greater apply 1 equivalent curing day per calendar day. When the average ambient air temperature is 40 F to less than 60 F apply 0.6 equivalent curing days per calendar day. When the average ambient temperature is less than 40 F apply 0.3 equivalent curing days per calendar day.


MaturityMaturity

What is Maturity?What is Maturity?• Maturity describes a relationship between

time and temperature• Measured in “Celsius-degrees-hours”

(C°H)• Represents a “rate of change” • “Simple” to calculate – area under the time

& temperature curve (calculus)• “Discovered” (described) by Nurse and

Saul in 1950’s 2017 WCPA/WisDOT Concrete Pavement Inspection Workshop

What is Maturity?What is Maturity?• What did Nurse & Saul “Discover” ?• “Concrete of the same mix at the same

maturity (reckoned in temperature-time) has approximately the same strength whatever combination of temperature and time go to make up that maturity” (Saul 1951)


What does Maturity Look Like?What does Maturity Look Like?

-15

-10

-5

0

5

10

15

20

25

30

35

40

0 1 2 3 4 5 6Time (days)

Tem

pera

ture

(deg

rees

C) M0-1 =

1,036°C-H

M1-2 = 1,066°C-H

M2-3 = 1,004°C-H

M0-2 = 2,102 °C-HM0-3 = 3,106 °C-H

M3-4 = 923°C-H

M0-4 = 4,029 °C-H

Maturity is Measured in Degrees Celsius*Hours


Computing MaturityComputing Maturity

• Nurse-Saul – Linear Relationship – Simple, Easy to Use, Most Conservative,

Safest and Most Widely Used


What does Maturity Look Like?What does Maturity Look Like?Strength vs. Maturity

0

1000

2000

3000

4000

5000

6000

7000

0 5000 10000 15000 20000 25000

Maturity, C*H

Stre

ngth

, PSI

90 F7345

Strength vs. Time

0

1000

2000

3000

4000

5000

6000

7000

0 500 1000 1500Time, Hours

Stre

ng

th,

PSI

90 F7345


2 for maturity sensors

Fingerprint of your mix design using 17 cylinders

15 (5 sets of 3) for testing

CalibrationCalibration


0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

0 5,000 10,000 15,000 20,000 25,000

Maturity (ºC-Hours)

Com

pres

sive

Str

engt

h (p

si)

Day 1Average

Day 2Average

Day 4Average

Day 7Average Day 14

Average

Average

Temperature-Time Factor for each break

Generating a calibration curve


Calibration – Fingerprint of your mix design

ASTM-1074-A

Calibration – Fingerprint of your mix design

ASTM-1074-A


• Cast 4 verification cylinders• Embed sensor in one; test remaining three compressively• Verify that the concrete is within 10% of the calibration curve

ASTM 1074-B

• Validation – To verify that your mix design has not changed

Quality Control Using Maturity


0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

0 5,000 10,000 15,000 20,000 25,000


Com

pres

sive

Str

engt

h (p

si)

X

XX

X

X

X

Deviation of 10% or greater – investigate cause!

+10%

-10%

ASTM 1074-B• Validation – Does the batch fit the curve?

QA/QC Example


Convert Maturity to Strength (apply the calibration curve)

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

0 5,000 10,000 15,000 20,000 25,000


Com

pres

sive

Str

engt

h (p

si)

3000

2600 CH

75% Design Strength

Design Strength

Targeting 75% Design Strength, based on in-place strength measurements, accelerates work flow significantly!


Maturity BenefitsMaturity Benefits• Provides a better representation of in situ

concrete strength gain than laboratory or field cured specimens

• Enables anytime in situ strength measurements• Provides better timing for strength dependent

construction activities• Saves time and money compared to

conventional strength testing procedures• Enables in situ strength measurements at lowest

strength locations• Enables in situ strength measurements at critical

strength locations2017 WCPA/WisDOT Concrete Pavement Inspection Workshop

TROUBLE SHOOTING/LESSONS LEARNEDTROUBLE SHOOTING/LESSONS LEARNED

CHAPTER 29



TROUBLESHOOTING/LESSONS LEARNED

TROUBLESHOOTING/LESSONS LEARNED

• 26 currently in the manual• Will add additional items as they are

identified

APPENDIX AAPPENDIX A

Commonly Used Forms and Worksheets


FormsForms• DT 1307 Cementitious Materials Data Card• DT 1308 Concrete Cylinder Test Data Card• DT 1348 Sieve Analysis for Mixture of Fine and Coarse

Aggregates • DT 1349 Source of Materials Report• DT 1378 Static Load Test of Batching Scales• DT 1926 Automatic Controls and Tolerance Record for

PCC Plants • DT 2220 Determination of Field Batch Weights for

Concrete


WorksheetsWorksheets• WS 3010 Aggregate Moisture, Combined P200, and W/C Worksheet• WS 3011 Production Sample Locations• WS 3012 Combined Concrete Aggregate Gradation Worksheet• WS 3013 Placement Test Site Sample Locations• WS 3014 Aggregate Gradation Chart• WS 3015 Running Average Calculation Worksheet• WS 3016 Combined P200 Control Chart• WS 3017 Aggregate Gradation Control Chart• WS 5013 Ancillary Concrete Daily Test Report• WS 5014 Concrete Mixture Design• WS 5015 Sieve Analysis for Concrete Aggregate Worksheet • WS 5016 Air Content Control Chart for Concrete Pavement• WS 5018 Compressive Strength Cylinder Summary Table for Concrete Pvmt.


MiscellaneousMiscellaneous• Daily Portland Cement Inventory• Daily Fly Ash Inventory• PCC Cylinder Inventory


Discussion & QuestionsDiscussion & QuestionsFor Additional Information Contact:

Wisconsin Concrete Pavement Association4001 Nakoosa Trail, Suite 101

Madison, WI 53714

Phone: 608-240-1020Fax: 608-240-1019

www.wisconcrete.org
