Notice to Bidders: RFB WCSD-25-038 Repair and Replace Concrete Paving

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
PAVEMENT REHABILITATION
PART 1 - GENERAL
1.01 SECTION INCLUDES
A. Full and Partial Depth PCC Patches
B. Full and Partial Depth Asphalt Patches
C. Full Depth Composite Patches
D. Diamond Grinding
E. Milling
F. Cleaning and Filling Joints and Cracks
G. Curb and Gutter Replacement
H. Dowel Bar Retrofit
I. Core Hole Cutting and Replacement
1.02 DESCRIPTION OF WORK
A. Construct full depth PCC, asphalt, and composite patches.
B. Construct partial depth PCC and asphalt patches.
C. Grind existing PCC pavement surface for profile improvement using a diamond grinder.
D. Mill the surface of asphalt or PCC pavement to improve the surface profile and cross-section
in preparation for resurfacing.
E. Clean and fill longitudinal and transverse joints and random cracks in PCC and asphalt
pavement.
F. Remove existing pavement and curb and gutter.
G. Install epoxy coated dowel bars on transverse joints and cracks.
H. Cutting and replacement of pavement cores.
1.03 SUBMITTALS
Comply with Division 1 - General Provisions and Covenants, as well as the following:
A. PCC mix design.
B. Asphalt mix design.
1.04 SUBSTITUTIONS
Comply with Division 1 - General Provisions and Covenants.
1 Revised: 2023 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
1.05 DELIVERY, STORAGE, HANDLING, AND SALVAGING
Comply with Division 1 - General Provisions and Covenants, as well as the following:
A. PCC: See Section 7010.
B. Asphalt: See Section 7020
1.06 SCHEDULING AND CONFLICTS
Comply with Division 1 - General Provisions and Covenants.
1.07 SPECIAL REQUIREMENTS
None.
1.08 MEASUREMENT AND PAYMENT
A. Full Depth Patches:
1. Measurement: Measurement will be in square yards for each type and thickness of full
depth patch. Patches less than 2 square yards in area will be considered 2 square yards.
2. Payment: Payment will be made at the unit price per square yard for each type and
thickness of full depth patch.
3. Includes: Unit price includes, but is not limited to, sawing, removing, and disposing of
existing pavement and reinforcing; restoring the subgrade; furnishing and installing tie
bars and dowel bars; furnishing and placing the patch material, including the asphalt
binder and tack coat; forming and constructing integral curb; surface curing and
pavement protection; joint sawing and filling; and placing backfill and restoring disturbed
surfaces.
B. Subbase Over-excavation:
1. Measurement: Measurement will be in tons of subbase material placed for authorized
over-excavation.
2. Payment: Payment will be made at the unit price per ton of subbase material.
3. Includes: Unit price includes, but is not limited to, removal of existing subbase or
subgrade, disposal of materials removed, furnishing and placing subbase material, and
any additional excavation required for subbase placement.
C. Partial Depth Patches:
1. Measurement: Measurement will be in square feet for each type of partial depth patch.
Patches less than 1 square foot in area will be considered 1 square foot.
2. Payment: Payment will be made at the unit price per square foot for each type of partial
depth patch.
3. Includes: Unit price includes, but is not limited to, sawing, removing, and disposing of
existing pavement; furnishing tack coat or bonding agent; furnishing and placing the
patch material; curing; joint filling (PCC patches only); placing backfill; and restoring
disturbed surfaces.
2 Revised: 2023 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
1.08 MEASUREMENT AND PAYMENT (Continued)
4. Extra Payment: When partial depth patches are constructed to full depth at the direction
of the Engineer, payment will be at 2 times the unit price per square foot for each type of
partial depth patch.
D. Crack and Joint Cleaning and Filling, Hot Pour:
1. Measurement: Measurement will be in linear feet measured along the cracks or joints.
2. Payment: Payment will be made at the unit price per linear foot of crack and joint
cleaning and filling.
3. Includes: Unit price includes, but is not limited to, furnishing crack and joint filler material
and routing, sawing, cleaning, and filling joints or cracks.
E. Crack Cleaning and Filling, Emulsion:
1. Crack Cleaning and Filling, Emulsion:
a. Measurement: Measurement will be in linear feet measured along the cracks. Map
cracked areas will not be measured.
b. Payment: Payment will be made at the unit price per linear foot of crack cleaning
and filling.
c. Includes: Unit price includes, but is not limited to, furnishing emulsified crack filler
material, cleaning cracks, placing soil sterilant, and filling cracks.
2. Asphalt for Crack Filling:
a. Measurement: Measurement will be in tons of asphalt used for filling cracks greater
than 1 inch. Quantity will be based upon scale tickets. Mixture not used in the work
will be deducted based upon scaled weights.
b. Payment: Payment will be made at the unit price per ton for asphalt used in filling
cracks over 1 inch.
c. Includes: Unit price includes, but is not limited to, cleaning, applying tack coat, and
furnishing and placing asphalt for crack filling.
F. Diamond Grinding:
1. Measurement: Measurement will be in square yards for the area of diamond grinding.
2. Payment: Payment will be made at the unit price per square yard of diamond grinding.
3. Includes: Unit price includes, but is not limited to, diamond grinding pavement, testing
for smoothness according to the contract documents, and removal of slurry and residue
from the project site.
G. Milling:
1. Measurement: Measurement will be in square yards for the area of milling.
2. Payment: Payment will be made at the unit price per square yard of milling.
3. Includes: Unit price includes, but is not limited to, milling pavement; furnishing water;
and salvaging, stockpiling, and removing cuttings and debris.
3 Revised: 2023 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
1.08 MEASUREMENT AND PAYMENT (Continued)
H. Pavement Removal:
1. Measurement: Measurement will be in square yards. No deduction in area will be made
for manholes, storm sewer intakes, valve boxes, or other structures less than 2 square
yards in area. Pavement removal for patching is included as part of the patching item
and will not be measured separately.
2. Payment: Payment will be made at the unit price per square yard.
3. Includes: Unit price includes, but is not limited to, sawing, breaking, removing, and
disposing of existing pavement and reinforcing steel.
I. Curb and Gutter Removal:
1. Measurement: Measurement will be in linear feet measured along the back of curb.
2. Payment: Payment will be made at the unit price per linear foot of curb and gutter
removed.
3. Includes: Unit price includes, but is not limited to, sawing, breaking, removing, and
disposing of existing curb and gutter.
J. Dowel Bar Retrofit:
1. Measurement: Each size of dowel bars satisfactorily placed will be counted.
2. Payment: Payment will be made at the contract unit price for each size of dowel bar.
3. Includes: Unit price includes, but is not limited to, cutting the slots, preparing the slots,
placing and grouting the bars, and curing the surface.
K. Core Hole Cutting and Replacement:
1. Measurement: Measurement will be by count of the number of core holes replaced.
2. Payment: Payment will be made at the contract unit price per core hole replaced.
3. Includes: Unit price includes but is not limited to, cutting the core hole, vacuum
excavation, furnishing and placing backfill material and pavement, or replacing the
pavement core using waterproof bonding material, if specified.
L. Sampling and Testing: Required sampling and testing for pavement repair and
rehabilitation work is incidental to other project costs and will not be paid for separately.
4 Revised: 2023 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
PART 2 - PRODUCTS
2.01 MATERIALS
A. PCC:
1. Standard Patching: Use Class C mix complying with Section 7010. Comply with Iowa
DOT Materials I.M. 401. Construct all patches as standard patches unless otherwise
specified in the contract documents.
2. High Early Strength Patching: Use Class M mix complying with Section 7010. Do not
use calcium chloride unless otherwise specified in the contract documents.
3. Partial Depth Patching: Use a coarse aggregate in concrete mix complying with Iowa
DOT Article 4109.02, Gradation No. 5 in the Aggregate Gradation Table.
B. Asphalt: Provide a minimum Low Traffic (LT) mixture complying with Section 7020, unless
otherwise specified in the contract documents. Provide mixture with an asphalt binder
meeting or exceeding PG 58-28S.
C. Crack and Joint Filler Material:
1. Hot Pour Crack and Joint Filler: Comply with Iowa DOT Section 4136.
2. Emulsified Asphalt Crack Filler: Provide CRS-2 or CRS-2P emulsions complying with
Iowa DOT Section 4140.
3. Asphalt for Filling Cracks:
a. Provide a 3/4 inch, 1/2 inch, or 3/8 inch asphalt mixture complying with Section 7020,
or a similar mixture from a commercial source subject to approval from the Engineer.
b. Upon approval of the Engineer, a high performance bituminous cold premix may be
used, depending on the availability of the specified asphalt.
4. Blotting Material: Provide sand complying with Iowa DOT Sections 4124 or 4125, or
similar sand approved by the Engineer.
5. Soil Sterilant: Provide soil sterilant as specified in the contract documents.
D. Primer or Tack Coat Bitumen: Comply with Iowa DOT Article 2303.02.
E. Epoxy for Bonding Dowel and Tie Bars: Comply with Iowa DOT Materials I.M. 491.11.
F. Tie Bars and Dowel Bars: Provide epoxy coated bars complying with Iowa DOT Section
4151 or glass fiber reinforced polymer bars complying with Iowa DOT Section 4156.
G. Subbase Material: Unless otherwise specified in the contract documents, use modified
subbase complying with Section 2010.
H. Liquid Curing Compound: Comply with Iowa DOT Section 4105.
I. Sand-cement Grout: Provide a sand-cement grout mixture with a ratio of one part water to
one part sand and two parts cement.
J. Preformed Compression Relief Material: Provide 1/4 inch polystyrene, 1/4 inch
polyethylene, 1/4 inch Styrofoam, or 3/16 inch waxed coated cardboard.
5 Revised: 2023 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
2.01 MATERIALS (Continued)
K. Epoxy Coated Dowel Bars: Comply with Figure 7010.101 and Iowa DOT Section 4151 for
the length and diameter specified. Uniformly coat dowel bars with approved bond breaker
according to Iowa DOT Article 4151.02, B. Include tight fitting nonmetallic end caps that
allow a minimum of 1/4 inch movement at each end.
L. Dowel Chairs: Prevent movement of the dowel bar during grout placement with epoxy
coated or nonmetallic dowel chair devices which provide a minimum clearance of 1/2 inch
between the bottom of the bar and the surface upon which the bar is placed and also
between the bar and the end walls of the slot.
M. Caulking Filler: Any commercial caulk designed as a concrete sealant that is compatible
with the grout material being used.
N. Foam Core Inserts: Provide 3/8 inch 1/8 inch thick closed cell foam core board filler faced
with film, foil, or poster board material on both sides.
O. Rapid Set Patch Material:
1. Provide a shrinkage compensated rapid set patch material meeting Iowa DOT Materials
I.M. 491.20 and the following strength requirements:
* 3 hour minimum compressive strength of 3,000 psi according to ASTM C 39.
* 24 hour minimum compressive strength of 5,000 psi according to ASTM C 39.
2. Use grout material from packaged bags or proportioned on site from bulk cementitious
materials.
a. Extend packaged bags with pea gravel, proportioned and mixed according to the
manufacturer's recommendations. Fine aggregate additions and water in excess of
the manufacturer's recommendations are not allowed.
b. Use bulk cementitious materials equivalent in composition to the cementitious
materials used in packaged bags and proportioned with fine aggregate and water
and extended with pea gravel to produce a mixture equivalent to the packaged bag
mix meeting the manufacturer's recommendations. Water in excess of the
manufacturer's recommendations is not allowed.
c. Supply fine aggregates meeting Iowa DOT Section 4110.
3. Provide pea gravel with a minimum Class 2 durability meeting the requirements of Iowa
DOT Article 4112.03, B and Article 4109.02, Gradation No. 9 in the Aggregate Gradation
Table.
4. Use water meeting the requirements of Iowa DOT Section 4102. Potable water obtained
from a municipal supply, suitable for drinking, may be accepted without testing.
P. Backfill Material:
1. CLSM or foamed cellular concrete, per Section 3010, 2.06, if required by the Jurisdiction.
2. Class I granular material meeting Section 3010, 2.02, A or pea gravel complying with
Iowa DOT Article 4109.02, Gradation No. 21.
Q. Waterproof Bonding Material: Meet ASTM C 928 with a minimum bond strength of 1,500
psi at one day and 2,000 psi at 7 days. Carry an AASHTO H-25 truck load within 1 hour
when temperature is 50 degrees F.
6 Revised: 2021 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
PART 3 - EXECUTION
3.01 GENERAL
A. Conduct all operations to minimize inconvenience to traffic. Confine operations to one traffic
lane, unless the road is to be closed to traffic. Minor encroachment into the adjacent lane,
such as for sawing and installing forms, will be acceptable with the use of a flagger according
to MUTCD.
B. Do not remove pavement for either full depth or partial depth patching unless the patch can
be completed before the end of the working day.
C. Construct full depth and partial depth patches to the dimensions specified in the contract
documents or as marked by the Engineer in the field. Construct all full depth patches to full
panel width.
D. Make saw cuts parallel or perpendicular to the centerline.
E. Remove and dispose of materials not designated for salvage.
F. Restore the area outside the pavement by placing and compacting backfill material, placing
topsoil, and sodding or seeding as specified in the contract documents.
G. For pavement patches in areas removed to determine utility locations, replace pavement
according to Figures 7040.101, 7040.102, 7040.103, and 7040.107 as directed by the
Jurisdiction.
3.02 FULL DEPTH PATCHING
A. Pavement Removal:
1. Saw pavement to full depth at the edges of the patch. A second saw cut, 2 inches inside
the initial saw cut, may be required to prevent damage to adjacent pavement.
2. Do not damage pavement that is to remain. Do not use heavy equipment adjacent to
new concrete until the opening strength is achieved.
B. Restoring Subgrade or Subbase:
1. Excavate 2 inches below the bottom of the existing pavement. If more than 2 inches is
excavated, place and compact new subbase material as required to bring the subbase to
a level 2 inches below the bottom of the existing pavement. Correct unauthorized over-
excavation at no additional cost to the Contracting Authority.
2. Compact the exposed subgrade or subbase by a minimum of four complete passes with
a plate-type vibratory compactor with a minimum force rating of 3,500 pounds.
3. When unstable material or excessive moisture is encountered, the Engineer may order
removal and replacement of the unstable material.
a. Remove existing unstable subgrade or subbase, or both, to the depth directed by the
Engineer.
b. Place and compact new subbase material as required to bring the subbase to a level
2 inches below the bottom of the existing pavement.
C. Placing PCC Patches:
1. Equipment: Comply with Iowa DOT Article 2301.03, A, specifications on equipment for
standard concrete pavement.
7 Revised: 2021 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
3.02 FULL DEPTH PATCHING (Continued)
2. Tie Bars and Dowel Bars: Comply with Section 7010 and the figures in Sections 7010
and 7040.
a. When there is a common line between two adjacent patches, a bent bar may be
placed in a keyway and later straightened.
b. Coat dowel bars extending into the patch area with a bond breaker. Do not coat tie
bars.
3. Forms: Comply with Section 7010, 3.02, D, as well as the following.
a. Use forms on all exposed edges and along the centerline for patches that extend into
an adjacent lane, unless full pavement width patches are constructed.
b. Rigid wood forms may be used in lieu of steel.
4. Placing, Consolidation, and Finishing the Concrete:
a. Moisten the subbase or subgrade.
b. Except for preplanned joints, place the patch continuously until the patch is
completed.
c. When a delay of 45 minutes cannot be avoided, construct a day's work ('DW') joint.
d. Carefully place concrete into the patch area to avoid segregation; spread into place
and consolidate with a mechanical vibrator. Place full lane width patches over 25
feet in length with a suitable finishing machine that has at least one vibrating screed.
Avoid excessive vibrating.
e. Finish patches per Section 7010, 3.02, I.
f. For joints with tie bars, tool the edge. For joints with dowel bars, saw to a depth of
approximately 1 1/8 inch, leaving an opening of at least 3/8 inch in width to provide a
reservoir for joint filler.
g. Texture the patch to match the adjacent surface.
5. Curing: Comply with Section 7010, 3.02, J. Cure the concrete, including exposed
vertical edges, immediately after the concrete has been finished and the surface water
has evaporated.
6. Joints: Construct and fill joints according to Section 7010, 3.02. Place joints at locations
specified in the contract documents.
7. Pavement Protection: Comply with Section 7010, 3.04.
8. Use of Pavement: Comply with opening strength requirements of Section 7010, 3.05.
Maturity testing is not required.
D. Placing Asphalt Patches:
1. Use equipment complying with Iowa DOT Article 2303.03. Use of a paving machine is
not required.
2. Apply tack coat to the vertical edges of the remaining pavement at a rate of 0.10 to 0.15
gallons per square yard.
3. Place asphalt patch mixture in lifts that will not exceed 3 inches in thickness after
compaction, with the top lift not exceeding 2 inches in thickness when compacted.
4. Compact each lift while hot by rolling or compacting with a vibratory compactor.
Subsequent lifts may be placed as soon as the preceding lift has been properly
compacted.
8 Revised: 2023 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
3.02 FULL DEPTH PATCHING (Continued)
5. Smooth the final lift with a steel-tired finish roller. Ensure the final compacted surface is
level with, or no more than 1/8 inch above, the adjacent pavement and has a smooth
riding surface. If the patch becomes distorted for any reason, smooth the surface by
blading, scraping, grinding, filling, or other approved means.
6. Do not extend patch material beyond the edge of the existing pavement; remove patch
material that extends outside the patch limits.
7. Do not open to traffic until the mixture has cooled sufficiently to provide stability.
3.03 PARTIAL DEPTH PATCHING
A. Pavement Removal:
1. Ensure all patches are square or rectangular in shape.
2. For removal by the saw and chip method, cut at the designated removal limits to a
minimum depth of 2 inches and a maximum depth of T/2 or the top of the dowels in PCC
pavement. For PCC patches, taper the sides of the removal area 30 to 60 degrees from
vertical using a pneumatic hammer to eliminate the polished face.
3. Using a 15 pound maximum size pneumatic hammer, remove the deteriorated pavement
down to sound pavement. A 30 pound pneumatic hammer may be used if it does not
result in damage to the patch area and edges.
4. In lieu of sawing and removal with a pneumatic hammer, the designated patch area may
be milled to the prescribed depth. Milling equipment must provide tapered edges 30 to
60 degrees from vertical for PCC patches. Chip out secondary spalling resulting from
milling at no additional cost to the Contracting Authority.
5. Remove pavement to the appropriate depth. Do not damage steel reinforcement during
the removal process on PCC pavements. Damaged steel will be the responsibility of the
contractor. If the end of a dowel bar is exposed, cut and remove the bar. Place duct
tape, form oil, grease or use other method approved by the Engineer as a bond breaker
on dowels not removed. If the required depth to sound pavement exceeds the maximum
T/2 removal depth, construct a full depth patch.
B. PCC Patch Placement:
1. Clean removal area by sandblasting or water blasting, followed by airblasting, until the
area is clean and dry. Ensure the compressed air used for cleaning is oil and moisture
free. Place concrete the same day as cleaning.
2. Install preformed compression relief material in joints or cracks or tool the joint in the
plastic concrete. Use material equal in width to the adjacent joint or crack at the patch
boundary. For wide openings, use multiple thicknesses. Compression relief material is
to extend at a minimum of 1/4 inch below the bottom of the patch so as to completely
separate all patching material on both sides and 3 inches beyond the patch boundaries.
If tooling of the joint is specified, complete a relief saw cut to the full depth of the patch
plus 1/4 inch as soon as the concrete has reached proper set.
3. Thoroughly coat the bottom and sides of the patch area with a cement grout immediately
prior to placement of concrete. Do not allow grout to set prior to placement of concrete.
Remove grout set by sandblasting and reapply.
9 Revised: 2018 Edition

SUDAS Standard Specifications Division 7 - Streets and Related Work
Section 7040 - Pavement Rehabilitation
3.03 PARTIAL DEPTH PATCHING (Continued)
4. Deposit concrete in the patch; finish patch from the center outward. Ensure concrete
does not infiltrate into existing cracks or joints.
5. Apply joint filler material to expansion joints. At the interface between the patch and the
slab, apply sand-cement grout to fill and seal the edge. Position the grout so 1 inch is
over the surrounding pavement and 3 inches are over the patch.
6. Texture the patch similar to the adjacent surface.
7. Cure patch according to Section 7040, 3.02.
8. Fill joints according to Section 7040, 3.06. Complete filling within 5 calendar days after
patch is placed.
C. Asphalt Patch Placement:
1. Clean removal area by airblasting until the area is clean and dry. Ensure the
compressed air used for cleaning is moisture free.
2. Cover the entire removal area with tack coat at a rate of 0.10 to 0.15 gallons per square
yard.
3. Place asphalt patch mixture in lifts that will not exceed 3 inches in thickness after
compaction, with the top lift not exceeding 2 inches in thickness when compacted.
4. Compact each lift while hot by rolling with an adequately weighted pneumatic tire roller or
by tamping with a mechanical tamper. Succeeding lifts may be placed as soon as the
preceding lift has been properly compacted.
5. Smooth the final lift with a steel-tired finish roller. Ensure the final compacted surface is
level with, or no more than 1/8 inch above, the adjacent pavement and has a smooth
riding surface. If the patch becomes distorted for any reason, smooth the surface by
blading, scraping, grinding, filling, or other approved means.
6. Do not open to traffic until the mixture has cooled sufficiently to provide stability.
3.04 DIAMOND GRINDING
A. Use equipment complying with Iowa DOT Article 2532.03, A.
B. Grind and texture the entire surface of the pavement parallel to the centerline until the
pavement surface on both sides of transverse joints and all cracks are in the same plane with
no greater than 1/16 inch difference between adjacent sides of joints and cracks and the
pavement surface meets the required smoothness. Feather grind into existing structures
such as manholes and water valves in a manner that eliminates abrupt edges or drops and
provides a uniform texture.
C. Ensure the ground surface is of uniform texture. In each lane, ensure at least 95% of the
area in each 100 foot section has a newly textured surface. Depressed pavement areas due
to subsidence or other localized causes and areas containing feathering due to pavement
structures will be exempted from texturing requirements.
D. Except at joints and cracks, ensure grinding depth does not exceed 1/2 inch. At joints and
cracks, ensure grinding depth does not exceed 3/4 inch.
10 Revised: 2023 Edition