Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020)

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-17

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

accept the resin injection work represented by the core samples when the core samples indicate that
90% of the crack void greater than 0.15 mm wide has been filled with resin and the concrete of the
core sample is bonded through the crack into a unit.

When resin injection work does not satisfy the acceptance criteria, the Contractor shall perform the
work again and correct it as necessary at no expense to the Owner. The Contractor shall install
additional injection ports, as required, to achieve satisfactory reinjection of resin.

After resin injection work is completed and accepted, the Contractor shall fill the core holes with a
suitable proprietary epoxy mortar as approved by the Engineer.

29.6

Sealing Concrete Surfaces and Cracks

All  exposed  concrete  surfaces  for  structures  indicated  on  the  Contract  plans  not  to  be  painted  or
waterproofed shall be sealed by the Contractor using materials, surface preparation, and application
of  penetrant  sealers  and  high  molecular  weight  mathacrylates  as  applicable,  as  specified  in  this
section,  and  in  accordance  with  each  material  manufacturer

’s recommendations. The Contractor

shall consult with the Engineer in the event of conflict between a

manufacturer’s recommendations

and this specification. The Contractor shall perform surface preparation and application for all areas
as shown in the Contract plans or in accordance with the Engineer

’s directions.

29.6.1

Penetrant Sealers

Penetrant sealers shall meet the requirements outlined in this section.

29.6.1.1

Materials for Penetrant Sealers

The Contractor shall use alkylalkoxysilane penetrant sealers with 40% solids and active materials
dispersed in water. Such sealers shall meet the requirements shown in Table 29-3.

Table 29-3: Physical properties of penetrant sealers

Property

Characteristic

Appearance

Clear

VOC content (EPA method 24)

Less than 350 g/l

Flash point (ASTM D3278 - 96(2011))

Greater than 93

C SETA

Resistance to chloride ion penetration AASHTO T 259-
2002(R 2006) and AASHTO T 260-97 (2011)

Less than 0.18 kg/m

(criteria of 1.5)

at 12.5 mm level; 0.00 kg/m

(criteria

of 0.75) at 25 mm level

Water absorption test (ASTM C642 - 06)

0.50% maximum / 48 hours;

1.5% maximum / 50 days

NCHRP 244

Water weight gain

85% reduction (minimum)

Absorbed chloride

95% reduction (minimum)

Scaling resistance test (ASTM C672 / C672M - 12)

(Non-air-entrained concrete) 0 rating
No scaling (100 cycles)

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-18

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.6.1.2

Surface Preparation for Penetrant Sealers

The Contractor shall prepare concrete surfaces to receive a penetrant sealer in accordance with
these specifications, dependent on whether the surfaces are of recently cast concrete (new
construction) or of existing concrete.

a. Surface Preparation for New Construction

The Contractor shall remove substances such as dust, grime, dirt, curing compounds, form oil, and
debris by water blasting, light sandblasting, wire brushing, or any other methods that are acceptable
to the E

ngineer, all in accordance with the penetrant sealer manufacturer’s recommendations. As a

final cleaning operation, when using cleaning methods other than water blasting, the Contractor shall
wash cleaned surfaces with water as described in Section 4.3.8 of Chapter 4, Concrete Works, of
these standard specifications.

b. Surface Preparation for Existing Concrete

The Contractor shall remove substances such as dust, grime, dirt, stains, mineral deposits, oil,
bituminous materials, debris, and all other deleterious material by using water blasting equipment of
sufficient operating capacity and pressure, all in accordance with the penetrant sealer manufacturer’s
recommendations.

c. Cleaning Equipment for Penetrant Sealer

The Contractor shall use approved water blasting equipment to clean existing concrete surfaces.
The Contractor shall use water blasting equipment that is specifically manufactured to clean concrete
surfaces. Such equipment shall have a minimum rated nozzle capacity of 41.5 MPa using the spray
head proposed for use in the work.

d. Water for Blasting to Prepare for Penetrant Sealer

The Contractor shall use water that meets the requirements outlined in Section 4.3.8 of Chapter 4,
Concrete Works, of these standard specifications.

e. Method for Cleaning Concrete Surface for Penetrant Sealer

During the cleaning operation, the Contractor shall be sufficiently careful to minimize the removal of
the  concrete  matrix.  The  Contractor  shall  furnish  hand  tools,  power  grinders,  and  other  similar
equipment  to  remove  materials  that  cannot  be  removed  by  water  blasting  without  abrading  the
concrete matrix beyond acceptable limits. As a final cleaning step, the Contractor shall use water
blasting equipment to wash all concrete surfaces that have been cleaned by other methods.

The Contractor shall limit the duration of water blasting to provide a light abraded surface. The
Contractor shall not allow surface abrasion to exceed 0.4 mm. The Engineer may not require further
cleaning of stains that are still apparent after abrading to a depth of 0.4 mm. The Contractor shall
avoid exposing coarse aggregate to water blasting.

If any concrete surfaces become contaminated after cleaning, the Contractor shall clean them again
at no expense to the Owner before applying the penetrant sealer.

29.6.1.3

Application of Penetrant Sealers

The Contractor shall apply a penetrant sealer only to surfaces that have been prepared in
accordance with these specifications and in a way that has been approved by the Engineer. When
applying penetrant sealer, the Contractor shall comply with the specifications in this article and the
penetran

t sealer manufacturer’s recommendations.

Before applying any penetrant sealer, the Contractor shall cure concrete for at least 21 days.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-19

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

The Contractor shall apply penetrant sealer no later than ten days after completing the surface
preparation, in a way determined by the Engineer, before any contamination of the prepared
surfaces.

a. Equipment for the Application of Penetrant Sealer

The Contractor shall apply the penetrant sealer using any suitable air or airless sprayer with an
operating pressure of approximately 0.14 MPa.

b. Limitations to the Application of Penetrant Sealer

The Contractor shall apply penetrant sealer material only when the ambient air temperature is
between 10º C and 32º C. The Contractor shall apply penetrant sealer only to concrete surfaces that
have dried for at least 48 hours after water last contacted the concrete surfaces. A penetrant sealer
shall not be applied when winds are blowing 40 km/h or more, during rainfall, or when water spray
or mist is present.

c. Method for Applying Penetrant Sealers

The Contractor shall apply penetrant sealer only to concrete surfaces that have been prepared in
accordance with the requirements and limitations set forth in the specifications of Article 29.6.1.3.
To determine the actual coverage rate in square metres per gallon, the Contractor shall conduct a
field trial at the beginning of any penetrant sealer application operation. The Contractor shall conduct
additional  confirmation  field  trials  once  for  every  465  square  metres  of  sealant  applied,  on  each
production day during the application process, or when the character of the work changes, whichever
occurs sooner. For each field trial, the Contractor shall determine the optimum coverage rate for 46.5
square  metres  of  surface  area.  The  Contractor  shall  maintain  a  rate  of  application  that  ensures
coverage  of  from  14.4  to  20.9  square  metres  per  gallon  of  penetrant  sealer  used.  Application  of
penetrant sealer shall be uniform, without puddling or skips. The Contractor shall use a squeegee to
redistribute any penetrant sealer that, after application, puddles in low areas over concrete surfaces.

Generally, the Contractor shall begin applying penetrant at the lowest elevation and proceed upward
to higher elevations.

The Contractor shall maintain operating pressures in the sprayers used for application of the
penetrant sealer material sufficiently low to prevent atomization or misting of the material.

29.6.1.4

Control of Concrete Sealing Materials

The Contractor shall control sealing materials in accordance with the specifications and requirements
outlined in this article.

a. Packaging and Identification of Concrete Sealing Materials

The Contractor shall deliver the penetrant sealer to the Project in unopened, sealed containers with
the manufacturer’s label identifying the product and with numbered seals intact. The Contractor shall
ensure that each container is clearly marked by the manufacturer with the following information:

•

Man

ufacturer’s name and address

•

Product name

•

Date of manufacture

•

Expiration date

•

Lot identification number

•

Container serial number

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-20

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Manufacturer’s Certification for Penetrant Sealer

The Contractor shall give the Engineer a certification from the manufacturer that confirms that the
penetrant sealer meets the requirements outlined in Article 29.6.1.4. The Contractor shall not
incorporate sealer into the Project until the Engineer has accepted and approved the certification for
the material. The Contractor shall submit such certification for each lot of material delivered to the
Project. In each certification, the Contractor shall identify the serial or lot numbers of the containers
certified.

c. Sampling Sealing Materials for Tests

The Engineer may require samples from each lot or container of materials delivered to the Project
or from containers at the point of use. When samples are required, the Contractor shall furnish
samples in accordance with the E

ngineer’s instructions.

d. Storage of Sealing Materials

The Contactor shall store materials delivered to the job site in original unopened containers within
an appropriate storage facility. The Contractor shall use a storage facility that provides protection
from the elements and safe and secure storage of the materials.

e. Disposal of Unused Sealing Materials

The Contractor shall not return unused material in opened containers to storage for later use. The
Contractor shall either apply such material to appropriate areas on concrete surfaces or remove and
dispose of it at offsite locations that have been provided by the Contractor.

f. Acceptance of Sealing Materials

The Engineer shall accept an application of penetrant sealer after determining that the Contractor
has properly cleaned all surface areas to be sealed and has applied the penetrant sealer within the
required rates of application.

29.6.2

High Molecular Weight Methacrylate Sealers

The Contractor shall perform the surface preparation and application of a high molecular weight
methacrylate (HMWM) to seal cracks on horizontal and slightly sloped concrete surfaces in a manner
approved by the Engineer. Applications on bridge decks and other concrete roadway surfaces
require the addition of sand over the treated areas to increase the friction (skid) number, as described
in ASTM E274 / E274M - 11.

The Engineer must approve the rate of application (amount of sealant in cubic metres per square
metre of concrete), the application method, and equipment before the Contractor shall commence
working.  The  Contractor  shall  submit  a  written  sealer  application  plan  based  on  the  total  area  of
cracked  surfaces,  size  and  depth  of  cracks,  and  internal  conditions  of  cracks  to  the  Engineer  for
approval.  In  addition,  the  Contractor  shall  provide  at  least  14  days  advanced  notice  to  enable
personnel from the Owner to be present at the beginning of work to evaluate the cracks and provide
final  approval  of  the  application  rate.  The  Contractor  shall  make  arrangements  with  the  material
manufacturer to provide on-site technical assistance for the initial application and to certify that the
mixing ratio, application methods, and sand broadcasting are correct and in accordance with their
recommendations.

The Contractor shall maintain a daily log of resin material used, which shall be verified by the
Engineer. In this log, the Contractor shall include the drum or container identification number, the
date, and the location of use. The Contractor shall retain the empty resin containers at the jobsite
until the Engineer verifies the use of the resin and authorizes removal of the containers from the site.

29.6.2.1

Materials for a Methacrylate System

A methacrylate system shall consist of the following three components:

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-21

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

•

Methacrylate monomer

•

Cumene hydroperoxide (CHP) initiator

•

Cobalt promoter

The Contractor shall use an HMWM monomer that has been approved by the Engineer. The
Contractor shall use an initiator and promoter that have been recommended and produced by the
same monomer manufacturer. The manufacturer shall submit the following documentation for the
Engineer’s approval:

•

Manufacturer’s material installation instructions showing that the product can be installed in
accordance with the requirements in this article.

•

Independent laboratory test data and results showing that the product has been tested in

accordance with the requirements of this article and meets the requirements.

a. Properties of Methacrylate Material

The Contractor shall use a methacrylate material that meets the physical and performance
requirements outlined in Table 29-4 .

Table 29-4: Physical properties of methacrylate resin

Property

Characteristic

Viscosity (Brookfield RVT)

14-20 cps at 50 rpm

Density (ASTM D1481 - 02(2007))

1,018

– 1,078 kg/m

at 25

Flash point (ASTM D3278 - 96(2011))

> 93

C (Pensky Martens CC)

Odour

Low

Bulk cure speed

3 hours at 23

C (maximum)

Surface cure

8 hours at 23

C (maximum)

Gel Time (ASTM D2471-99)

60 minutes (maximum)

Tack free time

5 hours (maximum) at 22

C and

50% relative humidity

Compressive strength (AASHTO T 106M/T 106-12)

45 MPa (minimum)

Tensile Strength (ASTM C307 - 03(2012))

9.0 MPa (minimum)

Shear bond adhesion (ASTM C882 / C882M - 12)

4.5 MPa (minimum)

Wax content

All three components of the methacrylate system shall have a shelf life of at least 12 months and
shall be no more than 8 months old at the time of application. The Contractor shall provide each
container shipped to the job site with the following information on a manufacturer’s label:

•

manufacturer’s name

•

product name

•

lot or batch number

•

date of production

•

drum serial number

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-22

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

The Contractor shall identify the catalysts by their generic classification and provide the date of
manufacture for each.

b. Sand for a Methacrylate System

The Contractor shall use uniformly graded 0.2 - 0.6 mm (or similar), clean, bagged, blast sand for
spreading over the applied material on bridge decks and other riding surfaces as recommended by
the manufacturer. They shall certify that the sand has a maximum moisture content of 0.25% or less
and that the maximum amount of dust or other material that may pass through a No. 200 sieve does
not exceed 0.75%.

The Contractor shall store the sand at a location that will preserve the above described conditions
and characteristics of the sand until it has been applied.

29.6.2.2

Surface Preparation for a Methacrylate System

Preparing a surface for a methacrylate system requires cleaning and containment.

a. Cleaning a Surface for a Methacrylate System

On the day of application, the Contractor shall thoroughly power sweep the area to be treated to
remove all dust, dirt, and debris. On bridge decks and other riding surfaces, the Contractor shall use
a tractor-mounted power broom with non-metallic bristles (or a suitable alternative tool) that is
suitable for the intended purpose. The Contractor shall use a power vacuum after sweeping when
sealing cracks on grooved bridge decks. The Contractor shall clean the deck again as necessary
just before the application to remove debris that may have been blown back onto the work area by
adjacent traffic or other means. If oils and oil-based substances are present, the Contractor shall
remove them from the concrete surface using an approved solvent.

b. Containing Sealing Material for a Methacrylate System

The Contractor shall provide adequate containment to prevent the sealer material from flowing
beyond the designated area of application. The Contractor shall plug any drain holes or openings
within the work area. Airborne material shall be prevented from dispersing onto open traffic lanes or
outside the work area.

29.6.2.3

Method for Applying Methacrylate

When applying methacrylate, the Contractor shall comply with the standards and requirements
outlined in this article.

a. Equipment for Applying Methacrylate

The Contractor shall apply the material according to the manufacturer’s specifications using mobile
equipment capable of distributing material on large areas of decks and riding surfaces. Such material
shall be applied by hand using adequate containers for isolated or localized applications.

b. Mixing Methyl Methacrylate

The Contractor shall mix the methylmethacrylate material following the manufacturer’s specified
mixing proportions for the catalysts. Initial mixing shall be performed by equally dividing the resin to
be used into two separate containers. In all instances, the Contractor shall mix the initiator (CHP) at
the HMWM manufacturer’s specified volume with 50% of the monomer resin in one container and
the cumene promoter

at the HMWM manufacturer’s specified volume with the other 50% in the

second container. After properly blending the monomer resin and cumene promoter, the Contractor
shall combine the two resins and mix them in accordance with the manufacturer’s instructions. For
spray bar application, the Contractor shall mix the activator and resin blend and the promoter and
resin blend through a static mixer in the feed line that is located ahead of the material distribution
bars where polymerization will start. The Contractor shall calibrate the valves to the static mixer to
ensure a one to one mixing ratio of the two blends.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-23

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

c. Mobile Distribution Method for Material Application

The Contractor shall apply the material only under weather conditions recommended by the
manufacturer and when no rainfall has occurred during the previous 48 hours and no rain is expected
for the next 6 hours following completion of the application. Unless the Engineer directs otherwise,
the Contractor shall distribute the monomer uniformly over the work area using a pressure nozzle or
spray head distribution bar system. The Contractor shall provide feed to the distribution bars using
positive displacement pumps that move equal amounts of the two monomer blends from two
calibrated drums.

Material application equipment shall be calibrated to mix the two monomer blends to the
recommended ratio (by volume) within ±5%. The Contractor shall calibrate discharge volume to the
moving speed to provide a discharge rate capability ranging from 1,230 to 4,900 m

at a pressure

ranging from 0.10 to 0.41 MPa.

A typical application rate of the material is approximately 2,450 m

. Before the Contractor applies

the monomer, the Engineer will determine the final production application rate based on the internal
characteristics of the cracks as determined from the cores that the Contractor supplied that the
Engineer approves as being representative of the overall cracking conditions.

d. Localized Distribution Method for Material Application

In localized small areas or areas where the Engineer considers the use of mobile distribution
equipment to be impractical, the Contractor shall distribute the material by hand over the work area
using pails or other suitable containers that are adequate for the size of the area. In areas that the
Engineer deems to be sufficiently large, the Contractor shall use mobile distribution equipment.

The Contractor shall apply the material only under weather conditions recommended by the
manufacturer and only on areas that have remained dry for at least 48 hours. The Contractor shall
ensure that the area remains dry for the next 6 hours following completion of the application.

e. Sealing of Cracks

Regardless of the method used to apply the material over a concrete surface, the Contractor shall
work the material back and forth over the cracks to maximize the amount of material to be absorbed
by the cracks. The Contractor shall move the material over the cracks using brooms, squeegees, or
paint brushes, as appropriate for the size of the area. The Contractor shall commence this operation
immediately after distributing the material on the concrete surface. This operation shall be continued
until no additional material is flowing inside the cracks or the material begins to exhibit signs of
polymerization.

The Contractor shall not distribute material over areas larger than what the available personnel can
effectively work over the cracks within the limits of the pot life.

f. Sand Distribution after Material Application

The Contractor shall apply sand over the monomer-treated area within a timely period after the
application of the material. This length of time shall be based on

the manufacturer’s

recommendations for the existing conditions. The Contractor shall use equipment that will produce
a uniform distribution of the sand over the treated area. Any wheel-mounted sand spreader used
shall have pneumatic tires that are compatible with the treatment material and that leave no tire
footprints on the deck surface.

The Contractor shall use an initial application rate of 3.25 (±0.027) kg of sand per square meter of
treated area, and adjust the rate as necessary to produce a skid number (SN) of no less than 25 at
24 hours and 30 at 7 days as described in ASTM E274 / E274M - 11. The Contractor shall coordinate
with the Engineer to conduct a preliminary on-site skid test to determine the actual sand application
rate prior to the beginning of production application. If friction numbers below those specified are
obtained, the Contractor shall completely remove all loose sand from the surface and apply the
material again at a rate of 3,680 m

/ m

, spreading additional sand as necessary to achieve the

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-24

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

specified skid numbers. The Contractor shall remove surface material by grinding or other approved
method if satisfactory friction values are not achieved. In accordance with the Engineer’s directions,
the Contractor shall conduct friction tests.

29.6.2.4

Opening Roadway Surfaces to Traffic

The Contractor shall protect the sand covered area from vehicular traffic until the material has fully
cured. When curing is complete, the Contractor shall use a power vacuum to remove excess sand
from the riding surface before opening the area to traffic.

29.6.2.5

Cure Test

The Contractor shall test curing on the treated area using a cotton strand or cotton ball. The
Contractor shall consider the material fully cured and ready for traffic when the material does not
adhere to the cotton ball when pressed against the treated surface and then pulled away. Before
reopening the area to traffic, the Contractor shall obtain approval from the Engineer.

29.7

Epoxy Compounds

When using epoxy compounds, the Contractor shall comply with the standards and requirements
outlined in this section.

29.7.1

Types of Epoxy Compounds

Epoxy resin compounds for the application to Portland cement concrete, bituminous cement
concrete, metals, and other type surfaces shall be two component systems of applicable types, as
designated in Table 29-5.

Table 29-5: Types of epoxy compounds

Type

Description

An epoxy resin, for bonding fresh concrete to hardened concrete.

An epoxy resin adhesive, for bonding hardened concrete to hardened
concrete and constructing doweled splices in precast prestressed concrete
piles.

A fluid epoxy for crack injection in the repair of old structures.

F-1
F-2

An epoxy for repairing spalled areas on concrete bridge structures with
these subtypes:

•

A non sagging gel type for vertical surfaces.

•

A pourable type for repairs where forms are to be used.

An epoxy for rebuilding expansion joints and associated wearing surfaces.

An epoxy for structural bonding where asphalt overlays are to be in
contact with the hardened compound.

An epoxy for filling small holes in concrete such as lifting bolt cut-outs on
beams, etc.

An epoxy for installing rebar and anchor bolts into hardened concrete.

An epoxy for underwater sealing of the bottom of the jacket of an integral
pile jacket system.

An epoxy for coating the interior of sewage disposal tanks.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-25

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Type

Description

A coal tar epoxy coating for steel sheet piles and H piles (water
immersion).

An epoxy for preparing mortars and concrete for patching Portland cement
concrete pavement.

An epoxy for bonding metals.

An epoxy for use in post tensioning anchorage protection systems.

Hot applied coal tar epoxy tape.

29.7.2

Epoxy Design Requirements

All types of compounds, except L and M, shall contain no volatile solvent.

All types of compounds, except F, J, L, M, and N, shall be basically pure reactive material with a
maximum ash content of 2%.

All types of compounds shall have simple mix ratios of one-to-one or two-to-one or shall be supplied
in pre-measured containers in which all of the contents of both packages are to be mixed.

Epoxy design terms have the following meanings:

Low modulus:

A stress-strain property for which ultimate tensile strength is attained at over
10% elongation.

High modulus:

A stress-strain property for which ultimate tensile strength is attained at under
6% elongation.

Non-sagging gel:

Grades of mixed compounds that will not perceptibly flow under their own
weight on a vertical surface in their unhardened state.

Pourable:

Grades of mixed compound that are sufficiently fluid that they (either neat or
filled) can be cast into a mould and will take the shape of that mould.

29.7.2.1

Certifications for Epoxy Products

The Contractor shall give the Engineer certification documents from the manufacturer of the epoxy
confirming that the epoxy meets the requirements outlined in Section 29.7.2. Each such certification
shall cover one batch of epoxy materials and shall conform to the specifications in Section 29.7.

29.7.3

Specific Requirements for Type A and Type B Epoxy
Compounds

Type A and type B epoxy compounds shall comply with the requirements outlined in this section.

29.7.3.1

Mixing and Applying Type A and Type B Epoxy Compounds

Types A and B epoxy compounds (for bonding fresh concrete to hardened concrete or bonding
precast concrete parts) shall be m

ixed, applied, and cured in accordance with the manufacturer’s

directions, or as might be directed otherwise by the Engineer.

Epoxy compounds shall be used only under conditions that are compatible with the material being
applied and in accordance with the specific directions of their manufacturers. Extreme care shall be
taken to avoid a de-bonding effect after the application.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-26

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.7.3.2

Performance Tests for type A and type B Epoxy Compounds

The Contractor shall test type A and type B epoxy compounds in accordance with the specifications
in this article.

•

Epoxy Bonding Compounds shall be prepared and tested in accordance with FM 3-C882 to

ensure that the ratio of the compressive strength of the composite cylinder to the compressive
strength of the weaker concrete is not be less than 0.90.

•

Epoxy mortar shall be prepared and tested in accordance with FM 3 C-882 to ensure that the

average compressive strength of the three test specimens is at least 34.5 MPa.

29.7.4

Specific Requirements for Type E Epoxy Compounds

In addition to the specifications for type B compounds, type E epoxies (which are used for crack
injection) shall also comply with the requirements shown in Table 29-6. The epoxy resin compound
shall be used only for dry cracks.

Table 29-6: Additional requirements for type E epoxy compounds

Property

Characteristic

Viscosity five minutes after mixing

300 to 600 cps at 25

C by ASTM D2393-86

Wet bond strength to concrete (minimum)

1.72 MPa at seven days by FM 5-518

29.7.5

Specific Requirements for Type F Epoxy Compounds

Type F epoxies (which are for repairing spalled areas) shall meet the requirements in this section.
For repairs to surfaces, including vertical surfaces, subtype F-1 epoxy shall be a trowellable, low
modulus, non-sagging gel epoxy compound that can bond to wet surfaces with the properties shown
in Table 29-7.

Table 29-7: Properties for subtype F-1 compounds

Property

Characteristic

Colour

Match gray in accordance with instructions from the
Engineer

Viscosity

Gel

Maximum sand loading

2.25 parts sand to one part mixed epoxy by volume

Elongation in tension (minimum)

10% by ASTM D638 - 10, seven day cure

Wet bond to steel and concrete (minimum) 1.72 MPa by FM 5-518

For filling larger spalls where a form is required to build back to the original surface, subtype F-2
shall be a pourable, low modulus compound that can bond to wet surfaces with the properties shown
in Table 29-8.

Table 29-8: Properties for subtype F-2 compounds

Property

Characteristic

Colour

Match gray in accordance with instructions from the
Engineer

Maximum sand loading

2.25 parts sand to one part mixed epoxy by volume

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-27

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Property

Characteristic

Elongation in tension (minimum)

10% by ASTM D638 - 10, seven day cure

Exotherm

C by ASTM D2471-99, one pint sample

Wet bond to steel and concrete (minimum) 1.72 MPa by FM 5-518

29.7.6

Specific Requirements for Type G Epoxy Compounds

Type G epoxies (which are for rebuilding expansion joints) shall be pourable epoxies that can mix
with sand and meet the requirements shown in Table 29-9.

Table 29-9: Requirements for the mix of type G epoxy compounds

Compressive strength

Characteristic

At 24 hours (minimum)

31.03 MPa

At seven days (minimum, by the method
outlined in Article 29.7.3.2)

51.71 MPa

Bond to wet concrete at seven days (by
FM 5-518)

1.72 MPa

Maximum sand loading

2.25 parts to one part mixed epoxy by volume

Elongation in tension at seven days
(minimum, based on ASTM D638 - 10)

Colour

Natural

Exotherm (maximum, by test method
ASTM D2471-99, one pint size)

29.7.7

Specific Requirements for Type H Epoxy Compounds

Type H epoxies (which are for structural bonding where bituminous pavement overlays will come in
contact with the hardened compound) shall meet the requirements for type A and type B compounds.
In addition, the manufacturer shall provide test data that shows that cutback and emulsified asphalts,
asphalt cement, and bituminous mixes shall bond to but not soften or otherwise damage the epoxy
after a curing period of four days.

29.7.8

Specific Requirements for Type I Epoxy Compounds

Type I epoxies (which are for cosmetic patching of small areas on new concrete structures and
components) shall be of any non-sagging grade that has a gray colour, as selected by the Engineer,
and that has been demonstrated to the Engineer to bond satisfactorily to the concrete.

29.7.9

Specific Requirements for Type J Epoxy Compounds

Type J epoxies (which are for installing rebar and anchor bolts into the hardened concrete) shall
meet the requirements of Section 29.8 and shall be installed in accordance with the directions in
Section 29.9. When the Contract documents call for the use of Type J, Class I, II, III, IV, epoxy or a
Class IV Adhesive Anchor System, the Contractor shall use materials that meet the requirements of
Section 29.8, constructed in accordance with Section 29.9.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-28

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.7.10

Specific Requirements for Type K Epoxy Compounds

Type K epoxies (which are for sealing the bottom of integral pile jackets in the repair of concrete
piles) shall harden underwater and meet the requirements outlined in Table 29-10 for the sand-epoxy
mix.

Table 29-10: Requirements for the sand epoxy mix of type K compounds

Property

Characteristic

Compressive strength at seven days (minimum,
by the method outlined in Article 29.7.3.2)

31.03 MPa

Bond

Bond to wet concrete (minimum)

1.72 MPa

Bond to wet pile jacket (minimum, by Florida
Method FM 5-518)

1.03 MPa

Maximum sand loading

2.25 parts to one part mixed epoxy, by
volume

Viscosity of mixed epoxy component at 25°C,
five minutes by ASTM D2393-86

1,000 to 2,000 cps

An epoxy sand mix shall be capable of flowing through water in the void area of the jacket to provide
a water tight seal of the depth indicated on the Contract plans or approved shop drawings and to
maintain this seal during subsequent construction steps.

29.7.11

Specific Requirements for Type L Epoxy Compounds

Type L epoxies (which are for coating the interior of sewage disposal system tanks) shall be of an
approved type. Manufacturers shall submit data and a record of previous usage showing satisfactory
performance in the protection of concrete from the aggressive effect of sewage for a five year
minimum to the Engineer.

29.7.12

Specific Requirements for Type M Epoxy Compounds

Type M epoxy coatings (which are for steel sheet and H piles used in bridges, fender systems and
other structures that are subject to immersion in water) shall comply with the requirements of US
Army Corps of Engineers Guide Specifications (USACE C-200). Products not meeting these
requirements may be approved by the Engineer on the basis of data furnished by the manufacturer
that documents equal or superior performance.

29.7.13

Specific Requirements for Type N Epoxy Compounds

Type N epoxy adhesives (which are for making epoxy mortar or concrete for patching Portland
cement concrete pavement) shall be any of approved products listed at the time of the work. The
Contractor shall submit mix designs for mortar and concrete to the Engineer at the time of the
preconstruction conference. To obtain approval, the Contractor shall conduct a field demonstration
that verifies that the epoxy meets the criteria of bonding to the pavement, matching colour, having
sufficient durability, and lacking excessive surface slicking under traffic flow.

Basic approval of new adhesives shall be made by the Engineer using a six month road test with
mortar-concrete mix designs as recommended by the epoxy manufacturer.

29.7.14

Specific Requirements for Type Q Epoxy Compounds

Type Q epoxy materials (which protect anchorages of posttensioning tendons or bars and may serve
other uses indicated in the Contract plans) shall produce a low exothermic reaction and have flow

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-29

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

and fill characteristics that are suitable for machine base plate applications. Such material shall be
extended with the aggregate supplied by the manufacturer. The Contractor shall mix with the full
aggregate loading unless the use of less aggregate is approved by the Engineer.

Such material shall be factory pre-proportioned and shall include factory-supplied aggregate. The
Contractor shall deliver such products in their original containers with the

manufacturer’s name, the

date of manufacture, a product identification label, and batch numbers. Such materials must be
within the manufacturer’s recommended shelf life. The Contractor shall store and condition the
product in full compliance with manufacturer’s recommendations.

Epoxy grout plus aggregate mix shall meet or exceed the specified physical properties stated in this
section as determined by the standard ASTM test methods identified in Table 29-11.

Table 29-11: Standard ASTM test methods for epoxy grout plus aggregate mix for type Q

epoxy

Property

Test value

Test method

Compressive strength cubes seven day
cure at 25

> 68.95 MPa

ASTM C579 - 01(2012)
Test Method B

Tensile strength at seven days

> 14.48 MPa

ASTM C307 - 03(2012)

Flexural strength at seven day cure at 25

C > 24.82 MPa

ASTM C580 - 02(2012)

Modulus of Elasticity, seven day cure at 25

< 14,480 MPa

ASTM C580 - 02(2012)

Coefficient of thermal expansion at 23

< 36 x 10

-6

mm/mm/

ASTM C531 - 00(2012)

Peak exotherm, specimen
300 mm x 300 mm x 75 mm

< 66

ASTM D2471-99

Slant shear at seven days (bond strength to
concrete)

> 20.68 MPa

ASTM C882 / C882M - 12

Thermal compatibility

Five cycles passed

ASTM C884 / C884M -
98(2010)

Linear shrinkage at seven days

0.025%

ASTM C531 - 00(2012)

Flowability and bearing area

90% contact area

ASTM C1339 - 02(2012)

Gel time, specimen
300 mm x 300 mm x 75 mm

< 4.00 hours

ASTM D2471-99

29.7.15

Specific Requirements for Type T Tape Compounds

Type T hot applied coal tar epoxy tape (which protects tie back rods on sheet pile walls and
bulkheads) shall comply with the requirements of the ANSI/AWWA C203-08. Application shall
comply with the manufacturers

’ published recommendations.

29.7.16

Packaging, Labelling, and Safety for Epoxy

All containers shall be identified as Component A - contains epoxy resin or Component B - contains
hardener, and shall show the type, mixin

g directions, batch numbers, manufacturer’s name, date of

packaging, shelf life expiration date and quantity (in kilograms or liters). Mix ratios shall be
prominently shown on labels. Potential hazards shall be stated on each package in accordance with
the Federal Hazardous Products Labeling Act.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-30

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.7.17

Storage of Epoxy

The Owner shall not accept the use of epoxy materials that have been in storage for more than 12
months.

29.7.18

Fillers for Mixing Mortars and Grouts

Fillers for mixing mortars and grouts may be as recommended by the manufacturer of the particular
epoxy compound and may be supplied as packages accompanying the epoxy or premixed in
accordance with approved properties.

If a manufacturer recommends only the gradation of filler, it shall be a silica sand that is commercially
available in UAE and shall be a gradation listed in Table 29-12 or a specified blend of these
gradations.

The silica sands specified in Table 29-12 shall be clean, kiln dried, packaged in strong moisture proof
bags, and be chloride free. They shall contain no more than 0.2% organic trash.

Fillers shall not be used with type E, type J, type L, or type M compounds.

When the fillers specified in Table 29-12 are used, the maximum amount shall be 2.25 volumes to
one volume of mixed compound.

Table 29-12: Gradation requirements for fillers for use with epoxy compounds

Grade

D**

Sieve opening size

Required passing percentage

No. 4

95-100%

No. 6

90-100%

No. 8

0-15%

85-100%

No. 16

65-97%

No. 20
No. 30
No. 50
No. 100

80-100%

0-40%
0-10%

0-20%

25-70%

5-35%

0-7%

*For use only in sections 38 mm or greater in thickness.

**Same as quartz sand fine aggregate for cement concrete.

29.8

Adhesive Bonding Material Systems

Adhesive bonding material systems for structural applications shall consist of pre-packaged two-part
chemical components. Material systems shall be specifically intended for use in structural
applications for bonding anchors and dowels to hardened concrete. Applications are limited to
anchors and dowels installed in positions ranging from vertically downward to horizontal.

The Contractor shall not use material from containers that are damaged or have been previously
opened. The Contractor shall use only full packages of components and shall not combine epoxy
bonding components from bulk supplies.

Material systems for Type HV (High Viscosity) and Type HSHV (High Strength and High Viscosity)
shall be pre-packaged to automatically proportion and mix the materials for use. The Owner shall
not permit the Contractor to manually proportion components.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-31

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Type HV Adhesives:

The Contractor shall use Type HV adhesive bonding materials for all horizontal

installations and vertical installations other than constructing doweled pile splices, except when Type
HSHV is required. Type HV adhesives may not be substituted for Type HSHV adhesives.

Type HSHV Adhesives:

The

Contractor shall use higher strength Type HSHV adhesive bonding

materials to install traffic railing barrier reinforcement and anchor bolts in existing concrete bridge
decks and approach slabs. The Contractor may substitute Type HSHV adhesives for Type HV
adhesives.

29.8.1

Certification of Adhesive Bonding Products

The Contractor shall provide the Engineer with certification documents from the manufacturer of the
adhesive bonding material system that confirm that the bonding products meet the requirements
outlined in this section. Each certification shall conform to the requirements described in these
specifications and shall cover only one lot of adhesive materials.

29.8.2

Minimum Performance Requirements for Adhesive Bonding
Materials

When tested in accordance with FM 5-568, the adhesive bonding material system, for general use,
shall meet the requirements shown in Table 29-13.

Table 29-13: Uniform bond stress for adhesive bonding material

Uniform bond stress

Type HV

Type HSHV

Confined tension

15.79 MPa

21.10 MPa

Damp-hole installation

11.58 MPa

12.62 MPa

Elevated temperature

15.79 MPa

21.10 MPa

Horizontal orientation

14.20 MPa

Short-term cure

11.79 MPa

Specified bond strength

7.45 MPa

12.62 MPa

The Contractor shall apply the following rules to determine the maximum coefficient of variation for
uniform bond stress at 20% of long-term load (creep):

1. Rate of displacement shall decrease during the 42 day application of load.

2. At 42 days, the total displacement due to creep (with load still applied) shall be less than 0.75

mm; during the last 14 days of the 42 day load duration, the total displacement due to creep
shall be less than 0.075 mm.

3. After removal of the 42 day load, the uniform bond stress from a subsequent confined tension

test shall be at least 12.59 MPa.

29.8.3

Product Identification (Fingerprint) Properties for Adhesive
Bonding Materials

References for comparison, including infrared absorption, density or average weight, gel time or
setting time, and bond strength shall be determined in accordance with FM 5-569.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-32

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.8.4

Packaging and Marking Adhesive Bonding Materials

An adhesive bonding material system shall be delivered to the Project site in original unopened
containers with manufacturer’s labelling that identifies each product. Each package shall be clearly
marked with the following information:

•

Manufacturer’s name and address

•

Product name

•

Date of manufacture

•

Expiration date

•

Lot identification number

•

Storage and handling requirements

Each package shall include the manufacturer’s instructions for anchor and dowel installation. Such
instructions shall include the following information:

a. Diameters of drilled holes for applicable anchor and dowel sizes

b. Cleaning procedure for drilled holes, including a description of permitted and prohibited

equipment and techniques

c. Allowable temperature ranges for storage, installation and curing

d. Identification of acceptable mixing/dispensing nozzles

e. Fabrication requirements for anchors and dowels

f. Description of tools permitted or required for installation

g. Method of identifying properly proportioned and mixed adhesive materials

h. Time and temperature schedule for initial set and full-strength cure

i. Special requirements for special installation conditions, such as damp holes, or horizontal

or near horizontal orientation of the anchor or dowel.

29.9

Adhesive-bonded Anchors and Dowels

The Contractor shall prepare and install adhesive bonded anchors and dowels in hardened concrete
as indicated in the Contract plans, as directed by the Engineer, and in accordance with the
manufacturer’s instructions and the requirements described in this section.

Anchors and dowels described in this section are intended for use in structural applications where
designated on the Contract plans.

29.9.1

Adhesive-bonded Anchors and Dowels

The Contractor shall use adhesive bonding material systems that meet the requirements of Section
29.8. For applications that involve the installation of traffic railing barrier reinforcement and anchor
bolts on existing bridge decks and approach slabs, the Contractor shall use only type HSHV
adhesives.

29.9.2

Storage of Adhesive-bonded Anchors and Dowels

The Contractor shall store materials delivered to the job-site in the original unopened containers
within an appropriate facility that is capable of maintaining storage conditions consistent with the
manufacturer’s recommendations.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-33

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.9.3

Equipment for installing Adhesive-bonded Anchors and
Dowels

The Contractor shall ensure that the equipment used to install adhesive-bonded anchors and dowels
is in conformance with the recommendations of the anchor and dowel manufacturer.

29.9.4

Preparing Concrete Members for Adhesive-bonded Anchors
and Dowels

The Contractor shall ensure that concrete members that receive adhesive-bonded anchors or dowels
are structurally sound and free of cracks in the vicinity of the anchor or dowel to be installed. Unless
the adhesive manufacturer recommends the use of other equipment, the Contractor, using a rotary
hammer drill and bit, shall drill holes to the diameter required by the manufacturer, but no less than
105% of the diameter including deformations, and no more than 150% of the nominal diameter of
the steel bar anchor or dowel.

The Contractor shall use a metal detector that is specifically designed for locating steel in concrete
to  avoid  conflicts  with  existing  steel  reinforcement  whenever  placement  tolerances  and  edge
clearances  permit.  The Contractor  shall  perform  core  drilling  to clear  existing steel  reinforcement
only  when  approved  by  the  Engineer.  The  Contractor  shall  dry  drilled  holes  completely  before
cleaning and installing the anchors or dowels.

The Contractor shall clean and prepare drilled holes in accor

dance with the manufacturer’s

recommendations, but shall use no method that is less effective than using oil-free compressed air
to remove loose particles from drilling, brushing inside surface to free loose particles that are trapped
in pores, and using compressed air again to remove any loose particles that still remain. The
Contractor shall use a non-metallic bristle brush and shall avoid over-brushing to the point of
polishing the inside surface of the drilled hole.

29.9.5

Method of Installing Adhesive-bonded Anchors and Dowels

The Contractor shall remove all debris, oils, and any other deleterious material from the anchors and
dowels to avoid contamination of the adhesive bonding material. The Contractor shall install anchors
or dowels in accordance with the details shown on the Contract

plans and the manufacturer’s

instructions, paying particular attention to any requirements and limitations caused by anchor
position, dampness, ambient temperatures, and curing.

The Contractor shall use adequate quantities of the adhesive bonding material to fill each drilled hole
to within 6.0 mm of the concrete surface, as measured after placement of the steel bar or anchor.
For horizontal and inclined installations, the Contractor shall provide temporary supports to maintain
the anchors or dowels in the centre of the drilled holes until adhesive bonding material has cured.

29.9.6

Testing Adhesive-bonded Anchors and Dowels

The Contractor shall field test installed anchors and dowels for traffic railing barrier applications using
type HSHV adhesives. The Engineer may also require testing of installed anchors and dowels for
other applications.

29.9.6.1

Field Tests for Adhesive-bonded Anchors and Dowels

The Contractor shall engage an independent testing agency to perform field testing of the installed
anchors and dowels under the direction of a Professional Engineer. The Contractor shall submit test
reports for each lot that has been signed and sealed by the Professional Engineer. The Contractor
shall perform restrained static tension tests to prevent damage to the surrounding concrete. A
restrained test is defined as a test conducted in accordance with ASTM E488 / E488M - 10, except
that the ASTM E488 / E488M - 10 support clearance requirements for test equipment do not apply.
A reaction base shall be approximately equal to a drilled hole

’s diameter for the anchor to preclude

concrete or masonry failure while allowing bond failure. Field testing does not require a displacement

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-34

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

measurement. The Contractor shall test individual anchors and dowels by proof loading in tension
to 85% of the specified bond strength defined in Section 29.8, based on the nominal anchor or dowel
diameter and embedment depth. Tension shall not exceed 90% of the yield strength of the anchor
or dowel, unless otherwise shown in the Contract documents.

The Contractor shall divide the anchors and dowels into lots for testing and acceptance. Each lot
shall contain no more than 100 anchors or dowels, of the same diameter, embedment length, and
adhesive bonding material system. Randomly, the Contractor shall select four of the anchors and
dowels in each lot for testing, except if there are three or fewer anchors or dowels in a lot, in which
case,  the  Contractor  shall  test  all  anchors,  unless  otherwise  directed  by  the  Engineer.  If  three
consecutive lots have no failing tests, the Contractor shall sample the next three lots at a 2% rate; if
these lots have no failing tests, the Contractor shall sample at a rate of 1% for the remaining  lots
unless there is a failure.

Regardless of lot size, however, the Contractor shall sample at least one dowel per lot. For every
failed field test, the Contractor shall perform two additional field tests on adjacent untested anchors
or dowels within a lot. The Contractor shall continue additional field tests until no more test failures
occur, or until all anchors and dowels within a lot have been tested. After any lot fails, the Contractor
shall increase the sampling rate to 4% for the next lot to be tested, but shall not test fewer than one
dowel per lot and shall conform to the sampling rate procedure above, including rate reductions as
appropriate.

29.9.6.2

Removal and Replacement of Adhesive-bonded Anchors and
Dowels that Have Failed Testing

The Contractor shall remove all anchors and dowels that fail the field test, without damage to the
surrounding concrete. The Contractor shall drill holes again to remove adhesive bonding material
residue and clean them in accordance with the directions in Section 29.9.4. New anchors and dowels
shall be reinstalled in accordance with the directions in Section 29.9.5. The Contractor shall not
reuse anchors and dowels that have failed testing unless the Engineer has approved doing so.
Reinstalled anchors shall be assigned only for new lots with anchors or dowels of the same diameter,
embedment length, and adhesive bonding material system. The Contractor shall field test reinstalled
anchors in accordance with the directions in Article 29.9.6.1.

29.9.7

Acceptance of Installed Adhesive-bonded Anchors and
Dowels

The Engineer will accept adhesive-bonded anchors and dowels after determining that they meet the
material requirements outlined in Section 29.8, the installation and testing requirements described
in this section, and the placement requirements of the Contract plans.

29.10

Embedment Anchors

Using embedment anchors includes installation and field testing of cast-in-place, grouted, adhesive-
bonded, expansion, and undercut steel anchors.

29.10.1

Prequalification for Embedment Anchors

The Contractor shall prequalify the following materials:

•

Concrete anchors, including cast-in-place

•

All bonded anchor systems, including grout, chemical compounds, and adhesives

•

Undercut steel anchors

For such prequalification, the Contractor shall use universal test standards that are designed to allow
approved anchor systems to be employed for any construction attachment use.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-35

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Tests for adhesive-bonded and other bonding compounds shall be conducted in accordance with
ASTM

’s Standard Test Methods for Testing Bond Performance of Bonded Anchors (ASTM E1512 -

01(2007)).

Expansion anchors shall be tested in accordance with ASTM

’s Standard Test Methods for Strength

of Anchors in Concrete Elements (ASTM E488 / E488M - 10).

Embedment anchor details shall comply with

Appendix B, Steel Embedments in ACI’s Code

Requirements for Nuclear Safety Related Concrete Structures and Commentary (ACI 349-06).

For anchor systems other than mechanical expansion anchors, the Contractor shall provide the
Engineer with certified test reports that have been prepared by an independent laboratory. Such
reports shall document that the system is capable of achieving the minimum tensile strength of the
embedment steel.

29.10.2

Materials for Embedment Anchors

The Contractor shall provide mill test reports to the Engineer to certify the physical properties,
chemistry, and strengths used to manufacture the anchors.

Either an epoxy, vinylester, or polyester chemical compound shall be acceptable for adhesive
anchors. Moisture-insensitive, high-modulus, low shrinkage, and high-strength adhesives shall be
used.

The Owner prohibits the use of additives to grout and bonding materials that are corrosive to steel
or zinc/cadmium coatings.

29.10.3

Construction Methods for Embedment Anchors

Adequate  edge  distance,  embedment  depth,  and  spacing to  develop  the required  strength  of the
embedment  anchors  shall  be  provided.  The  correct  drill-hole  diameter,  as  specified  by  the
manufacturer, shall be used. Rotary impact drilling shall be used unless diamond core drilling has
been specified or tested. If a reinforcing bar is encountered during drilling, the hole shall be moved
to a different location or the reinforcing steel shall be drilled through using a diamond core bit as
directed  by  the  Engineer.  Abandoned  holes  shall  be  patched  with  an  approved  bonding material.
Holes shall be thoroughly cleaned as recommended by the manufacturer.

The Contractor shall remove all loose dust and concrete particles from the hole and shall prepare
bonding material and install anchors according to the manufacturer's instructions or direction from
the Engineer.

Improperly installed embedded anchors or anchors that lack the required strength shall be removed
and replaced, at the Contractor's expense, to the satisfaction of the Engineer.

29.10.4

Inspection and Testing for Embedment Anchors

Where specified, sacrificial tests of the anchor system shall be done at the job site to the ultimate
loads to document that the system can achieve pullout loads equalling the full minimum tensile value
of the anchor employed. Anchor testing shall be done on fully cured concrete samples. At least three
anchors shall be tested by ASTM E488 / E488M - 10 methods, unless otherwise specified. The
Contractor may use any prequalified anchor systems that meet the requirements outlined above.

Provision shall be made for use of an alternative system that will reach the designated pullout
requirement, without delay in progress, if the job site proof loading proves incapable of achieving
minimum tensile values or the load required by the Engineer, or if too little concrete exists in which
to develop full ductile loads.

After bonding material has been installed and has cured, the Contractor shall torque each anchor
system to its specified values using approved torque methods. If torque values are not specified, the
Contractor shall use the manufacturer's recommendations or values provided by the Engineer.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-36

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.11

Bridge Deck Wearing Surfaces

Installing  wearing  surfaces  shall  consist  of  placing  a  wearing  surface  of  durable  and  impervious
material  on  the  roadway  surface  of  bridge  decks,  tunnels,  and  underpasses.  It  includes  the
preparation  of  surfaces  of  either  existing  or  new  decks  to  receive  such  an  overlay  of  surfacing
material.

Wearing  surfaces  of  bridge  decks,  tunnels,  and  underpasses  shall  be  asphaltic  concretes.  The
thickness  of  wearing  surfaces  shall  be  as  designated  in  the  Contract  documents.  Materials  and
installation  requirements  for  asphaltic  concrete  wearing  surfaces  shall  be  in  compliance  with  the
applicable requirements of Chapter 3, Pavement, of these standard specifications. Unless otherwise
specified in the Contract documents or directed by the Engineer, an asphaltic concrete overlay shall
not be used directly on a Portland cement concrete deck without waterproofing the roadway surface
as per Section 28.5 of Chapter 28, Waterproofing, of these standard specifications.

If the type of wearing surfaces is not specified in the Contract documents, the selection of a wearing
surface by the Contractor shall subject

to the Engineer’s approval and shall include evaluation of the

following requirements:

•

Sufficient ductility and strength to accommodate expansion, contraction, and imposed

deformation without cracking or debonding

•

Sufficient fatigue strength to withstand flexural stresses due to composite action of the

wearing surface with the bridge deck resulting from local flexure

•

Sufficient durability to resist rutting, shoving, and wearing

•

Imperviousness to water, motor vehicle fuels, and oils

•

Resistance to deterioration from solar radiation and aging

•

Provision of skid-resistant surface

•

Ability to distribute wheel loads

When specified in the particular specifications, Latex-modified Concrete type wearing surfaces shall
be furnished and installed in accordance with the requirements of the following sections.

29.11.1

General Requirements for the Installation of Latex-modified
Concrete Type Wearing Surfaces

All equipment used to prepare the surface and to proportion, mix, place, and finish the latex concrete
shall be subject to approval by the Engineer before use. This approval will be contingent on
satisfactory performance and will be rescinded in the event such performance is not being achieved.
Equipment shall be on hand sufficiently ahead of the start of construction operations to be examined
and approved. Any equipment that leaks oil or any other containment onto the deck shall be
immediately removed from the job site until repaired.

A technician who is well-experienced in the proportioning, mixing, placing, and finishing of latex-
modified concrete shall be employed by the Contractor and shall be present and in technical control
of the work whenever these operations are underway. The Contractor shall submit the qualifications
of this technician, including a list of projects on which the technician was employed and the
technician's level of responsibility on each, to the Engineer, who must approve the employment of
this technician before operations start.

Approval by the Engineer of equipment or technicians shall not relieve the Contractor of any
responsibility for the successful completion of the work.

If not otherwise specified in the Contract documents, the minimum thickness of latex-modified
concrete wearing surfaces shall be 32 mm.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-37

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.11.2

Materials for the Installation of Latex-modified Concrete
Wearing Surfaces

29.11.2.1 Portland Cement

Portland cement shall conform to the requirements outlined in Section 4.3.1 of Chapter 4, Concrete
Works, of these Standard Specifications, except that only types I or II shall be used.

29.11.2.2 Aggregates

Aggregate shall conform to the requirements of AASHTO M 6-08 for fine aggregate and to AASHTO
M 80-08 for coarse aggregate. Coarse aggregate shall be graded 13 mm to 4.75 mm per AASHTO
M 43-05 (2009) (ASTM D448 - 08).

29.11.2.3 Water

Water for mixing concrete shall conform to the requirements outlined in Section 4.3.8 of Chapter 4,
Concrete Works, of these Standard Specifications.

29.11.2.4 Latex Emulsion for the Wearing Surfaces

Formulated latex emulsion admixture shall be a non-hazardous, film forming, polymeric emulsion in
water, to which all stabilizers have been added at the point of manufacture, and shall be
homogeneous and uniform in composition.

a. Physical Properties of Latex Emulsion for the Wearing Surfaces

The latex modifier shall conform to the requirements shown in Table 29-14.

Table 29-14: Polymer type stabilizers styrene butadiene

Property

Value

Latex

Nonionic surfactants

Portland cement composition

Polydimethyl siloxane

Percent solids

46.0% to 49.0%

Mass per litre at 25

1.0 kg

Colour

White

A Certificate of Compliance signed by the manufacturer of the latex emulsion, certifying that the
material conforms to the above Specifications, shall be furnished for each shipment used in the work.

Latex admixture to be stored shall be kept in suitable enclosures that will protect it from prolonged
exposure to temperatures in excess of 30° C. Containers of latex admixture may be stored at the
bridge site for a period not to exceed ten days. Such stored containers shall be covered completely
with suitable insulating blanket material to avoid excessive temperatures.

29.11.3

Mix Design of Latex-modified Concrete for Wearing Surfaces

The latex-modified concrete for use on the Project shall be a workable mixture that meets the
requirements specified in Table 29-14 and Table 29-15.

•

Following sampling of the discharged, normally mixed material, the commencement of the

slump test shall be delayed from 4 to 5 minutes.

•

Water may be added to obtain slump within the prescribed limits.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-38

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

•

Dry weight ratios are approximate and should produce good workability; due to gradation

changes, however, these may be adjusted within limits established by the Engineer. Parts by
weight of sand may be increased by as much as 0.2 if the coarse aggregate is reduced by
an equivalent volume.

Table 29-15: Approximate latex-modified concrete mixture proportions

Ingredient

Amount for a volume of one cubic metre

Cement

299 kg

Sand

776 kg

Coarse aggregate

517 kg

Latex*

92.7 litres

Water

71.9 litres

*Assumed 48% solids, 52% water by mass

Because of the surfactants used in the manufacture of latex, excessive amounts of air can be
entrained when latex is mixed into a Portland-cement system, unless an antifoam agent is
incorporated in the latex.

For styrene-butadiene latexes, these are usually silicone products and are often added by the latex
supplier. The relationship between air content and antifoam agent content is a function of the specific
latex, in particular, the level and type of its surfactant system and antifoam agent used. Field
experience has shown that the composition of the cement and the aggregates can affect air content,
so it is important to evaluate the mixture before use. No reported work has been done to identify the
components of the cement or aggregates that affect the air content.

29.11.4

Applying Latex-modified Concrete for Wearing Surfaces

Procedures to apply wearing surfaces shall comply with the requirements and specifications outlined
in this section.

29.11.4.1 Preparing the Surface

When preparing the surface for a wearing surface overlay, the Contractor shall comply with the
specifications and requirements outlined in this article.

a. Preparing New Deck Surface for the Wearing Surface Overlay

Surfaces of new decks upon which a wearing surface overlay is to be placed shall be finished to a
rough texture by coarse brooming or other approved methods.

After curing of the deck concrete is complete and before placement of the overlay, the Contractor
shall  blast-clean  the  entire  area  of  the  deck  surface  and  the  vertical  faces  of  curbs,  concrete
parapets,  and barrier walls up to a height of 25 mm above the top elevation of the overlay. Such
blast-cleaning shall produce a bright, clean appearance that is free from laitance, curing compound,
dust, dirt, oil, grease, bituminous material, paint, and all foreign matter. Blast cleaning for an area of
the deck shall normally be performed within 24 hours before placement of the overlay on the area.
Blast cleaning may be performed by either wet sandblasting, high-pressure water blasting, blasting
grits, shrouded dry sandblasting with dust collectors, or another method approved by the Engineer.
Water blasting equipment shall operate with a minimum pressure of 24.5 MPa. Any blast cleaning
method used shall  conform to applicable air and water pollution regulations and to applicable safety
and health regulations. All debris, including dirty water, that results from blast cleaning operations
shall be immediately and thoroughly cleaned from the blast-cleaned surfaces and from other areas
where  debris  may  have  accumulated.  All  blast-cleaned  areas  shall  be  protected  as  necessary
against contamination before placement of the overlay. Contaminated areas and areas exposed for

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-39

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

more than 36 hours after cleaning shall be blast-cleaned again, as directed by the Engineer, and at
the Contractor's expense.

Immediately before placing the overlay, the Contractor shall remove all dust and other debris by
flushing the area with water or blowing the area with compressed air. Prepared surfaces shall then
be soaked with clean water for at least one hour before the placement of the latex overlay. Before
the overlay is applied, all free water shall be blown out and off, and this procedure shall continue
until the surface appears dry or barely damp.

An air supply system for blast cleaning and blowing shall be equipped with an oil trap in the air line,
and provisions shall be made to prevent oil or grease contamination of the surface by any equipment
before placement of the overlay.

b. Preparing Existing Deck Surface for Wearing Surface Overlay

Any surfaces of existing decks that have become contaminated by traffic usage shall be scarified to
the depth specified in the Contract documents. If no depth is shown or specified, a minimum of 6
mm of material shall be removed by scarification.

Before beginning scarification and until operations are completed, all deck drains, expansion joints,
and other openings where the Engineer determines that damage could result shall be temporarily
covered or plugged to prevent entry of debris.

Scarifying shall be done with power operated mechanical scarifiers, or other approved devices, that
are capable of uniformly removing the existing surface to the depths required without damaging the
underlying concrete. Machine scarifiers shall not be operated in ways that damage hardware, such
as drain grates and expansion joint  armour. In areas that machine scarifying cannot reach and in
areas  of  spalling  and  where  steel  reinforcement  is  exposed,  scarifying  and  the  removal  of
deteriorated  or  unsound  concrete  shall  be  accomplished  with  hand  tools.  Pneumatic  hammers
heavier than nominal 200 N shall not be used.

No scarifying or chipping shall be allowed within 1.8 m of a new overlay until 48 hours after its
placement.

In areas where the Engineer determines that deteriorated or unsound concrete has been
encountered, such concrete shall be removed to a depth of 20 mm below the top mat of reinforcing
steel. A minimum of 20 mm clearance shall be required around the reinforcing steel, except where
lower bar mats make this impractical. Care shall be exercised to prevent damaging the exposed
reinforcing steel. All reinforcing steel shall be blast-cleaned. Repaired areas are to be filled during
the overlay operation.

After scarification and removal of unsound concrete has been completed, the deck surface shall be
blast-cleaned and prepared as specified in Sub-article a of Article 29.11.4.1.

29.11.4.2 Proportioning and Mixing to Apply the Wearing Surfaces

The Contractor shall submit to the Engineer for approval, 14 days prior to date of placement, the
proposed mix design in writing and samples of all mix materials in sufficient quantity to produce a
minimum of 0.08 m3 of concrete for laboratory mix design testing.

Proportioning and mixing equipment shall be a self-contained, mobile, continuous mixing, volumetric
proportioning-type mixer.

Continuous-type mixers shall be equipped so that the proportions of the cement, natural sand, and
coarse aggregate can be fixed by calibration of the mixer and cannot be changed without destroying
a seal or other indicating device affixed to the mixer. In addition to being equipped with a flow meter
for calibrating the water supply portion of the mixer, the mixer shall also be equipped with a
cumulative-type water meter that can be read to the nearest 0.4 Litres. Water meters shall be readily
accessible, accurate to within one percent, and easy to read. Both water meters shall be subject to
checking by the Engineer each time the mixer is calibrated. The Contractor shall provide approved
methods for adding an admixture. Admixtures shall be added so as to be kept separated as far as is

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-40

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

practicable. The Contractor shall calibrate a continuous-type mixer to the satisfaction of the Engineer
before starting the work. Yield checks normally will be made for each 38 m3 of mix. Recalibration
will be necessary when indicated by the yield checks and at any other times that the Engineer deems
necessary to ensure proper proportioning of the ingredients. Continuous-type mixers that entrap
unacceptable volumes of air in the mixture shall not be used.

The mixer shall be kept clean and free of partially dried or hardened materials at all times. It shall
consistently produce a uniform, thoroughly blended mixture within the specified air content and
slump limits. Malfunctioning mixers shall be immediately repaired or replaced with acceptable units.

Aggregate stockpiles being used should be of uniform moisture content. Mixing capability shall be
such that finishing operations can proceed at a steady pace, with final finishing completed before
the formation of the plastic surface film.

29.11.4.3 Installation Procedures for the Wearing Surfaces

The Contractor shall provide a detailed work plan, which shall include equipment and manpower, for
approval before beginning any work.

Concrete  batches  shall  not  be  carted  over  the  completed  overlay  until  the  overlay  concrete  has
attained a compressive strength of 21 MPa. If carts are used,  the Contractor shall provide timber
planking of at least 20 mm thickness for the remainder  of the curing period. The Contractor shall
provide  carts  equipped  with  pneumatic  tires.  Curing  operations  shall  not  be  interrupted  for  the
purpose of carting concrete over finished slabs.

a. Weather Restrictions for the Wearing Surface Installation

The Contractor shall not start the placement of latex-modified concrete when the temperature is or
is expected to fall below 7° C or rise above 27° C), or when high winds, rain, or low humidity
conditions are expected to occur before final set of the concrete. If any of these conditions occur
during placement, placement shall be terminated and a straight construction joint formed. Placement
at night may be necessary when daytime conditions are not favourable. If placement is performed at
night, adequate lighting shall be provided by the Contractor.

b. Equipment for the Wearing Surface Installation

Placing and finishing equipment shall include hand tools for placing and brushing in freshly mixed
latex-modified concrete and for distributing it to approximately the correct level for striking off with
the screed. Hand-operated vibrators, screeds, and floats shall be used for consolidating and finishing
small areas.

An approved finishing machine complying with the following requirements shall be used for finishing
all large areas of work:

1. The finishing machine shall be self-propelled and capable of forward and reverse movement

under positive control. The length of the screed shall be sufficient to extend at least 150 mm
beyond the edge of both ends of the section being placed. This finishing machine shall also
be capable of consolidating the concrete by vibration and of raising all screeds to clear the
concrete for travelling in reverse. This machine shall be either a rotating roller-type or an
oscillating screed-type.

2. Rotating roller-type machines shall have one or more rollers, augers, and 25 to 40 Hz

vibratory pans.

3. Oscillating screed-type machines shall have vibrators on the screeds whose frequency of

vibration can be varied between 50 and 250 Hz. The

screed’s bottom face shall be not less

than 100 mm wide and shall be metal.

Rails shall be required for the finishing machine to travel on. Rails shall be sufficiently rigid to support
the weight of the machine without appreciable deflection and shall be placed outside of the overlay

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-41

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

area. Rail anchorages shall provide horizontal and vertical stability and shall not be shot ballistically
into concrete that will not be overlaid.

A suitable portable lightweight or wheeled work bridge shall be furnished for use behind the finishing
operation.

c. Placing the Wearing Surface

The finishing machine shall be test-run over the entire area to be overlayed each day before
placement is started to ensure that the required overlay thickness will be achieved.

Immediately ahead of placing the overlay mixture, a thin coating of the polymer modified concrete
mixture to be used for the overlay shall be thoroughly brushed and scrubbed onto the surface as a
grout-bond coat for the overlay. More coarse particles of the mixture that cannot be scrubbed into
contact with the surface shall be removed and disposed of in a manner approved by the Engineer.
The Contractor shall be careful to ensure that all vertical and horizontal surfaces receive a thorough,
even coating and that the rate of progress is limited so that the material brushed on does not become
dry before it is covered with the full depth of latex-modified concrete.

The latex-modified concrete shall be placed on the prepared and grout-coated surface immediately
after being mixed. This mixture shall be placed and struck off approximately 6 mm above final grade,
then consolidated by vibration and finished to final grade with the approved finishing machine. Spud
vibrators may be used in deep pockets, along edges, and adjacent to joint bulkheads. Supplemental
vibration shall be provided along the meet lines where adjacent pours come together and along curb
lines. Hand finishing with a float may be required along the edge of the pour or on small areas of
repair.

Screed rails and construction bulkheads shall be separated from the newly placed material by
passing a pointing trowel along their inside face. Expansion dams shall not be separated from the
overlay. The Contractor shall be careful to ensure that this trowel cut is made for the entire depth
and length of rails after the mixture has stiffened sufficiently.

d. Finishing the Wearing Surface

Finishing equipment shall be operated to produce a uniform, smooth, and even-textured surface.
The final surface shall not vary more than 3 mm from a 3 metre straightedge placed longitudinally
on it. Before the plastic film forms, the surface shall be textured by tinning in accordance with the
requirements of Section 21.10.1 of Chapter 21, Concrete Structures, of these Standard
Specifications.

e. Installing Construction Joints for the Wearing Surfaces

Planned construction joints shall be formed by bulkheads set to grade. Before placing concrete
against previously placed overlay material, the construction joint shall be sawed to a straight vertical
edge. Sawing of joints may be omitted if the bulkhead produces a straight, smooth, vertical surface.
The

joint’s face shall be sand or water blasted to remove loose material.

The Owner shall permit longitudinal construction joints only at the centreline of roadway or at lane
lines unless otherwise shown in the Contract documents or permitted by the Engineer.

If delays in the placement operation exceed one hour, an approved construction joint shall be formed
by removing all material not up to finish grade and sawing the edge in a straight line. During minor
delays of one hour or less, the end of the placement may be protected from drying with several layers
of clean, wet burlap.

29.11.5

Curing Latex-modified Concrete Wearing Surfaces

The wearing surface shall be promptly covered with a single layer of clean, wet burlap as soon as
the surface can support it without deformation.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-42

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Within one hour after covering a surface with wet burlap, the Contractor shall wet the burlap again,
if necessary, place

a layer of 100 μm polyethylene film or wet burlap-polyethylene sheets over the

wet burlap, and cure the surface 24 hours.

During cold weather, freshly placed LMC shall be protected from temperatures below 7° C during
the first 72 hours of curing. If the temperature falls below 7° C during curing, the duration of the wet
cure shall be extended as directed by the Engineer.

The Owner shall prohibit traffic on an overlay while it is curing.

29.11.6

Testing and Acceptance of Latex-modified Concrete Wearing
Surfaces

After curing is completed, the Contractor shall visually inspect an overlay for cracking and other
damage. The Contractor shall also use a chain drag or other suitable device to inspect wearing
surfaces for de-laminations and bond failures.

The Contractor shall seal surface cracks that are10 mm deep or less with an epoxy penetrating
sealer followed by an application of approved sand.

To repair cracks that are deeper than 10 mm, the Contractor shall use methods approved by the
Engineer or remove and replace the affected portions of the wearing surface. The Contractor shall
remove and replace any delaminated or unbounded portions of a wearing surface or portions that
have been damaged by rain.

After completion of the wet cure, the surface shall be tested for flatness and corrected, if necessary,
as provided in Section 21.10.1.4 of Chapter 21, Concrete Structures, of these Standard
Specifications.

All corrective work shall be at the Contractor's expense.

29.11.6.1 Compression Strength Test for the Wearing Surfaces

Compression strength test shall be done according to ASTM C31 / C31M - 12. Specimens shall be
cured at the job site under the same conditions as the overlay. Specimens shall be tested to
determine when overlay has achieved a specified strength of 21 MPa or as specified in the Contract
documents for opening to traffic.

29.12

Drip Check Angle

Where shown on the Contract plans, the Contractor shall fix 25 x 25mm stainless steel angle bedded
on approved gun applied sealant to outside faces of bridge deck concrete. The Contractor shall
design fixings of stainless steel and drill them on the Project site.

29.13

Lockable Doors, Access Covers, and Internal Access
Walkways

Lockable doors, access covers, frames, and internal access steelwork shall be as detailed on the
Contract plans. All doors and access covers shall include an approved arrangement for locking from
the outside. Access covers in the soffit and top slab of decks and cross beams shall include a means
of securing in the open position.

29.14

End walls for ducts

Ends of contingency utility ducts shall terminate in cast-in-situ cantilevered concrete retaining walls
(duct end wall) to help protect the roadway, sidewalk, curbs, and other works over the ducts from
damage due to excavation. Such protection shall enable workers to open the end of the ducts for
utility placement at some future date. Duct end walls shall be constructed at the locations and to the
details as shown on the Contract plans and as approved by the Engineer, and in accordance with

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-43

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

the applicable requirements of Chapter 4, Concrete Works, Chapter 5, Reinforcing Steel, and
Chapter 21, Concrete Structures, of these standard specifications.

29.14.1

Materials for the Construction of End Walls for Ducts

All concrete and reinforcing steel for duct end walls shall comply with the requirements under Section
4.3 of Chapter 4, Concrete Works, and Section 5.3 of Chapter 5, Reinforcing Steel, of these Standard
Specifications. Blinding concrete shall be of Class 15/20 concrete. The structural end wall concrete
shall be of Class 35/20. Reinforcement shall be Grade 60, uncoated rebar, unless designated
otherwise.

Waterproofing shall meet the requirements outlined in Section 28.2 of Chapter 28, Waterproofing.

Coal tar epoxy protective coatings shall meet the requirements outlined in Section 24.5 of Chapter
24, Painting. Duct pipe extending through the headwall shall meet the appropriate pipe requirements
for  the  various  types  and  sizes  of  contingency  utility  ducts  as  otherwise  specified  in  Chapter  12,
Storm Water Drainage, of these Standard Specifications. End caps for the contingency utility ducts
shall  be  commercially  manufactured  of  materials  similar  to  the  respective  contingency  utility  duct
pipe material and sized to match the belled joint end of the duct pipe, using a rubber gasketed seal,
meeting the requirements as otherwise specified for pipe joints for the respective contingency utility
duct pipe material type. Each cap shall have a pulling handle and attachment for a wire pulling rope
where such is applicable for electrical and telephone ducts. For smaller PVC ducts (ducts with 20
cm or smaller diameters), the Contractor may use a tight fitting PVC cap as an option to the gasketed
cap; such cap can be inserted into the bell end of a typical PVC-bonded type pipe joint fitting that is
sealed with a liberal application of silicone sealer.

All contingency utility duct pipe end caps shall be suitable for long term buried conditions and shall
makes the duct water tight.

29.14.2

Construction Methods for End Walls for Ducts

Each duct end wall shall be designed site specific by the Contractor and shown in plans and sections
of shop drawings, which shall conform to the typical details and locations shown on the Contract
plans, or as otherwise approved by the Engineer.

Excavation,  dewatering,  construction  and  backfilling  for  duct  end  walls  shall  meet  the  applicable
construction requirements for surface drainage structures as detailed in Chapter 12, Storm Water
Drainage, of these Standard Specifications. Forms shall be smooth and tight fitting forms that can
be  held  rigidly  to  line  and  grade  during  placement  of  concrete  and  that  can  be  readily  removed
without injuring the green concrete. Duct end wall base slab shall be placed in conjunction with the
contingency utility duct construction such that the contingency utility duct pipe can be placed true to
grade  with  the  capped  bell  end  of  the  duct  pipe  installed flush  with  the face  of the  end  wall.  The
contingency utility duct pipe shall be fixed and held securely in position such that it is not displaced
during the duct end wall concrete placement. The backfilled back-side surface of a duct end wall and
base  slab  shall  be  protected  with  waterproofing  membrane  that  complies  with  Section  28.2  of
Chapter  28,  Waterproofing.  The

duct end wall’s backfilled front surface (the side that can be

excavated for utility placement at some future date) shall be protected with a coal tar epoxy coating.
Exposed portions of the duct end wall surfaces along the top shall be protected with a clear
penetrating epoxy sealant.

The

duct end wall’s top shall be rubbed finish to match the particular curb or top configuration in

accordance with each site's requirements, as shown on the shop drawings and approved by the
Engineer. The

duct end wall’s final finish shall be obtained by rubbing with a fine carborundum stone

and water. Rubbing shall be continued until

a duct end wall’s entire surface is of a smooth texture

and uniform colour. After the final rubbing is completed and the surface has dried, it shall be rubbed
with burlap to remove loose powder and shall be left free from all unsound patches, paste, powder,
and objectionable marks.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-44

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Appropriate utility markers shall be installed in the top of the duct end wall on the centreline of the
matching duct type, immediately after towelling smooth the freshly placed concrete. The utility
marker shall be pushed into the wet concrete, on duct and end wall width centrelines, such that the
marker is flush with the surface of the end wall. The Contractor shall be careful to remove any wet
concrete from the surface of the utility marker and to leave the top of the end wall equal to the rubbed
type finish, as described above.

Before backfilling, the Contractor shall allow the duct end wall concrete to cure to 7-day concrete
strength, clean the ducts, and cap and seal the contingency utility duct pipe ends. After obtaining
final approval from the Engineer, the Contractor shall backfill the end wall with load bearing borrow
material. Such backfill shall be compacted as specified for the placement of load bearing borrow
materials, in equal height lifts on each side of the end wall, such that uneven pressure is not exerted
on the wall from either side.

29.15

Scour Protection

If scour protection is specified in the Contract documents or Contract plans, it shall comprise a layer
of 5kg to 100kg rock and shall be installed around the marine bridge piers as shown on the Contract
plans, with a geo-textile layer (having minimum grade 600 g/m

) under the rock.

29.15.1

Method Statement

No later than two (2) months before commencement of construction of the scour protection, the
Contractor shall submit to the Engineer for consent, full details of the proposed construction methods
for the structure(s).

The details shall include, but not be limited to:

a. Proposed source(s) of rock material including documentation showing that the proposed

materials from each quarry or quarry face comply with the specification, and evidence that
the source(s) can supply the required quantity at the required rates.

b. Method statement for quarrying, grading, sorting, stacking, inspection, weighing and

transportation of the rock materials. The Contractor shall give his proposals for sampling and
testing rock and for ensuring compliance with the requirements of these specifications.
Details shall include the sampling rate and size of sample and shall take into account such
factors as the number of quarries or quarry faces, rate of delivery to site, methods of
stockpiling and handling and rate of placing.

c. Method statement for the construction of the scour protection including, but not limited to,

•

Proposed plant and labour resources

•

Method of placing the rock materials

•

Founding of the seabed

•

Geo-textile placement

•

Aggregate bedding layers over geo-textile

•

Construction programme

•

Setting out control, inspection and survey procedures

•

Monitoring of seabed and fill displacements and settlement

•

Environment protection and silt screens

d. Health and Safety considerations

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-45

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.15.2

Rock Materials

29.15.2.1 Physical Properties

Rock shall comply with Requirements (1) to (4) presented in Table 29-16 when tested in accordance
with BS 812-103.1:1985, Requirement (5) when tested in accordance with ASTM C131 - 06 and
Requirement (6) when tested in accordance with Appendix B of BS 6349-1:2000: Part 1. Submerged
rock means all material below -0.5m NADD (New Abu Dhabi Datum), wetted rock means all material
that lies above -0.5m NADD. The frequency of testing shall be as per the particular specifications
and as approved by the Engineer.

The petrography analysis of the rocks shall be submitted by the C

ontractor for the Engineer’s

evaluation and approval.

Table 29-16: Rock physical properties for scour protection

Material property

Submerged rock

Wetted rock

Saturated surface dry density

> 2,600 kg/m3

>2,750 kg/m3

Water absorption

< 3% by weight

< 1% by weight

Aggregate impact value

< 30%

<30%

Ten percent fines value

> 100kN

>150kN

Los Angeles abrasion value

< 30%

< 20%

Soundness of coarse agg. (5 cycles
MgSO4)

< 10%

< 5%

29.15.2.2 Cracks, Laminations and Other Deficiencies

Individual rocks for rock armour units shall be free from cracks, laminations and cleavage planes,
weathered material and solution cavities. All rocks shall be free of all remains of quarry blasting
materials.

29.15.2.3 Length to Thickness Ratio

No more than 50% of the rock armour units shall have a length to thickness ratio (L/d) greater than
2, and no rock shall have an L/d ratio greater than 3, where the length, L, is defined as the greatest
distance between any two points on the rock, (ie. diametrically opposite corners of a cuboidal block),
and the thickness, d, the minimum distance between two parallel straight lines through which the
rock can just pass.

29.15.2.4 Grading of Rock

The grading for rock shall be in accordance with the system described in the Rock Manual 2007
(CIRIA-C683), the Use of Rock in Hydraulic Engineering.

The system is analogous to particle size distribution charts for aggregates but the horizontal axis is
the weight of a rock instead of a sieve size, and the vertical axis is the "cumulative percentage by
weight of all rocks in a given sample that are lighter than", instead of the "percentage passing".

Rather than using grading envelopes drawn on a cumulative plot to define the limits of standard
grading, the system adopted shall refer to a series of specified weights of stones, (rock sizes a, b, c
and d in increasing size order), and the associated allowable range of "y", the "cumulative
percentage by weight lighter than" values.

In addition, an effective mean weight, W

, is specified. It is the arithmetic mean weight of all rocks

in a given sample, excluding those lighter than the lightest rock size (a). Rock for the structure(s)
shall be classified by weight and comply with the grading(s) indicated in

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-46

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

Table 29-17.

The Contractor shall provide and display in a prominent location, to the agreement of the Engineer,
a series of sample rocks clearly marked with their weight covering the range of rock sizes to be used
on the Project. These rocks shall be used as a visual reference to assist in rock inspections.

Table 29-17: Rock grading(s)

Rock

Class

Description

Rock Size (kg)

(kg)

(a)

(b)

(c)

(d)

min

max

5 to 100 kg rock

100

150

Allowable range of y

y<2%

0%<y<10%

70%<y<100%

97%<y

29.15.2.5 Quality Control

The Contractor shall undertake sampling and testing for each quarry, quarry face or other source in
accordance with the schedule set out in Table 29-18 for the tests set out in Article 29.15.2.1, Article
29.15.2.2, Article 29.15.2.3, and Article 29.15.2.4

Table 29-18: Rock test requirements for scour protection

Frequency of Testing

Sample Size for Grading and Visual

Inspection

Class A

Every 2,000 tonnes

5 tonnes

The Contractor shall undertake sampling and testing for each quarry, quarry face or other source
before commencement of the work for the tests (2), (3), (4), (5) and (6) set out in Article 29.15.2.1.

In addition, the Contractor shall undertake additional sampling and testing when circumstances so
dictate or as instructed by the Engineer.

Any rock in non-compliance shall be rejected and removed from the site by the Contractor.

29.15.3

Placing of Rock Materials

29.15.3.1 Transporting and Depositing Rock Materials

The Contractor shall supply and transport rock material by land or sea, or a combination of both, and
deposit it by means of marine or land operated plant. The Contractor shall take all precautions and
provide all means necessary to ensure that the various classes of rock material are deposited in the
position and to the slopes indicated on the Contract plans. The rock materials shall be placed using
techniques to achieve a dense fill with no segregation and no contamination from seabed deposits.

29.15.3.2 Grading of Armouring to be Maintained

The grading of armouring within each class shall be correctly maintained and to this end the
Contractor shall take all actions necessary to remove any rocks that may have been displaced by
wave or other action and washed, or swept or otherwise moved into voids of previously placed
armouring, before any further armouring necessary to complete the sections is placed.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-47

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.15.3.3 Survey Equipment

The Contractor shall provide and operate all necessary equipment required for progress surveying
of the structure(s). This shall include but not be limited to suitable optical/ electronic survey
equipment for above water surveys and a launch fitted with approved echo sounding equipment for
executing soundings. The soundings shall be expressed as reduced levels and shall be fully
compensated for tides and motion of the survey vessel. Soundings shall be accurate to ± 0.05m.

29.15.3.4 Construction Survey

Surveys shall be carried out before rock placing commences, and on the completion of any rock
layer. As a minimum these shall comprise cross sections at 5m centres across the scour protection
perpendicular to the pile caps. No surface shall be covered until the profile survey for the previous
layer has been completed, and it has been agreed by the Engineer that this layer meets the specified
requirements.

29.15.3.5 Above Water Survey Technique for Rock Armour

Rock armour above 0.0m NADD shall be surveyed using optical/electronic survey equipment. The
level and position of each rock on each profile shall be measured and recorded. The location of the
staff or target on each rock shall be discussed and agreed with the Engineer but shall generally be
on the highest point of the outermost part of the rock. Consistency of measurements is of the essence
to obtain meaningful results.

29.15.3.6 Below Water Survey Techniques for Rock Structures

Rock profiles below low water level shall be surveyed using a suitable echo sounder. The vessel on
which this equipment is installed shall also be fitted with suitable positioning equipment to allow the
survey lines sailed to be repeated to allow accurate comparisons of changes between surveys. For
the portions of the scour protection close to low water level the surveys shall be carried out at high
tide to allow the greatest possible overlay with the above water surveys as set out in this article.

29.15.3.7 Presentation of Results

At each profile, the actual measured profile of each part of the rock shall be plotted on the same plot
so that actual profile and layer thicknesses may be compared to the specified requirements. These
plots shall be at a minimum scale of 1:50.

29.15.3.8 Tolerances

Rock materials shall be placed to the levels, dimensions and slopes shown on the Contract plans.
Rock Materials shall comply with the tolerances given in the Table 29-19.

Table 29-19: Rock material tolerances

Armour Class

Description

Tolerance on layer thickness

Class A

5 to 100kg

-100mm

+300mm

Notwithstanding the tolerances tabulated above, the following requirements shall apply:

a. No two adjacent actual measured profiles shall both be in the negative tolerance band.

b. No two adjacent layer thicknesses shall both be in the negative tolerance band.

In addition to the above tolerances, all profiles shall be reviewed for general acceptability and
undesirable trends shall be corrected. In particular, attention shall be paid to deviation from the
design slope and unacceptable deviations shall be corrected.

TANDARD

ONSTRUCTION

PECIFICATIONS

ART

–

OAD

TRUCTURES

Page 29-48

HAPTER

29:

ISCELLANEOUS

TEMS FOR

TRUCTURES

First Edition -January 2018

29.16

Sea Port Authority Works

When a marine bridge crosses a navigable waterway and includes permanent piers with submerged
obstructions close to the navigation channel(s), the navigable channel(s) must remain open to sea
traffic during construction.

29.16.1

Navigation beacons

Within the navigation channel and in close proximity to its sides, upon each corner of the submerged
pile caps shall be fixed approved solar powered navigation beacons. They shall be of the Pharos
Marine type LBEA-85/R complete with SZ-10-100 solar system (or equal approved) mounted on
3.5m painted steel posts secured to the top of the pile caps with stainless steel fixing sockets cast
into the concrete.

The Contractor shall submit full details of the proposed beacons together with the fixing details in a
timely manner to ensure the necessary approvals are obtained without any delay to pier construction.

During construction, the Contractor shall ensure that any obstructions placed within or close to the
navigation channel(s) are suitably protected by temporary warning beacons to the approval of the
Sea Port Authority.

29.16.2

Navigation direction signs

The Contractor shall provide such navigation direction signs together with any lights, power supply
and cabling as are required by the Sea Port Authority for the purposes of delineating the shipping
channels beneath the marine bridge spans. The Contractor shall submit for the Engineer’s approval
details of suitable signing in accordance with the recommendations of the International Association
of Marine Aids to Navigation and Lighthouse Authorities (IALA)

Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020) - page 18