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HomeMy WebLinkAboutC2022-154 - 6/28/2022 - Approved PILOT PROGRAM FOR ROLLER COMPACTED CONCRETE ROADWAY IMPROVEMENTS AND PARTICIPATION AGREEMENT FOR KINGS LANDING SUBDIVISION This PILOT PROGRAM FOR ROLLER COMPACTED CONCRETE ROADWAY IMPROVEMENTS AND PARTICIPATION AGREEMENT ("Agreement") is entered into between the City of Corpus Christi (referred to in this Agreement as "City"), a Texas home- rule municipal corporation, acting by and through its City Manager, or designee, and MPM Development LP, (referred to in this Agreement as "Developer"), a Texas Limited Partnership. WHEREAS, Developer desires to develop and plat the Property designated on Exhibit 1 of this Agreement, which exhibit is attached to and incorporated in this Agreement by reference, to be known as King's Landing Unit 1 ("Unit 1"); WHEREAS, as a condition of the Plat for Unit 1, the Developer is required to expand, extend, and construct Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street) as depicted on and following the improvement requirements outlined in Exhibit 2, which exhibit is attached to and incorporated in this Agreement by reference; WHEREAS, the Developer is oversizing by constructing Iron Throne Drive and Drogon Street as C-3 collector streets in lieu of 28' residential local streets; WHEREAS, the Developer desires to utilize Roller Compacted Concrete (referred to in this Agreement as "RCC pavement") for the Roadway Improvements within the King's Landing Subdivision (Exhibit 3); WHEREAS, the Developer is willing to warranty Roller Compacted Concrete Roadway Improvement for 10 years; WHEREAS, it is in the best interests of the City to have the public street infrastructure installed by the Developer in conjunction with the final Plat; WHEREAS, Section 212.071 of the Texas Local Government Code authorizes a municipality to make a contract with a developer of a subdivision or land in the municipality to construct public improvements related to the subdivision or land; and WHEREAS, this Agreement is made pursuant to Section 212.071 & 212.072 of the Texas Local Government Code and Article 8, Section 8.4.1, of the Unified Development Code of the City of Corpus Christi. NOW, THEREFORE, in order to provide a coordinated public street construction and improvement project, the City and the Developer agree as follows: Section 1. RECITALS. The parties agree that the language contained in the preamble of this Agreement is substantive in nature, is incorporated into this Agreement by reference, and has been relied on by both parties in entering and executing this Agreement. SCANNED Section 2. ROLLER COMPACTED CONCRETE PAVEMENT. Per this Pilot Agreement, the City agrees that it will authorize the use of roller compacted concrete pavement (as that term is defined by the RCC Pavement Council) for the King's Landing Subdivision as outlined within Exhibit 3 under the following conditions: (a) Developer agrees to construct all roadway improvements within Kings Landing Subdivision with roller compacted concrete pavement (RCC pavement), except those portions of the roadways that are cul-de-sacs, in which case traditional rebar-reinforced portland cement concrete pavement shall be utilized in conformance with the City's Unified Development Code and City Design Standards. (b) For King's Landing Unit 1 , Developer shall construct the RCC pavement in accordance with the site-specific geotechnical report as depicted in Exhibit 4 and engineering plans and specifications as depicted in Exhibit 2. Concrete curb and gutter construction shall be constructed to City Design Standards. (c) For future King's Landing Subdivision phases, Developer shall submit site-specific geotechnical report signed and sealed by a Professional Engineer licensed by the State of Texas ("Geotechnical Engineer") and engineering plans and specifications signed and sealed by an Engineer of Record licensed by the State of Texas ("Engineer of Record") that depict the RCC pavement paving details to the City Engineer for approval. The RCC pavement paving details shall equal or exceed the minimum parameters specified in the approved Plans (Exhibit 2) and Geotechnical Report (Exhibit 4). Concrete curb and gutter construction shall be as depicted in compliance with the City Design Standards, or an alternate approved by the City. (d) Developer will construct collector streets with at least 8 inches thick roller compacted concrete. All residential local streets smaller than a collector street will be constructed with at least 7 inches thick roller compacted concrete. (e) Prior to installation of the RCC pavement, the Engineer of Record and the Geotechnical Engineer must review and approve all material submittals associated with RCC pavement prepared by the general contractor, and provide reviewed and approved submittal copies to the City. (f) Prior to installation of the RCC pavement, Developer shall submit the experience record of the RCC pavement operators and installers to the City Engineer for review. All contractors involved with the construction operations of the RCC pavement, including maintenance, repair, and replacement, must have at least five (5) years' experience in the day-to-day installation, field management, and oversight of RCC pavement projects and meet all insurance and indemnification requirements of the City Contract under which the original RCC pavement was constructed, unless modified by mutual agreement. Associated Insurance Certificates shall be submitted to the City prior to beginning work (g) Prior to installation of RCC pavement, Developer shall obtain approval of construction engineering plans from the City Engineer. Page 2 of 15 (h) Prior to the acceptance of roadway improvements, the Developer's Engineer of Record must submit record drawings to the City certifying that the RCC pavement was constructed in strict accordance with the approved construction drawings and technical specifications. The authorization to utilize RCC pavement per this Agreement is limited to the King's Landing Subdivision as outlined within Exhibit 3. The City may terminate this Authorization to use RCC pavement at any time for any reason and require future streets within Kings Landing subdivision be constructed with rebar-reinforced portland cement concrete pavement meeting City Design Standards. Section 3. TERM. This Agreement becomes effective, is binding upon, and inures to the benefit of the City and the Developer from and after the date of the last signatory to this Agreement. This Agreement shall continue during the development of the Kings Landing Subdivision as outlined within Exhibit 3. This agreement will expire in 25 years or upon the expiration of the last Roadway Improvement warranty for the last developed phase of Kings Landing Subdivision, whichever is later. The Developer must complete the Roadway Improvements for King's Landing Unit 1 not later than July 31st, 2023. The Developer must complete the Roadway Improvements for the entire Kings Landing Subdivision, as outlined within Exhibit 3, not later than July 31st, 2032. Section 4. DEVELOPER PARTICIPATION. Subject to the terms of this Agreement, the Developer will construct Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street) as C-3 collector streets with at least 8-inch thick RCC pavement per Exhibit 2 and Exhibit 4 for and on behalf of the City in accordance with the plans and specifications approved in advance of construction by the City Engineer on behalf of the City. The parties acknowledge and confirm the total cost estimate for construction of the Roadway Improvements, which estimate is attached to and incorporated in this Agreement as Exhibit 5 (the "Cost Estimate"). Subject to the limitations set forth below, the Developer shall pay a portion of the construction costs of Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street). Further, subject to the limitations set forth below, the City shall pay for a portion of the construction costs of Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street) up to $1,248,780.65 plus $321,426 previous paid for partial construction of Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street) under previous participation agreement. Section 5. CITY PARTICIPATION. Notwithstanding any other provision of this Agreement, the total amount that the City shall pay for the City's agreed share of the actual costs of the Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street) shall not exceed $1,248,780.65. Additionally, City participation includes $321,426 previous paid for partial construction of Iron Throne Drive and Drogon Street under previous participation agreement. Section 6. REIMBURSEMENT. The Developer shall be responsible for the entire up-front expenses of the Roadway Improvements for Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street). The City shall reimburse the Developer upon completion of all Roadway Improvements within Kings Landing Unit 1 contingent upon the certificate of acceptance issued by the City Engineer, sworn certification on City form that Page 3 of 15 the Developer has paid all contractors and subcontractors in full, and presentment of a maintenance bond. Such reimbursement will be payable to the Developer at the address in the Notice Section of this Agreement. Section 7. PERFORMANCE BOND. In accordance with the Texas Local Government Code, the Developer shall execute a performance bond for the construction of the Iron Throne Drive and Drogon Street prior to construction to ensure the completion of the project. A corporate surety must execute the bond in accordance with Chapter 2253 of the Texas Government Code and in a form approved by the City Attorney. Section 8. MAINTENANCE BONDS. (a) For King's Landing Unit 1, the Developer shall provide a Maintenance Bond with a term of 7 years following completion of the Roadway Improvements within King's Landing Unit 1 . The maintenance bonds will cover 100 percent of the replacement cost to Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street), and Roadway Improvements within the King's Landing Unit 1 with traditional rebar-reinforced portland cement concrete pavement. In addition, before any reimbursement to the Developer for the construction of Lady Alexa Drive (formerly Iron Throne Drive) and Lady Claudia Street (formerly Drogon Street), the developer shall submit the maintenance bond for King's Landing Unit 1 and associated power of attorney to the City Engineer in forms approved by the City Attorney. (b) For future King's Landing Subdivision phases, the Developer shall provide a Maintenance Bond with a term of 7 years prior to acceptance of roadway improvements. The maintenance bonds will cover 100 percent of the replacement cost to replace the Roadway Improvements being accepted with traditional rebar-reinforced portland cement concrete pavement. The developer shall submit the maintenance bond and associated power of attorney to the City Engineer in forms approved by the City Attorney. Section 9. MAINTENANCE. (a) During the period of at least 7 years following acceptance of roadway improvements, all maintenance and repairs of the Roadway Improvements in the King's Landing subdivision will be performed entirely and exclusively by Developer. Failure of the Developer to promptly complete all maintenance and repairs of all streets in this subdivision will be a violation and breach of this agreement. The Developer shall complete all such maintenance or repairs of the streets within 60 days after being requested in writing to do so by the City Engineer. (b) Any deficiencies occurring during the Maintenance Period shall be immediately repaired at Developer's sole expense in accordance with the repair and replacement descriptions below or in accordance with the Texas Department of Transportation Concrete Repair Manual as attached as Exhibit 6, whichever is most applicable. In the event this Agreement and Repair Manual conflict, this agreement controls. Deficiencies requiring repair shall include: Page 4 of 15 1 .Minor Cracks. any crack greater than 1/8-inch and less than 1/4-inch other than cut joints; 2.Minor Differential Vertical Separation. any differential vertical separation between RCC pavement panels equal to or less than 1/8-inch across the joint; 3.Minor Spalling. any spalling, honeycombing, or other defects less than 2 square feet or less than 1-inch deep; 4. Minor Curb Separation. any separation of RCC pavement from curb and gutter equal to or less than-1/8 inch; and 5.Joint Sealant. any separated, cracked, or missing joint sealants. (c) Repairs shall include: 1 .Minor Cracks. Any crack greater than 1/8-inch and less than 1/4-inch width shall be sealed with a City-approved flowable elastomeric pavement crack sealant (Sikaflex or equal). Minor cracks will not include any differential vertical movement (up-down) greater than 1/8-inch across the joint. 2.Minor Differential Vertical Separation. Any differential vertical separation between RCC pavement panels equal to or less than 1/8-inch across the joint shall be diamond grinded to eliminate differential vertical separation. 3.Minor Spalling. Any surface spalling of areas less than 2 square feet or less than 1-inch deep shall be high-pressure wash prepared to remove all dirt, debris, and loose material, prepared with a bonding agent, and filled with a low- shrink epoxy modified grout. 4. Minor Curb Separation. Any separation of RCC pavement from curb and gutter equal to or less than 1/8-inch shall be sealed with a City-approved flowable elastomeric pavement crack sealant (Sikaflex or equal). 5.Joint Sealant. Any separated, cracked, or missing joint sealants shall be cut out and replaced with new elastomeric joint sealant (Sikaflex or equal) following high-pressure wash joint cleaning. (d) During the first 7 years following acceptance of RCC pavement roadway improvements, the City will not complete any maintenance or repairs of RCC pavement Roadway improvements. The City Manager is prohibited from authorizing city staff from making any repairs during the first 7 years following acceptance of RCC pavement roadway improvements. (e) Developer shall notify the City Engineer prior to repair to allow for inspection and approval of repair work. (f) The City Engineer will be the final authority in determining deficiencies and level of deficiencies of RCC pavement. Page 5 of 15 I Section 10. REPLACEMENT. (a) During the period of at least 10 years following acceptance of roadway improvements, the Developer shall replace RCC panels with deficiencies identified in this section. All replacement of RCC panels in the Kings Landing subdivision will be performed entirely and exclusively by Developer at Developer's sole expense. The Developer shall complete all such replacement of the street panels within 60 days after being requested in writing to do so by the City Engineer. (b) Deficiencies requiring replacement shall include: 1. Major Cracks. any panel with a crack across 50% of the length or width of the panel and greater than 1/4-inch at any point in the crack; 2. Major Differential Vertical Separation. any differential vertical separation between panels greater than 1/8-inch; 3. Major Curb Separation. separation of RCC pavement panel from curb and gutter greater than 1/8-inch; 4.. Uncontrolled Cracking. a RCC pavement panel with more than one uncontrolled crack; and 5. Major Spalling. any spalling, honeycombing, or other defects greater than 2 square feet or more than 1-inch deep. (c) Replacements shall include: 1. Major Cracks. Any RCC pavement panel with a crack greater than 'A-inch width across 50% of the length or width of the panel will be replaced with new RCC pavement panel or traditional rebar-reinforced portland cement concrete pavement with sealed perimeter construction joints. 2. Major Differential Vertical Separation. Any differential vertical separation between RCC panels at any location with differential movement (up-down) greater than 1/8-inch across shall be replaced with new RCC pavement panel or traditional rebar-reinforced portland cement concrete pavement with sealed perimeter construction joints. 3. Major Curb Separation. Any RCC pavement panel with separation from curb and gutter more than 1/8-inch shall be replaced with RCC pavement panel or traditional rebar-reinforced portland cement concrete pavement with sealed perimeter construction joints in a manner that keeps the original alignment o0f the curb and gutter. 4. Uncontrolled Cracking. Any RCC pavement panel with more than one uncontrolled crack will be replaced with new RCC pavement panel or traditional rebar-reinforced portland cement concrete pavement with sealed perimeter construction joints. Page 6 of 15 5. Major Spalling. Any RCC pavement panel with surface spalling of areas greater than 2 square feet or more than 1-inch deep shall be replaced with RCC pavement panel or traditional rebar-reinforced portland cement concrete pavement with sealed perimeter construction joints. (d). Saw cut. Any panel being replaced shall be saw cut out to the nearest adjacent contraction or expansion joints and replaced. (e) RCC Pavement System Failure. In the event of major cracking or major spalling deficiencies of more than 30% of RCC pavement panels on a street within the first 7 years, the City may in its sole determination and discretion require the removal and replacement of all RCC pavement panels within the subject street, both deficient and non-deficient RCC pavement panels, with traditional rebar-reinforced portland cement concrete pavement meeting City specifications. Any such roadway segment replacement will be at the Developer's cost. (f) Developer shall notify the City Engineer prior to replacement of RCC pavement panels to allow for inspection and approval of replacement work. (g) The City Engineer will be the final authority in determining deficiencies and level of deficiencies of RCC pavement. Section 11. WARRANTY. The Developer shall fully warrant the workmanship and construction of the Roadway Improvements within the King Landing Subdivision for a period of 10 years from and after the date of acceptance of the Roadway Improvements by the City Engineer. Upon notice by City of any defects and faults in materials, workmanship and design, Developer shall promptly, but no later than 60 days after notice, correct such defects and/or faults to the satisfaction of the City. Section 12. INSURANCE. Insurance requirements are as stated in Exhibit 7, the content incorporated by reference into this Agreement as if fully set out here in its entirety. Before performance can begin under this Agreement, the Developer must deliver a certificate of insurance ("COI"), as proof of the required insurance coverages, to the City's Risk Manager and Development Services Department. Additionally, the COI must state that the City will be given at least 30 days' advance written notice of cancellation, material change in coverage, or intent not to renew any of the policies. The City must be named as an additional insured. The City Attorney must be given copies of all insurance policies within 10 days of the written request. Section 13. CONSTRUCTION. The planned Roadway Improvements shall be constructed in accordance with the approved Plans, Geotechnical Engineering Reports, and related specifications and industry standard practices. Section 14. INSPECTIONS. (a)Throughout construction, the City may conduct periodic inspections and either approve the progress of the Roadway Improvements or promptly notify the Developer Page 7 of 15 of any defect, deficiency, or other non-approved condition in the progress of the Roadway Improvements. (b)Following completion of the Roadway Improvements, the City may conduct periodic inspections of the Roadway Improvements and will promptly notify the Developer of any defects and faults in materials, workmanship, and design. (c) The Developer or its representative shall attend quarterly site inspections with the City during the first 3 years of the warranty period to observe the RCC pavement and identify and document any needed repairs or replacements. After the first 3 years of quarterly inspections, inspections shall be every 6 months thereafter until the 10 year of warranty is met. The City will develop an associated Required Repair or Replacement plan following inspection, provided to the Developer for execution. All identified repairs or replacements shall be completed within 60 days of that plan unless the Developer and its approved contractor are delayed by force majeure or other events beyond its control. Section 15. INDEMNIFICATION. Developer covenants to fully indemnify, save and hold harmless the City of Corpus Christi, its officers, employees, and agents, ("indemnitees") against any and all liability, damage, loss, claims, demands, suits, and causes of action of any nature whatsoever asserted against or recovered from indemnitees on account of injury or damage to person including, without limitation on the foregoing, workers' compensation and death claims, or property loss or damage of any other kind whatsoever, to the extent any injury, damage, or loss may be incident to, arise out of, be caused by, or be in any way connected with, either proximately or remotely, wholly or in part, the construction, installation, existence, operation, use, maintenance, repair, restoration, or removal of the public improvements associated with Roadway Improvements within the Kings Landing Subdivision, including the injury, loss, or damage caused by the contributory negligence of the indemnitees or any of them, regardless of whether the injury, damage, loss, violation, exercise of rights, act, or omission is caused or is claimed to be caused by the contributing or concurrent negligence of indemnitees, or any of them, but not if caused by the sole negligence of indemnitees, or any of them, unmixed with the fault of any other person or entity, and including all expenses of litigation, court costs, and attorney's fees which arise, or are claimed to arise, out of or in connection with the asserted or recovered incident. This indemnity survives the termination of this Agreement. Section 16. DEFAULT. The following events shall constitute default: (a). Developer fails to submit plans and specifications for the Roadway Improvements to the City Engineer in advance of construction. Page 8 of 15 (b). Developer does not reasonably pursue construction of the Roadway Improvements under the approved plans and specifications. (c). Developer fails to complete construction of the Roadway Improvements for King's Landing Unit 1, under the approved plans and specifications, on or before July 31st, 2023. (d). Developer fails to perform warranty work. (e). Either the City or the Developer fails to comply with its duties or obligations under this Agreement. Section 17. NOTICE AND CURE. (a). In the event of a default by either party under this Agreement, the non-defaulting party shall deliver notice of the default, in writing, to the defaulting party stating, in sufficient detail, the nature of the default and the requirements to cure such default. (b). After delivery of the default notice, the defaulting party has 15 days from the delivery of the default notice ("Cure Period") to cure the default. (c). In the event the default is not cured by the defaulting party within the Cure Period, then the non-defaulting party may pursue its remedies in this section. (d). Should the Developer fail to perform any obligation or duty of this Agreement, the City shall give notice to the Developer, at the address stated in Notice Section of this agreement, of the need to perform the obligation or duty and, should the Developer fail to perform the required obligation or duty within 15 days of receipt of the notice, the City may perform the obligation or duty, charging the cost of such performance to the Developer. (e). In the event of an uncured default by the Developer, after the appropriate notice and Cure Period, the City has all its common law remedies and the City may: 1. Terminate this Agreement after the required notice and opportunity to cure the default; 2. Refuse to record a related plat or issue any certificate of occupancy for any structure to be served by the project; and/or 3. Bring Suit to enforce any provision of this agreement including the obligations to repair and replace. (f). In the event of an uncured default by the City after the appropriate notice and Cure Period, the Developer has all its remedies at law or in equity for such default. Section 18. FORCE MAJEURE. (a). The term "force majeure" as employed in this Agreement means and refers to acts of God; acts of a public enemy; insurrections; riots; epidemics; landslides; earthquakes; Page 9 of 15 fires; hurricanes; explosions; or other causes not reasonably within the control of the party claiming the inability. (b). If, by reason of force majeure that is not known or reasonably anticipated at the time of this agreement, either party is rendered wholly or partially unable to carry out its obligations under this Agreement, then the party claiming force majeure shall give written notice of the full particulars of the force majeure to the other party within 10 days after the occurrence or waive the right to claim it as a justifiable reason for delay. The obligations of the party giving the required notice, to the extent affected by the force majeure, are suspended during the continuance of the inability claimed but for no longer period, and the party shall endeavor to remove or overcome such inability with all reasonable dispatch. Section 19. NOTICES. (a). Any notice or other communication required or permitted to be given under this Agreement must be given to the other party in writing at the following address: If to the City: If to the Developer: City of Corpus Christi MPM Development, L.P. Attn: Director, Development Services Attn: Moses Mostaghasi 2406 Leopard Street / 78401 PO Box 331308 P.O. Box 9277/78469-9277 Corpus Christi, Tx 78401 Corpus Christi, Texas with a copy to: City of Corpus Christi Attn: City Engineer 1201 Leopard Street / 78401 P. O. Box 9277 / 78469-9277 Corpus Christi, Texas (b). Notice must be made by United States Postal Service, First Class mail, certified, return receipt requested, postage prepaid; by a commercial delivery service that provides proof of delivery, delivery prepaid; or by personal delivery. (c). Either party may change the address for notices by giving notice of the change, in accordance with the provisions of this section, within five business days of the change. Section 20. PROJECT CONTRACTS. Developer's contracts with the professional engineer for the preparation of the plans and specifications for the construction of the Roadway Improvements, contracts for testing services, and contracts with the contractor for the construction of the Roadway Improvements must provide that the City is a third-party beneficiary of each contract. Section 21 . DISCLOSURE OF INTEREST. In compliance with Corpus Christi Code Sec. 2- 249, the Developer agrees to complete the Disclosure of Interests form attached to this Agreement and incorporated by reference as Exhibit 8. Page 10 of 15 Section 22. CERTIFICATE OF INTERESTED PARTIES. Developer agrees to comply with Texas Government Code section 2252.908 and complete Form 1295 Certificate of Interested Parties as part of this agreement. Form 1295 requires disclosure of"interested parties" with respect to entities that enter contracts with cities. These interested parties include: (1) persons with a "controlling interest" in the entity, which includes: a. an ownership interest or participating interest in a business entity by virtue of units, percentage, shares, stock or otherwise that exceeds 10 percent; b. membership on the board of directors or other governing body of a business entity of which the board or other governing body is composed of not more than 10 members; or c. service as an officer of a business entity that has four or fewer officers, or service as one of the four officers most highly compensated by a business entity that has more than four officers. (2) a person who actively participates in facilitating a contract or negotiating the terms of a contract with a governmental entity or state agency, including a broker, intermediary, adviser, or attorney for the business entity. Form 1295 must be electronically filed with the Texas Ethics Commission at https://www.ethics.state.tx.us/whatsnew/elf info form1295.htm. The form must then be printed, signed, notarized and filed with the City. For more information, please review the Texas Ethics Commission Rules at https://www.ethics.state.tx.us/legal/ch46.html. Section 23. CONFLICT OF INTEREST. Developer agrees to comply with Chapter 176 of the Texas Local Government Code and file Form CIQ with the City Secretary's Office, if required. For more information and to determine if you need to file a Form CIQ, please review the information on the City Secretary's website at http://www.cctexas.com/government/city- secretary/conflict-disclosure/index Section 24. SEVERABILITY. The provisions of this Agreement are severable and, if any provision of this Agreement is held to be invalid for any reason by a court or agency of competent jurisdiction, the remainder of this Agreement shall not be affected, and this Agreement shall be construed as if the invalid portion had never been contained herein. Section 25. COOPERATION. The Parties agree to cooperate at all times in good faith to effectuate the purposes and intent of this Agreement. Section 26. ENTIRE AGREEMENT. Except as otherwise expressly provided herein, this Agreement contains the entire agreement of the Parties regarding the sharing of costs for the Roadway Improvements. It supersedes all prior or contemporaneous understandings or oral or written representations regarding the subject matter hereof. Page 11 of 15 Section 27. AMENDMENTS. Any amendment of this Agreement must be in writing and shall be effective if signed by the authorized representatives of both Parties. Section 28. APPLICABLE LAW; VENUE. This Agreement shall be construed in accordance with the laws of the State of Texas. Venue for any action arising hereunder shall be in Nueces County, Texas. Section 29. AUTHORITY. Each Party represents and warrants that it has the full right, power, and authority to execute this Agreement. Section 30. INDEPENDENT CONTRACTOR. Developer covenants and agrees that it is an independent contractor, not an officer, agent, servant, or employee of the City. Developer shall have exclusive control of and exclusive right to control the details of the work performed hereunder and all persons performing same, and shall be liable for the acts and omissions of its officers, agents, employees, contractors, subcontractors, and consultants. The doctrine of respondeat superior shall not apply between City and Developer, its officers, agents, employees, contractors, subcontractors, and consultants. Nothing herein shall be construed as creating a partnership or joint enterprise between City and Developer. Section 31. NON-APPROPRIATION. The continuation of this Agreement after the close of any fiscal year of the City, which fiscal year ends on September 30th annually, is subject to appropriations and budget approval specifically covering this Agreement as an expenditure in the said budget. It is within the sole discretion of the City's City Council to determine whether to fund this Agreement. The City does not represent that this budget item will be adopted, as said determination is within the City Council's sole discretion when adopting each budget. Section 32. WAIVER OF TRIAL BY JURY. City and Developer agree that they have knowingly waived and do hereby waive the right to trial by jury and have instead agreed, in the event of any litigation arising out of or connected to this Contract, to proceed with a trial before the court, unless both parties subsequently agree otherwise in writing. Section 33. ATTORNEY FEES. In the event that any action is instituted by City to enforce or interpret any of the terms hereof, City shall be entitled to be paid all court costs and expenses, including reasonable attorneys' fees, incurred by City with respect to such action, unless as a part of such action, the court of competent jurisdiction determines that each of the material assertions made by City as a basis for such action were not made in good faith or were frivolous. In the event of an action instituted by or in the name of the Developer under this Agreement or to enforce or interpret any of the terms of this Agreement, City shall be entitled to be paid all court costs and expenses, including attorneys' fees, incurred by City in defense of such action (including with respect to City's counterclaims and cross-claims made in such action), unless as a part of such action the court determines that each of City's material defenses to such action were made in bad faith or were frivolous. Section 34. NO WAIVER. The failure of the City to insist upon strict adherence to any term of this agreement on any occasion shall not be considered a waiver of any of the City's rights under this agreement or deprive the City of the right thereafter to insist upon strict adherence to that term or any other term of this agreement. Page 12 of 15 f Exhibits Attached and Incorporated by Reference: Exhibit 1 — Plat— King's Landing Unit 1 Exhibit 2 — Public Improvement Plans — King Landing Unit 1 Exhibit 3 — Preliminary Plat— King's Landing Exhibit 4 — Geotechnical Report Exhibit 5 — Cost Estimate Exhibit 6—Tx DoT Concrete Repair Manual Exhibit 7 — Insurance Exhibit 8 — Disclosure of Interest Page 13 of 15 4 EXECUTED in one original this ,)-c- day of ` , 2022. CITY OF CORPUS CHRISTI ATTEST: 1i 40 !. : 111L, ' I. RE:ECA HUERTA .,,y. •° '" '" CITY SECRETARY er Zanon. City Manager IL__AUItiUKIte► 1Y MUNCIE_12:21.1122 THE STATE OF TEXAS § § COUNTY OF NUECES § SECRETARY This instrument was signed by Peter Zanoni, City Manager, for the City of Corpus Christi, Texas, and acknowledged before me on the ,f)544' day of 1 ‘.( , 2022. .6, 0/.11/ C _ •tary Public, State o -xas 1 .,'pV PGs MARTHA VAZQUEZ I i�` Notary ID#128028579 0 �;,-I� My Commission Expires 'toF'c March 16,2026 p ornwrourwiergurampwmplopmprili APPROVED AS TO FORM: This Z ,J day of CA 1 l , 2022. 6111/d- Senior Assistant City Attorney Buck Brice I I Page 14 of 15 4 DEVELOPER: MPM Development, LP es Mostagashi Date General Partner STATE OF TEXAS § COUNTY OF NUECES § lilt This instrument was acknowledged before me ona5 � ate}--, 2022, by Moses Mostagashi, General Partner of MPM Development, LP, behalf of said company. < •••"'*'o a.,. CYNTHIA BUENO elY6'114°--(13* 1114)--- r'o .�:. ID# 1178588-3 Notary Public Notary Public's Signature `y? �y�= STATE OF TEXAS My Comm. 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Box 331308 Corpus Christi,Texas,78463 Attn: Mr. Moses Mostaghasi RE: GEOTECHNICAL ENGINEERING REPORT KING'S LANDING UNIT 1 PAVEMENT STUDY(REV 5) CR 49 AT FM 43(WEBER ROAD) CORPUS CHRISTI,N UECES COUNTY,TEXAS PSI Project No.03122159 Dear Mr. Mostaghasi: Professional Service Industries, Inc. (PSI), an Intertek company, is pleased to submit this Geotechnical Engineering Report for the referenced project.This report includes the results of field and laboratory testing along with recommendations for use in preparation of the appropriate design and construction documents for this project. PSI appreciates the opportunity to provide this Geotechnical Engineering Report and looks forward to continuing participation during the design and construction phases of this project. If there are any questions pertaining to this report,or if PSI may be of further service, please contact our office. PSI also has great interest in providing materials testing and inspection services during the construction of this project. If you will advise us of the appropriate time to discuss these engineering services, we will be pleased to meet with you at your convenience. Respectfully submitted, PROFESSIONAL SERVICE INDUSTRIES,INC. Texas Board of Professional Engineers Certificate of Registration#F003307 COIR- ef*c9::: .%* Reinaldo Vega-Meyer,E.I.T. Dexter Bacon,P.E. Project Manager DEXTER BACON Chief Engineer ,3: 54560 lkk oNa. 7/11/2022 www.intertek.com/building TABLE OF CONTENTS Page No. 1.0 PROJECT INFORMATION 1 1.1 PROJECT AUTHORIZATION 1 1.2 PROJECT DESCRIPTION 1 1.3 PURPOSE AND SCOPE OF SERVICES 1 2.0 SITE AND SUBSURFACE CONDITIONS 3 2.1 SITE DESCRIPTION 3 2.2 FIELD EXPLORATION 3 2.3 LABORATORY TESTING PROGRAM 4 2.4 SITE GEOLOGY 4 2.5 SUBSURFACE CONDITIONS 4 3.0 GEOTECHNICAL EVALUATION AND RECOMMENDATIONS 6 3.1 GEOTECHNICAL DISCUSSION 6 3.2 POTENTIAL VERTICAL MOVEMENT OF EXPANSIVE SOILS 6 3.3 UTILITY EXCAVATION AND LATERAL EARTH PRESSURE CONSIDERATIONS 7 3.4 DISCUSSION OF BEDDING AND BACKFILL MATERIALS 7 3.5 EXCAVATION AND SHORING CONSIDERATIONS 8 4.0 PAVEMENT DESIGN RECOMMENDATIONS 9 4.1 PAVEMENT DESIGN PARAMETERS 9 4.2 PAVEMENT SECTION RECOMMENDATIONS 10 5.0 CONSTRUCTION CONSIDERATIONS 13 5.1 INITIAL SITE PREPARATION CONSIDERATIONS 13 5.2 MOISTURE SENSITIVE SOILS/WEATHER RELATED CONCERNS 13 5.3 SULFATES EVALUATION 14 5.4 EXCAVATION OBSERVATIONS 14 5.5 DRAINAGE CONSIDERATIONS 14 5.6 EXCAVATIONS AND TRENCHES 14 6.0 REPORT LIMITATIONS 16 APPENDIX 17 Site Vicinity Map Boring Location Map Boring Logs Symbols Key Sheet AASHTO Design Spreadsheet Results TxDOT Special Specification 3016 Roller Compacted Concrete iii INDEX OF TABLES Page No. Table 1.1: General Project Description 1 Table 2.1: Site Description 3 Table 2.2: Field Exploration Summary 3 Table 2.3: Field Exploration Description 3 Table 2.4: Generalized Soil Profile 5 Table 3.1: Excavation and Shoring Data 8 Table 4.1: Pavement Design Parameters and Assumptions 9 Table 4.2: Roller Compacted Concrete Pavement Design Thickness 10 Table 4.3: Pavement Profile Design and Construction Recommendations 11 Table 4.4: Compaction and Testing Recommendations for Pavement Areas 12 Table 5.1: Subgrade Preparation for Non-Structural -General Fill 13 Table 5.2: Fill Compaction Recommendations Outside of Pavement Areas 13 iv King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 1.0 PROJECT INFORMATION 1.1 PROJECT AUTHORIZATION Professional Service Industries, Inc., (PSI), an Intertek company, has completed a field exploration and geotechnical evaluation for the proposed King's Landing Unit 1 Pavement Study project to be constructed at CR 49 at FM 43 (Weber Road) in Corpus Christi,Texas. Mr. Moses Mostaghasi, representing MPM Homes, authorized PSI's services by signing PSI Proposal No. 321057 dated September 9, 2020. PSI's proposal contained a proposed scope of work,fee,and PSI's General Conditions. 1.2 PROJECT DESCRIPTION Based on information provided by the Client, PSI's review of a site plan entitled "Public Improvements to King's Landing Unit 1,Corpus Christi, Nueces County,Texas",dated 4/2/2020 and prepared by Nixon Welsh, PE,RPLS,a summary of our understanding of the proposed project is provided in the following table. TABLE 1.1:GENERAL PROJECT DESCRIPTION Project Description Roller Compacted Concrete(RCC)Pavements,Utility Line Considerations Existing Grade Change within Project Site Approximate 5 feet Residential Street:50,000 ESALs Design Traffic Load Residential Collector:100,000 ESALs Local Street:1,000,000 ESALs Collector Street:2,000,000 ESALs The geotechnical recommendations presented in this report are based on the available project information, structure locations, and the subsurface materials described in this report. If any of the noted information made are incorrect,please inform PSI so that the recommendations presented in this report can be amended as necessary.PSI will not be responsible for the implementation of provided recommendations if not notified of changes in the project. 1.3 PURPOSE AND SCOPE OF SERVICES The purpose of this study is to evaluate the subsurface conditions at the site and develop geotechnical engineering recommendations and guidelines for use in preparing the design and other related construction documents for the proposed project.The scope of services included drilling borings, performing laboratory testing,and preparing this geotechnical engineering report. This report briefly outlines the available project information, describes the site and subsurface conditions, and presents the recommendations regarding the following: • General site development and subgrade preparation recommendations. • Estimated potential soil movements associated with collapsing, shrinking and swelling soils and methods to reduce these movements to acceptable levels. • Recommendations for site excavation, fill compaction, and the use of on-site and imported fill material under pavements. PAGE 1 Y 1 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 • Recommendations for the pavement profile design and construction of Roller Compacted Concrete (RCC) pavement for the proposed residential streets designed in consideration of the City of Corpus Christi standards. • Utility line excavation and construction considerations. The scope of services for this geotechnical exploration did not include an environmental, mold nor detailed seismic/fault assessment for determining the presence or absence of wetlands, or hazardous or toxic materials in the soil, bedrock, surface water, groundwater, or air on or below, or around this site. Any statements in this report or on the boring logs regarding odors, colors, and unusual or suspicious items or conditions are strictly for informational purposes. I I PAGE 2 �\j King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 2.0 SITE AND SUBSURFACE CONDITIONS 2.1 SITE DESCRIPTION The following table provides a generalized description of the existing site conditions based on visual observations during the field activities and other available information. TABLE 2.1:SITE DESCRIPTION Site Location CR 49 and FM 43,Corpus Christi,Nueces County,Texas Site History Agricultural Land Existing Site Ground Cover Cultivated Fields North:Undeveloped Cultivated Fields Site Boundaries/Neighboring Development East:London School South:Weber Road West:Residential Subdivision 2.2 FIELD EXPLORATION Field exploration for the project consisted of drilling a total of 18 borings.The boring design element,boring labels,and approximate depths are provided in the following table. TABLE 2.2:FIELD EXPLORATION SUMMARY Design Element Boring Label Approx.Depth of Boring Residential Streets B-1 thru B-4,B-6 thru B-10& 6 feet B-12 thru B-18 Residential Streets&Utilities B-S&B-11 20 feet The boring locations were selected by PSI personnel and were located in the field using available landmarks and GPS coordinates using a recreational-grade device. Elevations of the ground surface at the boring locations were not provided to PSI and should be surveyed by others, if required.Therefore,the references to elevations of various subsurface strata are based on depths below existing grade at the time of drilling.The approximate boring locations are depicted on the Boring Location Plan provided in the Appendix. TABLE 2.3:FIELD EXPLORATION DESCRIPTION Drilling Equipment Truck-Mounted Drilling Equipment Drilling Method Continuous-Flight Auger Drilling Procedure Applicable ASTM and PSI Safety Manual Field Testing Procedures Hand Penetrometer Standard Penetration Testing(ASTM D1586) Sampling Procedure Split-Barrel Sampling of Soils(ASTM D1586) Thin-Walled Tube Sampling of Soils(ASTM D1587) PAGE 3 Y 1 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 Frequency of Groundwater Level Measurements Initial Reading and After Drilling Reading Boring Backfill Procedures Soil Cuttings Sample Preservation and Transportation General accordance with ASTM D4220 Procedure During the field activities, the encountered subsurface conditions were observed, logged, and visually classified(in general accordance with ASTM D2488).Field notes were maintained to summarize soil types and descriptions,water levels,changes in subsurface conditions,and drilling conditions. 2.3 LABORATORY TESTING PROGRAM PSI supplemented the field exploration with a laboratory testing program to determine additional engineering characteristics of the subsurface soils encountered.The laboratory testing program included: • Moisture Content Tests(ASTM D2216) • Atterberg Limits(ASTM D4318) • Material Finer than No.200(ASTM D1140) • Unconfined Compression Strength Test(ASTM D2166) The laboratory testing program was conducted in general accordance with applicable ASTM test methods. The results of the laboratory tests are provided in the Appendix on the Logs of Boring. Portions of samples not altered or consumed by laboratory testing will be retained for 60 days from the date shown this report and will then be discarded. 2.4 SITE GEOLOGY As shown on the Geologic Atlas of Texas,Corpus Christi Sheet,reprinted in 1979,the site is located in an area where the Beaumont Formation (Qb) is mapped at or near the ground surface.The formation is from the Quaternary Period and Holocene Epoch. This formation consists of mostly clay, silt, sand and gravel with stream channels,point bars, natural levees and backswamp deposits. 2.5 SUBSURFACE CONDITIONS The results of the field and laboratory testing have been used to develop a generalized surface profile of the project site.The following subsurface descriptions highlight the major subsurface stratification features and material characteristics.This soil profile descriptions have been summarized in the following table. PAGE 4 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 TABLE 2.4:GENERALIZED SOIL PROFILE Depth of Range Range Layer(ft) Range Range Range %Pass. Hand Pen Avg.UC Layer Soil Type w(%) LL(%) PI (tsf) Top Bot. #200 (tsf) 1 0 20 Fat Clay and Fat 27-41 66-89 39-58 72-90 1.75-4.25 2.25 Clay w/Sand 2* 4 13 Lean Clay 21-33 43 23 80-85 2.0-2.5 2.75 Note: w:Moisture Content LL:Liquid Limit PI:Plasticity Index %Pass.#200:Percent Passing the No.200 Sieve by Wash Hand Pen:Field Hand Penetrometer(tons per square foot) UC:Unconfined Compression Testing of Undisturbed Soil Samples(tons per square feet) *Only encountered in Boring B-11 The boring logs included in the Appendix should be reviewed for information at the boring locations. The boring logs include soil descriptions, stratifications, locations of the samples, and field and laboratory test data.The stratifications shown on the boring logs only represent the conditions the specific boring location and represent the approximate boundaries between subsurface materials. The actual transitions between strata may be more gradual or more distinct.Variations will occur and should be expected across the site. 2.5.1 GROUNDWATER INFORMATION Water level measurements were performed during drilling and after completion of drilling. Specific information concerning groundwater is noted on each boring log presented in the Appendix of this report. No groundwater was encountered during our drilling and sampling activities. Groundwater levels fluctuate seasonally as a function of rainfall, proximity to creeks, rivers and lakes, the infiltration rate of the soil, seasonal and climatic variations and land usage. If more detailed water level information is required, observation wells or piezometers should be installed at the site, and water levels monitored. The groundwater levels presented in this report are the levels that were measured at the time of our field activities.The contractor should be prepared to control groundwater,if encountered,during construction. PAGE 5 Y 1 King's Landing Unit 1 Pavement Study(Rev S) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 3.0 GEOTECHNICAL EVALUATION AND RECOMMENDATIONS 3.1 GEOTECHNICAL DISCUSSION PSI understands that the City of Corpus Christi pavement design requirements for the new Residential Streets pavements within the subdivision be designed for the IDM required 50,000 18-kip Equivalent Single Axle Loads with a 30-year design life. Pavement design sections are also provided for Residential Collector (100,000)ESALs,Local Street(1,000,000 ESALs)and Collector Street,C3(2,000,000 ESALs). Based upon the information obtained from the soil borings and laboratory testing,the clay soils encountered at this site within the seasonally active zone, estimated to be 10 feet below existing grade, have a high potential for expansion.The expansive potential (i.e. "Potential Vertical Movement" or PVM) of these soils should be addressed in the design and construction of this project. The following design recommendations have been developed based on the previously described project characteristics and subsurface conditions encountered.If there are changes in the project criteria,PSI should be retained to review the changes to determine if modifications of the recommendations presented in this report will be required.The findings of such a review will be presented in a supplemental report. Once final design plans and specifications are available, a general review by PSI is recommended to verify that the earthwork and pavement recommendations presented in this report have been properly interpreted and implemented within the construction documents. 3.2 POTENTIAL VERTICAL MOVEMENT OF EXPANSIVE SOILS The soils encountered at the soil boring locations exhibit a high potential for volumetric changes, due to fluctuations in soil moisture content. PSI has conducted laboratory testing on the soils to estimate the expansive soil potential with soil moisture variations.These soil moisture variations are based on historical climate change data. Determining the soil potential for shrinking and swelling, combined with historical climate variation, aids the engineer in quantifying the soil movement potential of the soils supporting the pavement systems.Various shrink/swell movement procedures and the Texas Department of Transportation (TxDOT) test method TEX-124-E, were used to estimate the Potential Vertical Movement (PVM) for this location. 3.2.1 SHRINK/SWELL MOVEMENT(PVM)ESTIMATE Based on laboratory testing results and our analyses,the potential vertical movement was estimated to be approximately 4 inches±1/:inch. It is not possible to accurately quantify actual soil moisture changes and resulting shrink/swell movements. The PVM and referenced structural movement values provided should be considered approximate values based on industry standard practice and experience. Extreme soil moisture variations could occur due to unusual drought severity, leaking water or sewer lines, poor drainage (possibly due to landscape changes after construction), perched groundwater infiltration, springs, etc. Therefore, because of these unknown factors, the shrink/swell potential of soils can often be significantly underestimated using the previously mentioned methods of evaluating PVM. The unknown factors previously mentioned cannot be determined at the time of the geotechnical study. Therefore,estimated shrink/swell movements are calculated only in consideration of historical climate data �1A\ PAGE 6 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 related to soil moisture variations.Movements exceeding those estimated should be anticipated and routine maintenance should be provided to address these issues throughout the life of the pavements. 3.3 UTILITY EXCAVATION AND LATERAL EARTH PRESSURE CONSIDERATIONS New utility lines may be installed below the pavement.The pipe designer should account for sustained loads due to the soil overburden pressures and potential surcharge loads that may be applied to the pipe.The load due to the soil overburden pressures can be estimated using the total and effective unit weights of the soil and depths of each layer of soil.A total unit weight of 110 pcf or buoyant weight of 64 pcf may be assumed for on-site clayey material. In addition, hydrostatic pressures and/or surcharge loads,if present, should also be accounted for in the design. Unbalanced thrust forces could also be developed in the pipeline due to changes in direction,cross-sectional areas, or if the pipe is terminated.These forces may cause joints to disengage if not adequately restrained. To resist movement and overstressing the pipe, suitable buttressing should be provided. In general, thrust blocks and/or concrete encasement are common methods of providing reaction for the thrust restraint design.For design of thrust blocks and similar other thrust restraints may be designed in consideration of an allowable passive resistance of 1,200 psf. Unbalanced forces produced by grade and alignment changes can be resisted by friction on the pipe. The frictional resisting force can be computed by multiplying the pressure produced by the combined weight of the pipe, contained water,and soil overburden by a coefficient of friction between the pipe and underlying bedding material.Based upon the recommended pipe installation and bedding,the unfactored coefficient of friction is anticipated to be approximately 0.3. The Occupational Safety and Health Administration (OSHA)Safety and Health Standards(29 CFR Part 1926, Revised October 1989), require that excavations be constructed in accordance with the current OSHA guidelines. Furthermore, the State of Texas requires that detailed plans and specifications meeting OSHA standards be prepared for trench and excavation retention systems used during construction. Most soils at this site consist primarily of clays that would be classified as OSHA Type "B" soils requiring a temporary excavation slope no steeper than 1H:1V. However,any soils below the groundwater table would be classified as Type"C"soils requiring temporary slopes no steeper than 1 1/2 H: 1V. Groundwater was not encountered in the test borings during our field exploration.We recommend that the contractor perform an investigation to establish groundwater levels prior to construction to evaluate sloping and dewatering requirements prior to construction. 3.4 DISCUSSION OF BEDDING AND BACKFILL MATERIALS Typically,the bedding and initial backfill around a buried pipeline is designed to support and protect the pipe. Secondary backfill is then placed over the initial backfill and pipe to help protect the pipe, reestablish the ground surface at the trench,and provide support to structures overlying the trench. Generally,the bedding and initial backfill materials for piping consist of a graded gravel.The existing soils at the pipe bearing levels should be removed to a minimum depth of six(6)inches below the bottom of the pipe and replaced with gravel bedding.The bedding material should embed the lower quadrant or to the midpoint of the pipe at a minimum and should be compacted in maximum compacted thickness of eight(8)inches with mechanical hand compaction equipment.The initial backfill should extend from the surface of the bedding PAGE 7 Y 1 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 to a point one(1)foot above the top of the pipe and should be compacted in maximum compacted thickness of eight(8)inches with mechanical hand compaction equipment. The secondary backfill may consist of material excavated from the trench.The secondary backfill should be free of debris and should not contain stones greater than three(3)inches in diameter.The secondary backfill should be placed at moisture contents between optimum and plus four(+4) percentage points of optimum and compacted to at least 95 percent of the maximum dry density as determined by ASTM D698. Each lift should be placed with a maximum compacted thickness of six(6)inches.Care should be taken during backfill compaction to prevent structural damage to the pipe. 3.5 EXCAVATION AND SHORING CONSIDERATIONS Lateral earth pressures from the soils will be applied to the trench shoring.Additionally,hydrostatic pressures and any equipment loads,and other surcharges should be considered for trench shoring design.The follow table should be utilized for the design of the allowable temporary slopes and trench shoring. TABLE 3.1:EXCAVATION AND SHORING DATA Material Type OSHA Soil Type At-Rest Condition,Ko Fat and Lean Clay(CH "B" 0.60 and CL) Fat and Lean Clay below GWT(CH and CL), "C" 0.60 Clayey Sands(SC) A lateral earth pressure of 120 pcf*Ko*depth(ft) should be used to evaluate lateral earth pressures applied to the shoring in a rectangular distribution. These values do not consider hydrostatic pressures. We recommend that the hydrostatic pressure be added to the lateral earth pressure in a triangular distribution of 62.4 pcf* (X)for that portion of the shoring below the groundwater table. PAGE 8 Y 1 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 4.0 PAVEMENT DESIGN RECOMMENDATIONS 4.1 PAVEMENT DESIGN PARAMETERS PSI understands that Roller Compacted Concrete pavements are being considered for this project.Pavement design recommendations based on the City of Corpus Christi IDM pavement design requirements for the various planned street types as outlined in Table 4.1 below are provided.In addition,PSI utilized the"AASHTO Guide for Design of Pavement Structures" published by the American Association of State Highway and Transportation Officials to evaluate the pavement thickness recommendations in this report.This method of design considers pavement performance,traffic, roadbed soil, pavement materials, environment, drainage and reliability. Each of these items is incorporated into the design methodology. PSI is available to provide laboratory testing and engineering evaluation to refine the site-specific design parameters and sections,upon request.Details regarding the basis for this design are presented in the table below. TABLE 4.1:PAVEMENT DESIGN PARAMETERS AND ASSUMPTIONS 70 for Residential Street,28 feet wide Reliability,percent 75 for Residential Collector,40 feet wide 80 for Local Street,50 feet wide 90 for Collector Street C3,50 feet wide Design Life 30 Years Initial Serviceability Index 4.5 Terminal Serviceability Index 2.5 Residential Street:50,000 ESALs Traffic Load Residential Collector:100,000 ESALs Local Street:1,000,000 ESALs Collector Street:2,000,000 ESALs Standard Deviation 0.39 Concrete Compressive Strength 4,000 psi Estimated Subgrade California Bearing Ratio(CBR) 2.0 for high plasticity clay subgrade Estimated Subgrade Modulus of Subgrade Reaction,k in pci 75 for high plasticity clay subgrade Pavements supported on expansive soils will be subject to PVM previously presented(approximately 4 inches ±1/2 inch).These soil movements typically occur to some degree over the life of the pavement.Consequently, pavements can be expected to crack and require periodic maintenance.The pavement section thickness of approximately 15 to 16 inches would reduce the anticipated PVR to approximately 2%2 inches.It is our opinion that this magnitude of PVR can be primarily resisted considering a concrete or RCC pavement section. During the paving life, maintenance to seal surface cracks within concrete pavement and to reseal joints within concrete pavement should be undertaken to achieve the desired paving life. Perimeter drainage should be controlled to prevent or retard influx of surface water from areas surrounding the paving. Water penetration leads to paving degradation. Water penetration into subgrade materials, sometimes due to irrigation or surface water infiltration, leads to pre-mature paving degradation. Curbs should be used in conjunction with concrete paving to reduce potential for infiltration of moisture into the subgrade.Clay type compacted materials(12-25)or flowable fill should be placed on top of the base and beneath the sidewalk so that a path for moisture infiltration under the curb and into the pavement section is mitigated. PAGE 9 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 The City of Corpus Christi requires the base and subgrade to be extended beneath the curb and gutter and to 2 feet behind the Curb. In accordance with City Standard Spec 025612(Concrete Curb and Gutter)there is a requirement for compaction behind the Curb within 48 hours of removing forms. Material specifications, construction considerations, and thickness section requirements are presented in following sections. The presented recommended pavement sections are based on the field and laboratory test results for the project,City of Corpus Christi pavement design practice,design assumptions presented herein and previous experience with similar projects. The project Civil Engineer should verify that the design values are appropriate for the expected traffic and design life of the project. PSI should be notified in writing if the assumptions or design parameters are incorrect or require modification. 4.2 PAVEMENT SECTION RECOMMENDATIONS PSI anticipated that the roadways will be used primarily by typical residential traffic primarily consisting of passenger vehicles, pickup trucks, school buses, delivery vehicles, and garbage trucks. PSI is providing thickness sections based on experience with similar facilities constructed on similar soil conditions for the design traffic loading anticipated. 4.2.1 ROLLER COMPACTED CONCRETE PAVEMENT Thickness recommendations for roller compacted concrete(RCC)pavement are provided below. Roller Compacted Concrete Lime Treated Subgrade Native Soil FIGURE 4.1:ROLLER COMPACTED CONCRETE PAVEMENT TYPICAL SECTION TABLE 4.2:ROLLER COMPACTED CONCRETE PAVEMENT DESIGN THICKNESS Thickness(in) Material Residential Residential Street Collector Local Street Collector RCC Pavements 7.0 7.0 8.0 8.0 Lime/Cement Treated Subgrade 8 8 8 8 The AASHTO design calculation spreadsheets for these various street classifications are included in the Appendix. PAGE 10 Y 1 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 4.2.2 GENERAL PAVEMENT DESIGN AND CONSTRUCTION RECOMMENDATIONS Roller compacted concrete pavement should be constructed in general accordance with TxDOT Special Specification 3016, Roller Compacted Concrete (included in the Appendix). Recommendations based upon the TxDOT specification are presented in the following table. TABLE 4.3:PAVEMENT PROFILE DESIGN AND CONSTRUCTION RECOMMENDATIONS Minimum Undercut Depth 6 inches or as needed to remove roots Reuse Excavated Soils Free of roots and debris and meet material requirements of intended use Undercut Extent 2 feet beyond back of curb Proof-roll with rubber-tired vehicle weighing at least Exposed Subgrade Treatment 20 tons.A representative of the Geotechnical Engineer _ should be present during proof-roll. Excavate to firmer materials and replace with compacted Proof-Rolled Pumping and Rutting Areas general or select fill under direction of a representative of the Geotechnical Engineer Materials free of roots,debris,and other deleterious General Fill materials with a maximum rock size of 4 inches with a CBR greater than 3.This will be confirmed by CMT. Minimum General Fill Thickness As required to achieve grade Maximum General Fill Loose Lift Thickness 9 Inches Performed in general accordance with TxDOT Item 260. Subgrade treated with lime should achieve a pH of 12.4 or greater.A lime series test should be performed at the time of construction after the pavement subgrade soils are established to determine the lime requirement.For estimating purposes,use 3%lime by dry weight.Sulfate Lime/Cement Treatment testing should also be conducted before placement of lime to evaluate the potential for sulfate induced heave from the lime stabilization.The organic content of the subgrade should not exceed 3%. Once the min.24 hour mellowing period for lime is complete,the lime stabilized subgrade should be cement stabilized with 5%cement per TxDOT Item 275. Proposed RCC Mix Design should be reviewed by City of RCC Mix Design Corpus Christi and PSI prior to construction.A trial batch is required to ensure workability and compressive strength. Concrete Compressive Strength(28 days) Minimum 4,000 psi Cement:TxDOT Item 421. Concrete Cement and Aggregates Aggregates:RCC Combined Aggregates Gradation for RCC Surface Course.Materials Passing the No.40 Sieve should have a Plasticity Index of less than 4. PAGE 11 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 The RCC should be compacted to a min.dry density of at least 95%of the Modified Proctor(ASTM D-1557) maximum dry density within 2%of optimum moisture content. Quality Control of RCC Pavements Molding compressive strength:Per ASTM C1435,1 set of 4 of cylinders for 2@7 days,2@28 days compression testing for every 1,500 cy of RCC with a minimum of 2 sets per day. The concrete batch plant should be within 30 minutes from point of placement. Production of RCC must be Placement of RCC Pavements adequate to mitigate the potential of unplanned cold joints.The pavement should be placed and compacted as required by TxDOT Special Specification 3016. ASTM C1040-In-Place Density of Unhardened and Hardened Concrete, Including Roller Compacted Compaction Testing of RCC Pavements Concrete,By Nuclear Methods.Single Lift and a minimum of 2 tests per day or per 500 CY.Testing should be completed within 30 minutes after rolling. Transverse Joints: Maximum 15-foot intervals.Joints should be saw blade width to a depth of at least%the pavement thickness and filled and sealed with approved RCC Crack Control joint sealants and fillers. Expansion and Control Joints:As required. Filled and sealed with approved joint sealants and fillers. TABLE 4.4:COMPACTION AND TESTING RECOMMENDATIONS FOR PAVEMENT AREAS Test Method for Percent Optimum Testing Location Material Density Compaction Moisture Frequency Determination Content Pavement Scarified On-site 1 per 7,500 SF; Areas Soil(Subgrade) ASTM D698 >_95% 0 to+4% min.3 tests General Fill (Onsite ASTM D698 >_95% 0 to+4% 1 per 10,000 SF; Material) min.3 per lift RCC Pavement ASTM D1557 >95% Single Lift 1 per 500 CY or Single Lift RCC Pavement ASTM 1170 ?98% 1 per CY PAGE 12 �\J King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 5.0 CONSTRUCTION CONSIDERATIONS PSI should be retained to provide observation and testing of construction activities involved in the earthwork, pavements and related activities of this project.PSI cannot accept any responsibility for any conditions which deviate from those described in this report,nor for the performance of the pavements if not engaged to also provide construction observation and materials testing for this project. The PSI geotechnical engineer of record should be retained to provide continuing geotechnical consulting services and construction document review,even if periodic on-call testing is contracted with PSI Construction Services. 5.1 INITIAL SITE PREPARATION CONSIDERATIONS 5.1.1 SUBGRADE PREPARATION FOR SITE WORK OUTSIDE PAVEMENT AREAS Grade adjustments outside of the pavement areas can be made using select or general fill materials.The clean excavated onsite soils may also be reused in areas not sensitive to movement. TABLE 5.1:SUBGRADE PREPARATION FOR NON-STRUCTURAL-GENERAL FILL Minimum Undercut Depth 6 inches or as needed to remove roots,organic and/or deleterious materials Proof-roll with rubber-tired vehicle weighing at least Exposed Subgrade Treatment 20 tons.A representative of the Geotechnical Engineer should be present during proof-roll. Excavate to firmer materials and replace with compacted Proof-Rolled Pumping and Rutting Areas general or select fill under direction of a representative of the Geotechnical Engineer General Fill Type Clean material free of roots,debris and other deleterious material with a maximum particle size of 4 inches Maximum General Fill Loose Lift Thickness 8 inches TABLE 5.2:FILL COMPACTION RECOMMENDATIONS OUTSIDE OF PAVEMENT AREAS Test Method for Percent Optimum Testing Location Material Density Compaction Moisture Frequency Determination Content Outside of Pavement General Fill ASTM D698 >_95% 0 to+4% 1 per 10,000 SF; Areas min.3 per lift 5.2 MOISTURE SENSITIVE SOILS/WEATHER RELATED CONCERNS The soils encountered are sensitive to disturbances caused by construction traffic and changes in moisture content. During wet weather periods, increases in the moisture content of the soil can cause significant reduction in the soil strength and support capabilities. In addition, soils which become wet may be slow to dry and thus significantly retard the progress of grading and compaction activities. It will, therefore, be advantageous to perform earthwork,foundation,and construction activities during dry weather. PAGE 13 Y I Kings Landing Unit 1 Pavement Study(Rev S) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 5.3 SULFATES EVALUATION As indicated previously, the pavement subgrade soils and imported embankment fills should be regularly screened for sulfates during construction. When soluble sulfates are detected above 500 ppm TxDOT Guidelines for Treatment of Sulfate Rich Soils shall be followed.TxDOT has identified mitigation procedures of sulfate bearing soils into three categories,Traditional Treatment,Modified Treatment,and an Alternative Treatment. The Contractor shall follow the mitigation procedures outlined above when high sulfate concentrations (above 3000 ppm) are encountered along the alignment. The amount of mellowing time and moisture content required shall be determined during the mix design process using Tex-145-E, Part II as outlined in TxDOT Guidelines. Furthermore, the sulfate content and the treatment shall be verified in the field in accordance with project Quality Assurance Procedures and TxDOT specifications. 5.4 EXCAVATION OBSERVATIONS The excavations should be observed by a representative of PSI prior to concrete placement to assess that the materials are consistent with the materials discussed in this report.This is especially important to identify the condition and acceptability of the exposed subgrades under the pavements. Soft or loose soil zones encountered at the bottom of the beam excavations should be removed to the level of competent soils as directed by the Geotechnical Engineer. Cavities formed as a result of excavation of soft or loose soil zones should be backfilled with compacted select fill or lean concrete. After opening,excavations should be observed,and concrete placed as quickly as possible to avoid exposure to wetting and drying.Surface run-off water should be drained away from the excavations and not be allowed to pond.If excavations must be left open an extended period,they should be protected to reduce evaporation or entry of moisture. 5.5 DRAINAGE CONSIDERATIONS Water should not be allowed to collect in or adjacent to excavations or on prepared subgrades within the construction area either during or after construction.Proper drainage around grade supported sidewalks and flatwork is also important to reduce potential movements. Excavated areas should be sloped toward one corner to facilitate removal of collected rainwater,groundwater,or surface runoff. 5.6 EXCAVATIONS AND TRENCHES Excavation equipment capabilities and field conditions may vary. Geologic processes are erratic and large variations can occur in small vertical and/or lateral distances. Details regarding "means and methods" to accomplish the work (such as excavation equipment and technique selection) are the sole responsibility of the project contractor. The comments contained in this report are based on small diameter borehole observations.The performance of large excavations may differ. The Occupational Safety and Health Administration (OSHA) Safety and Health Standards (29 CFR Part 1926, Revised October 1989), require that excavations be constructed in accordance with the current OSHA guidelines. Furthermore, the State of Texas requires that detailed plans and specifications meeting OSHA standards be prepared for trench and excavation retention systems used during construction. PSI understands that these regulations are being strictly enforced,and if they are not closely followed,the owner and the contractor could be liable for substantial penalties. PAGE 14 ��11 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 The contractor is solely responsible for designing and constructing stable,temporary excavations and should shore, slope, or bench the sides of the excavations as required to maintain stability of both the excavation sides and bottom.The contractor's"responsible person",as defined in 29 CFR Part 1926,should evaluate the soil exposed in the excavations as part of the contractor's safety procedures. In no case should slope height, slope inclination, or excavation depth, including utility trench excavation depth, exceed those specified in local,state,and Federal safety regulations. PSI is providing this information solely as a service to the client. PSI does not assume responsibility for construction site safety or the contractor's or other parties' compliance with local,state,and Federal safety or other regulations.A trench safety plan was outside the scope of this project. 0 PAGE 15 ��11 King's Landing Unit 1 Pavement Study(Rev 5) PSI Project No:03122159 Corpus Christi,Texas July 11,2022 6.0 REPORT LIMITATIONS The recommendations submitted in this report are based on the available subsurface information obtained by PSI and design details furnished by the client for the proposed project. If there are any revisions to the plans for this project, or if deviations from the subsurface conditions noted in this report are encountered during construction, PSI should be notified immediately to determine if changes in the foundation recommendations are required.If PSI is not notified of such changes,PSI will not be responsible for the impact of those changes on the project. The Geotechnical Engineer warrants that the findings, recommendations, specifications, or professional advice contained herein have been made in accordance with generally accepted professional Geotechnical Engineering practices in the local area. No other warranties are implied or expressed.This report may not be copied without the expressed written permission of PSI. After the plans and specifications are more complete, the Geotechnical Engineer should be retained and provided the opportunity to review the final design plans and specifications to check that the engineering recommendations have been properly incorporated in the design documents. At this time, it may be necessary to submit supplementary recommendations. If PSI is not retained to perform these functions, PSI will not be responsible for the impact of those conditions on the project. This report has been prepared for the exclusive use of MPM Homes for specific application to the proposed King's Landing Unit 1 Pavement Study to be constructed at CR 49 at FM 43 (Weber Road), Corpus Christi, Nueces County,Texas. PAGE 16 4 APPENDIX ' 4 h. 0 z r s'a ist, em• ^ L ISS N:.��.' ,t re•• 0 :`.1 t„ y i, I. �n � ` f , .e z o r IUti i • s,;. i OAte-. A,. 1 1N •y, ..‘ 4, 4. Jh 1 .01e/ _To �o ., �Ir s1 I �.t.:6-4-' !eF m If, I a X '1Ki 1 CL 2 . ji,, I cv N ,2 .•IC N S - c� p ,— > in � � Ur, - F.{ I U O I DMZ i� C N 0 c I d U N Cl) J u n. I0 !Y • v N � cr -0,0 n a� I c o 2 U • 0• • r • '0 I o , jv N CD O O O • xW Q) .„,,, x _ N Q_H O . c) . Clop Q_ ..=:m 0 O.= (n ' O _o n n o o U Y 1 t •••4(ill'P: ••••• -'-- - ' 4111<Z . 1-iiii,:i :I. t; t�'. 0 W N I• J O Q tiww i F P a A a R R A , I _L .., ti T rFri ` F ' . t�} t t - � tlri ft i .- " 11,1E 'om 6 �4 rte' v r..M ..�.. -trii '.-. J_ 1 I a m rl.....n 1 ... a 0 X M i` 6 X a.t is a Ia F a a a s 1F I1 01 . ., ., 0 (( ( I l ` `v �rir� C� g 'f1 T 11 j - T. ,eao iCO nn p :`J U c> 00 (n J � gZ �' • .. tT LL -.0 -17:__: �; ; m -a.)U Q ea + ec o ! Y U • A ._._t! " ip �4,./, laa ,. CO 0 1191 > cn Y iCO as n m m v Sao x N rd ~M .p N 7 U o UL '- kr 0 co o U I t'1 I_1 Y. •r I l "1 g •I a King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-1 LOCATION: 27.694402',-97.488189° 4 N _ 0 HAND PEN(TSF) UNC CMP(TSF) I; J F- 0 4t o6 g �_ I- 2.0 4.0 6.0 3 O w Z 0 z~w w 0 J J GW C) SOIL DESCRIPTION F Q a Ct E o - o N o 2 Q (L)Z v7 av< o o 5 N om �z PL WC LL ~ � W v, oo W Q c� g f x f o ZJ CL Elevation: N/A .. o 20 ao 60 > _07 FAT CLAY with SAND(CH),dark to light gray,very stiff 35 82 76 31 45 4. 40 —5 40 d x Boring terminated at an approximate __ depth of 6 feet. —10— 0 .... . - —15— F- o -- 0 0 I- w z z w ——— m a 0•--- z z —20- 0 0 z --- Y .. . . . .. ....... . .... . .... . 0 O F w 0 —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9128/20 SEEPAGE(ft.):NONE ENCOUNTERED rtent* END OF DRILLING(ft.): None Observed i DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-2 LOCATION: 27.693555°,-97.488160' F- _ } 0 HAND PEN(TSF) •UNC CMP(TSF) O )— —1 cc Z 0 xs_ 0 g 2.0 4.0 6.0 d SOIL DESCRIPTION ~� U Q oH � W z PL C LL �" o co w U 00 w Q cn~> d a f X zm 0 D- g ° 20 40 60 Elevation: N/A o a / FAT CLAY(CH), gray, stiff to hard •• • 39 --— \ I 36 86 84 33 51 * »4. __ lI —5 33 88 ® X __ Boring terminated at an approximate depth of 6 feet. . .... . —10— o .... . . .... . — —15- 0 ❑——— CD 3 ... .- — 0 H W Z z wm C7. .. . z z—20- 0 z O 0 t—25— COMPLETION DEPTH. 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED sited*, END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-3 LOCATION: 27.694164',-97.486943' H F } Q HAND PEN(TSF) •UNC CMP(TSF) a: W 0 4t H 2.0 4.0 6.0 0 W O z W 0 I-w U 0 - J U X I I U.-, }LL I- •CC) a SOIL DESCRIPTION r Z ? p U p o PL WC LL 00 W a ,a- > g g gZ f X f 0 U Elevation: N/A a o o J 20 4o so --9, FAT CLAY(CH), tan and gray.very • stiff 39 © ... . 40 ... (1).... X. ... . .... . —5 37 90 86 28 58 b * X > __ Boring terminated at an approximate depth of 6 feet. —10— • 0 ...... .. • .... . .... . —15— C I- W z - m K a z z —20— o z _—— a C z --- Y O I- 0 —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.): NONE ENCOUNTERED rtMck END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-4 LOCATION: 27.692707°,-97.486971° J L14-F Q - O HAND PEN(TSF) •UNC CMP(TSF) a. LL 0 �z w , 2.0 4.0 6.0 O °0 SOIL DESCRIPTION � — z z a D cc cc o v Pa LL Ncc o � 3o u~ai~> a c~n gz f X f °~ Z� Elevation: N/A o o =� g ° 20 ao 60 FAT CLAY with SAND(CH),gray,stiff to very stiff 34 80 40 :_ X. ... • • • FAT CLAY(CH),gray,very stiff I -5 36 86 85 41 44 »• f Boring terminated at an approximate —— depth of 6 feet. —10— 10 -—- - —15— h - 0 I- W z z w ——— m tt .. - z z —20- 0 z _-- 5 0 z -- Y rn N 0 O H W H — 0 0—25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED Korb*, END OF DRILLING(ft.): None Observed )St DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-5 LOCATION: 27.690883°,-97.486942° 1 • J W F 0 F O HAND PEN(TSF) •UNC CMP(TSF) 4. LI; Dz w ^v7 5_ 2.0 4.0 6.0 0 p u_ 0 J W �W Z U Z�-'w W O J J U I I , U LL }LL = 00 0- f- SOIL DESCRIPTION I-1- z Da_, w d a O ~p LL co fx D d .c m Q tnz ►-UQ v7z PL WC LL zl- a w u7 o � 3 0 0 w20 � Q ccn'-> • c77 g �— f X f 0 " z m Elevation: N/A o e. n ° 20 40 60 D -__r FAT CLAY with SAND(CH),dark gray, stiff to very stiff 34 77 70 30 40 O +)It + ...... --- I t 37 4 -5 34 83 di 41< FAT CLAY(CH),tan,very stiff I 29 88 66 21 45 ....... M f 2.25 104 29 -10 / 11 --- / FAT CLAY with SAND(CH),tan,very --- stiff 26 84 69 22 47 + - —15 1- Ilk ti 0 11 z II co Z ti a % I 1 32 • X 0 .. . z O -20 h Borin terminated at an approximate depth of 20 feet.so pp z z --- Y 0 N • N) 0 N`—— I- .. ... W I- ___ 0 0-25- COMPLETION DEPTH: 20.0 Feet DEPTH TO GROUND WATER DATE: 9/25/20-9/25/20 SEEPAGE(ft.):NONE ENCOUNTERED Wort". END OF DRILLING(ft.): None Observed /St DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-6 LOCATION: 27.689265°.-97.486913' N — 0 HAND PEN(TSF) •UNC CMP(TSF) n. co �F— 0 xt as w g 2 r 2.0 4.0 6.0 0 u. �W w 0 Z~W C. 0 - J Uw 1 ULL }W = C0 v11±1SOIL DESCRIPTION Z 0 0 w < oow Q ~ > 6 ¢ g— f X f °°~ zJ o v o_ ii n- 20 40 60 z Elevation: N/A r FAT CLAY with SAND(CH),dark gray, very stiff 29 76 67 28 39 +,(C f iiiL' 1 30 ..... 0 III -5 26 80 d Boring terminated at an approximate __ depth of 6 feet. —10— O .. - -15- •F • - a I— W _ z W.--- m CCa a --- z CD z -20- 0 z —— — z --— Y .... . . .. . .. . ... .. .. . .. O to O tuD -25- COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED wort* END OF DRILLING(ft.): None Observed • DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-7 LOCATION: 27.694120°,-97.485361' CD F-- — Q HAND PEN(TSF) •UNC CMP(TSF) 0 cn �)- o �* us 2 r 2.0 4.0 6.0 O J W W Z Z~W W 0 - J U W I 1 1 0^ }LL SOIL DESCRIPTION _~ a - a? cc c o c.� o o a } Q Q z 1- I- < o o 5 1- z PL WC LL o� � � 3 �� a cn�> c� g f X f U Elevation: N/A o a a ° 20 40 so FAT CLAY with SAND(CH),dark to light gray,very stiff 41 • 37 76 89 33 56 /' »f ..... I . _ /I -5 38 p k .. . . ._ . _ Boring terminated at an approximate depth of 6 feet. —10— - —15— o -- 0 0 F- w z LL, -—— m a 0——— —20- 0 z _- a C.0 z--— Y ,(J O F W F- --- 0 —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED intertek END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-8 LOCATION: 27.693555°,-97.485724' a ( F F" } 0 HAND PEN(TSF) •UNC CMP(TSF) U cnF 04t xs g t 2.0 4.0 6.0 0 5 I- O w d Z W O F W 0 0 - -J UX 1 I U^ = MI a SOIL DESCRIPTION z z z D W c7 w D 2 Q >a �z F cin I-0 - c~i� Q� PL WC LL o~ �m WO (n > Q cn a.F> C7 f x f U Elevation: N/A o a _J a. ° 20 40 60 Z V FAT CLAY with SAND(CH),dark gray, very stiff to hard 33 78 75 24 51 f SIC I f --- I 32 .. . ..... .... . .. . I / ... . .... . FAT CLAY with SAND(CH),tan,very —— stiff I j —5 34 81 J1» __ Boring terminated at an approximate depth of 6 feet. —10— • O .. . ... .... . 0 '0 --- - —15— F U 0 I- W z m r a a--- z Z—20— s rn t O f- O —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED '^rte'"` END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-9 LOCATION: 27.694159',-97.483607° 4 2 H L- 0 HAND PEN(TSF) •UNC CMP(TSF) a ~ J w - 0 xc oa—Pu) 2 H 2.0 4.0 6.0 w w =, v > Q SOIL DESCRIPTION �Z Q - ?a rx o - �p zCX w c}i) ¢ 3 OD w Q a_> o o z PL WC * O Zm V _� a D- 20 40 60 z D Elevation: N/A o ——� - FAT CLAY with SAND(CH).dark to light gray,very stiff 36 77 74 30 44 �C Qf 39 4)4 -5 36 85 ChX ___ Boring terminated at an approximate depth of 6 feet. —10— o . 0 a —15— o C� C7 w Z z - m a - F . ... . z CD —20— E z -—— a rn h _ N -- 0 O I- Lu I- _—- -25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.): NONE ENCOUNTERED '"tom END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-10 LOCATION: 27.693016°,-97.483549° N _ Q HAND PEN(TSF) •UNC CMP(TSF) �F— 0 It 00 m g 2.0 4.0 6.0 O = 0 W �W w Z ZR� 0 U Uw 1 1 I ULL �� SOIL DESCRIPTION I— o f ct 0 1-0co W 0 00 W m~> o a Tr �� PL WC f °~ zJ o 7 g D- 20 40 60 z Elevation: N/A o - FAT CLAY with SAND(CH),dark gray, very stiff 35 p�( --- I f 32 83 83 32 51 »0 FAT CLAY with SAND(CH),tan,very -- fl -5 stiff 27 79 Boring terminated at an approximate -- depth of 6 feet. -10- 0 - -15- w w Z w —-- m 0 • a 0——— z z-20- 0 z a y Y 0 O —- F N I- 0 0 -25- COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED '"b°rtek, END OF DRILLING(ft.): None Observed pst DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-11 LOCATION: 27.691366°,-97.483994° NH. Q HAND PEN(TSF) •UNC CUP(TSF) d -' w � �z w * °a M 2 1- 2.0 4.0 6.0 0 ,---- u- O O f-w O 0 J J O 1 1 1 U- I- DESCRIPTION I-w za (Z z a-_1 w ci U co re LL CI_ N 3 0a Lu a 0_F_> . a _ f X f °~ zJ Elevation: N/A o o a 20 ao 60 > -__V FAT CLAY with SAND(CH),dark gray, , very stiff to hard • 31 72 70 29 41 f 30 I \ e LEAN CLAY with SAND(CL),light % -5- gray to tan,very stiff 21 80 43 20 23 • CP at 26 85 4 2.75105 . . f --- 33 ..� iC -10 / 1 I Il iii , 1 FAT CLAY with SAND(CH),tan,very 1 1 stiff to hard 27 85 67 24 43 f 0 I 1 - -15 / I 1 o FI i z I . 1 z m cc I a %Z I . I • F 32 *. z z• 20 Boring terminated at an approximate _, depth of 20 feet. In 0 zY m h ',7.. -—— o O w I- N ...... W 0 -25- _ COMPLETION DEPTH: 20.0 Feet DEPTH TO GROUND WATER DATE: 9/25/20-9/25/20 SEEPAGE(ft.):NONE ENCOUNTERED iim*. END OF DRILLING(ft.): None Observed p ,t DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-12 LOCATION: 27.689265°,-97.483983° NF t_ r 0 HAND PEN(TSF) 0 UNC CMP(TSF) ~ J w IA z o ' o($ (n FX 2.0 4.0 6.0 O P u_ O O Ew U O J J U_Ll.) 1 1 I U y LL CID a 1- SOIL DESCRIPTION i-~ Q - z n: cf cc a — F-rn LL`n o D CL 3o Lij a ��> o o ; gz PL WC • o~ Zm Elevation: NIA o o _ a.a. a 20 40 60 z p FAT CLAY with SAND(CH),dark gray, i I very stiff 317366 27 39G� - 16 i X41 31 orr FAT CLAY with SAND(CH),tan,very 'jstiff 29 81 d X Boring terminated at an approximate -—— depth of 6 feet. —10— 0 ID--- - —15— — 0 0 I- --- I- w z z w --- m W a' 0——— • z z—20- 0 z -- J C 0 z y a' .. U) N --- N M O N--- I- w O —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED "'t" , END OF DRILLING(ft.): None Observed psi DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-13 LOCATION: 27.693641',-97.482696° CD H — } O HAND PEN(TSF) •UNC CMP(TSF) 0 • J w CKZ ww D P W 0 0 Ux 2.0 4.0 6.0 0. U- • ca ii SOIL DESCRIPTIONw Q zCL:— J wo v D- r Q Q ~z < 0 Q o o `n z PL WC LL o• o m wo vy � �� u)a cn~ > C7 g f X f • z� Elevation: N/A o 0 20 40 60 D —r FAT CLAY(CH),light gray,very stiff to hard 28 q --— t \ 30 85 83 27 56 'AC »f I .1.. . —— — FAT CLAY(CH), tan, hard I —5 26 86 X Ch Boring terminated at an approximate ——— depth of 6 feet. —10— —— o—15— I 0 0 F- --- z — m I- • . . .. z z —20- 0 O W 0 —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED ontertek END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-14 LOCATION: 27.693684',-97.480846° A 2 F H } Q HAND PEN(TSF) •UNC CMP(TSF) 0: co * xs g H 2.0 4.0 6.0 CL w SOIL DESCRIPTION �� Q - z a _ er o - )=o u c a r Q ¢ (z F- (up n I- < o o 5 1 �z PL WC LL p~ P cn � 0� -C1‘: cn > C7 g g- f X f U Elevation: N/A o a 20 ao so ___1 FAT CLAY with SAND(CH),dark gray, hard Q 26 75 83 32 51 f 1 >>f I 29 t --- FAT CLAY wth SAND(CH),tan, hard ); I -5 29 87 X b -- Boring terminated at an approximate depth of 6 feet. -10- tD --- - -15- E 0 W z z W --- m a — F .. . .... . .. . 2 z -20- zz _-- a • Z --- Y •rn M V1--- -25- COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED '^*0ft II END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-15 LOCATION: 27.693684°,-97.479215° CD F — r 0 HAND PEN(TSF) •UNC CMP(TSF) 0 LL J va W H 0 4t xs g 2 H 2.0 4.0 6.0 O r= 0 W Z W ( F-LLl 0 0 — --I (3 X I I U g a_ 1— SOIL DESCRIPTION H� z � z d cc ct 0 — F p LL w D- 2 2 Q (z H F-U Q F- �z PL WC LL z P o < �0 w a~> a — f X f o Elevation: N/A o 8.?. g ° 20 4o so ——� FAT CLAY with SAND(CH),gray,very stiff 32 73 72 30 42 I 36 I � I FAT CLAY with SAND(CH),tan and—5gray,very stiff 32 81 d X __ Boring terminated at an approximate depth of 6 feet. -10- - - - -15— 0 U W Z z W——— m W c� -- — z z —20- 0 z --- 2 cnN O V7 — - VI —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.): NONE ENCOUNTERED '"(`"t`"` END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas BORING B-16 Project No. 0312-2159 LOCATION: 27.696498°,-97.479312` H O HAND PEN(TSF) .UNC CMP(TSF) Q ~ (t w F- as 2.0 4.0 6.0 0 Z UJ Hw U O J UX I 1 U., >,W = m SOIL DESCRIPTION �� z d to C7 v p u: CL Q z dUJQ o }— u)z PL WC LL p~ m o 0 0 C</c) cn > c� g �— f X f — Elevation: N/A o -J a 20 40 60 z __7 FAT CLAY with SAND(CH),gray,very • • stiff • 31 —— 35 82 76 31 45 — t�j fejE f —5 31 81 bC . . . .. . .... . .... . .... . . Boring terminated at an approximate depth of 6 feet. ........ ........ —10— ... .. . ...... o . . • -15— I- 0——- cI I- -- I- W Z z W— -- m a 0——— 2 z —20— O N U --- Y O O I —25— COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED " `l`, END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT):N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-17 LOCATION: 27.697176,-97.482781° --- - - --- -- ---- � �---- F F"" 0 HAND PEN(TSF) UNC CMP(TSF) d. OJ ,v1-1-1 W� 0 ��� o I- 2.0 4.0 6.0 D_' LL Z W _W 0 — 5 I 1 I _ co SOIL DESCRIPTION F tW - Z ?n p v 1—pW LL w N Oo w FT) 0-§ o 5- PL WC LL a~ �m o gU 2 g n- f X-41 o z Elevation: N/A o o_ D 20 40 60 Z FAT CLAY with SAND(CH).dark gray, -- very stiff to hard 36 78 72 30 42 R f 4( t 32 - -- FAT CLAY with SAND(CH),tan,very I / stiff I i -5 32 81 X Boring terminated at an approximate ___ depth of 6 feet. • -10- • 0 - -15— I- c� U I- w z z w --— m LU a 2 Z -20- 0 z --- a 0 z --- Y T O N -— I- W I- --- 0 0 ' -25- COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED untertek END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT): N/A King's Landing Unit 1 CR 49 at FM 43, Corpus Christi, Texas Project No. 0312-2159 BORING B-18 LOCATION 27.695365',-97.482684' A 2 H F- Q HAND PEN(TSF) •UNC CMP(TSF) LL _I v> ~ 0 0 06F-W 0 0 - 1-11 5 X 2.0 4.0 6.0 (7) LL nJ SOIL DESCRIPTION �F- ¢ - ?a in w 0 1-0 Z o w < 50 w a ��> o 0 0 g g— PL WC f 0 -' Zm 0 Cf D- _� o_ a 20 40 60 z Elevation: N/A -_� FAT CLAY(CH). gray,very stiff 37 85 80 31 49 fqt f 34 �� .. __ FAT CLAY(CH),tan,very stiff // -5 34 88 ___ Boring terminated at an approximate depth of 6 feet. -10- . N_ -15- •0 I- w z w --- m to • a — f- ...... .... ... . z z —20— o z _-- •0 z --— Y rn N ——— O F W C -25- COMPLETION 25-COMPLETION DEPTH: 6.0 Feet DEPTH TO GROUND WATER DATE: 9/28/20-9/28/20 SEEPAGE(ft.):NONE ENCOUNTERED ',tette* END OF DRILLING(ft.): None Observed DELAYED WATER LEVEL(FT):N/A Symbol Key Sheet Material Symbols N, t-- . ,\\.1,,,,‘ %,00 ...1 N "FILL" Clay(CH) % ., N - Sandy Clay(CL) %0 0 Silty Clay(CL) n Lean Clay(CL) \\\N 7"..",- ••.'.• In Asphalt Clayey Sand(SC) ..•...1-1'.' Sand(SP) , . Silty Sand(SM) ........ Gravelly Sand(SP) .•:••••••::: • " .. ....... • • Base \,%, Clayey Silt(ML) Ili 1 Sandy Silt(ML) IIII Silt(ML) min Gravelly Silt(ML) to,-.-cii 7," 1 IR oli Concrete 4,0i., Clayey Gravel(GC)R* Sandy Gravel(GP) 11 Ila Silty Gravel(GM) .liv Gravel(GP or GW) t'rli Conglomerate I Limestone - — — - Marl , i -. Sandstone Shale _ _ / . Strength of Cohesive Soils Soil Plasticity Density of Granular Soils Undrained Shear Degree of Plasticity SPT Blow Consistency Strength, KSF Plasticity Index(PI) Descriptive Term Count(blows/ft) Very Soft less than 0.25 None 0 to 5 Very Loose less than 4 Soft 0.25 to 0.50 Low 5 to 10 Loose 4 to 10 Firm 0.50 to 1.00 Moderate 10 to 20 Medium Dense 10 to 30 Stiff 1.00 to 2.00 Plastic 20 to 40 Dense 30 to 50 Very Stiff 2.00 to 4.00 Highly Plastic more than 40 Very Dense more than 50 Hard greater than 4.00 Standard Penetration Test (ASTM D 1586) Driving Record Note Drivmg is tinted to 50 blows per$nlerval,or 25 blows for 025 inch advancement.whichever controls This,s done to aced demagog sampling!cols Blows Per Foot Description 25 Sampler was seated 6 inches,then 25 blows were required to advance the sampler 12 inches. 75/8" Sampler was seated 6 inches,25 blows were required for the second 6 inch increment and the 50 blow limit was reached at 2 inches of the last increment. Ref/2" Sampler could only be driven 2 inches of the 6 inch seating penetration before the 50 blow limit was reached. Terms Characterizing Structure Soil Terms Description Blocky Contains cracks or failure planes resulting in rough cubes of material. Calcareous Contains appreciable quantities of calcium carbonate. Fissured Contains shrinkage cracks,which are frequently filled with fine sand or silt. The fissures are usually near vertical in orientation. Interbedded Composed of alternating layers of different soil types. Laminated Composed of thin layers of varying color and texture. Nodules Secondary inclusions that appear as small lumps about 0.1 to 0.3 inch in diameter. Partings Inclusion of different material less than 1/8 inch thick extending through the sample. Pockets Inclusion of different material that is smaller than the diameter of the sample. Seams Inclusion of different material between 1/8 and 3 inches thick,and extends through the sample. Slickensided Has inclined planes of weakness that are slick and glossy in appearance. Slickensides are commonly thought to be randomly oriented. Streaks or Stains Stains of limited extent that appear as short stripes,spots or blotches. Rock Terms Bedding Plane A surface parallel to the surface of deposition,generally marked by changes in color or grain size. Fracture A natural break in rock along which no displacement has occurred. Joint A natural break along which no displacement has occurred,and which generally intersects primary surfaces. %Recovery The ratio of total length of recovery to the total length of core run,expressed as a percentage. ROD-Rock Quality The ratio of total recovered length of fragments longer than 4 inches to the total run length,expressed Designation as a percentage. Weathering The process by which rock is broken down and decomposed. Sampler Symbols H Flight Auger 1:1 Core Barrel Disturbed r — No Recovery G Grab Sample Undisturbed _ Shelby Tube(3") Z SPT Sample Shelby Tube(3") \ AASHTO Pavement Section Calculations—King's Landing Unit 1 Kings Landing Unit Kings Landing Unit 1 1 -Residential -Residential Project Name Street Project Name Collector Provide By: DB Provide By: DB Date: 7/11/2022 Date: 7/11/2022 ESAL ESAL W18 = 2,019,993 Pass W18= 1,765,427 Pass R= 70 % R= 75 % ZR= -0.524 ZR = -0.674 So= 0.39 So= 0.39 t= 7 inches — t= 7 inches po = 4.5 pc= 2.5 po= 4.5 S'c= 680 psi p` 2.5 — - Sc' = 680 psi J 3.2 Cd = 1 J 3.2 Ec= 5,000,000 psi Cd = 1 k= 125 pci Ec = 5,000,000 psi f'c = 4,000 psi k= 125 pci fc = 4,000 psi Project Kings Landing Unit 1 - Name Local Street Kings Landing Unit 1 Provide By: DB Project Name -Collector-C3 Date: 7/11/2022 Provide By: DB ESAL Date: 7/11/2022 ESAL W18 = 1,519,567 Pass __ R= 80 % W18= 2,232,073 Pass ZR= -0.841 R= 90 So= 0.39 ZR = -1.282 t= 7 inches So= 0.39 po= 4.5 t= 8 inches pt= 2.5 po= 4.5 S'c= 680 psi pi= 2.5 J 3.2 S'c = 680 psi Cd = 1 J 3.2 Ec = 5,000,000 psi Cd = 1 k= 125 pci Ec = 5,000,000 psi f'c= 4,000 psi k= 125 pci f'c = 4,000 psi 3016 Special Specification 3016 =_ rBX88 Roller Compacted Concrete Depet of Thansportadon 1. DESCRIPTION Construct roller compacted concrete(RCC)pavement.RCC will provide the final riding surface unless shown on the plans as base course where it will be covered with one or more lifts of asphalt concrete pavement. This specification references select Sections in Items 360,420,and 421 of the Texas Department of Transportation's Standard Specifications for Construction and Maintenance for Highways,Streets,and Bridges incorporating current Texas Department of Transportation required special provisions to the Items. Contractor must comply with Item 360,"Concrete Pavement"unless otherwise specified herein. 2. MATERIALS Furnish materials in accordance with Section 421.2,"Materials"of Item 421,"Hydraulic Cement Concrete" and meet requirements of the following: 2.1. Aggregate.Meet the requirements of Section 421.2.6,"Aggregate"except for gradation and additional requirements shown below. For aggregate,use a well-graded aggregate and conforming to one of the combined gradation(s)shown in Table 1. Tablet RCC Combined Aggregate Gradation Sieve Size RCC Surface Course- RCC BaselSubbase Course- Percent Passing by Weight Percent Passing by Weight 1" 100 100 3/4" 100 90-100 1/2" 70-90 70-90 3/8" 60-85 60-85 #4 40-60 40-60 #16 20-40 20-40 #100 6-18 0-10 #200 0-8 --- The surface course gradation may be used for a RCC base/subbase course. The base/subbase gradation is not allowed for a surface course mix. The maximum Plasticity Index(PI)for materials passing the#40 sieve is four(4). The use of recycled crushed hydraulic cement concrete as a coarse or fine aggregate is allowed.Limit recycled crushed concrete fine aggregate to a maximum of 20%of the fine aggregate. 2.2. RCC Mix Design.Design the RCC mix to meet Sections 421.4.2,"Mix Design Proportioning"and 421.4.3, "Concrete Trial Batches"except for the following; • The requirements of Table 8 in Item 421 do not apply to RCC; • The requirements of Table 9 along with all requirements for slump,and mix design options in Item 421 do not apply to RCC. The mix shall be stiff enough to support the compaction equipment and while containing adequate cement paste,evenly distributed,to achieve the required strengths. • The use of Type Ill cement or accelerators is not allowed unless field demonstrated to allow adequate time for placement and compaction and approved by the Engineer. • Develop design strength in accordance with the following procedure: 1 -10 03-15 OTU 3016 1. Select Aggregates meeting the requirements of Section 2.1,"Aggregate" 2. Select a minimum of three cementitious contents.(Select the cementitious contents such that one content will be at an estimated optimum content,a minimum of one additional content below estimated optimum and a minimum of one above estimated optimum) 3. Determine the optimum moisture content for each cementitious content in accordance with ASTM D 1557,"Standard Test Methods for Laboratory Compaction Characteristics of Soil Using Modified Effort." 4. Cast three samples at optimum moisture content for each cementitious content in accordance with ASTM C 1435,"Standard Practice for Molding Roller-Compacted Concrete in Cylinder Molds Using a Vibrating Hammer." 5. Unless otherwise approved,test all specimens cast for compressive strength in accordance with Tex- 418-A at 28 days.Plot the obtained compressive strengths(psi)with their cementitious contents(%). Determine the optimum cementitious content to have a minimum compressive strength of 4,000 psi at 28 days. 6. If the determined optimum cementitious content varies significantly from all cementitious contents used for specimens,determine the optimum moisture content in accordance with ASTM D1557 at the determined optimum cementitious content,recast three specimens in accordance with ASTM C 1435, and test recast specimens with Tex-418-A to verify the compressive strength. 2.3. Curing Compound.Provide Type 2 membrane curing compound conforming to DMS 4650,"Hydraulic Cement Concrete Curing Materials and Evaporation Retardants."Provide SS 1 emulsified asphalt conforming to Item 300,"Asphalts,Oils,and Emulsions,"for RCC pavement to be overlaid with asphalt concrete under this Contract unless otherwise shown on the plans or approved. 3. EQUIPMENT Construct roller compacted concrete with any combination of equipment that will produce a completed pavement meeting the requirements for mixing,transporting,placing,compacting,finishing,and curing and in accordance with this specification. Meet the requirements of Section 421.3,"Equipment"except as follows. The mixing equipment will only include the Pugmill and Central-Mixed. All equipment shall allow for the following requirements to insure quality production. • Inspection of Equipment. Before start-up,the Contractor's equipment will be carefully inspected. Should any of the equipment fail to operate properly,cease work until the deficiencies are corrected. • Access for Inspection and Calibration.Provide the Engineer or their representative access at all times for any plant,equipment,or machinery to be used in order to check calibration,scales,controls,or operating adjustments. • Measurement of Materials.Meet the requirements of 421.4.5,"Measurement of Materials," except that Section 4.4.2,Table 2,"Tolerances for Mixture Ingredients"applies. 3.1. Mixing Plant. Locate the mixing plant within a thirty-minute haul time from the point of RCC placement. Use only plants capable of producing an RCC pavement mixture in the proportions defined by the final approved mix design and within the specified tolerances. The capacity of the plant must be sufficient to produce a uniform mixture at a rate compatible with the placement equipment. If the plant is unable to produce material at a rate adequate to prevent unnecessary cold joints and frequent paver stoppages,the Engineer may halt production until such time that a plant of appropriate capacity is used. Provide and operate plants in accordance with the requirements here and Section 421.4.6,"Mixing and Delivering Concrete." 3.1.1. Pugmill Plant. Use only pugmill plants of the central plant type with a twin-shaft mixer,capable of batch or continuous mixing,equipped with synchronized metering devices and feeders to maintain the correct 2-10 03-15 OTU 3016 proportions of aggregate,cement,pozzolan,water and chemical admixtures,capable of producing a uniform mixture. Other pugmill plant requirements are as follows: • Aggregate Storage. If previously blended aggregate is furnished,storage may be in a stockpile from which it is fed directly to a conveyor feeding the mixer. If aggregate is furnished in two size groups, follow proper stockpiling techniques to ensure aggregate separation. • Aggregate Feed Rate. Use aggregate bins with a feed rate controlled by a variable speed belt,or an operable gate calibrated to accurately deliver any specified quantity of material. If two aggregate size stockpile sources are used,the feed rate from each bin must be readily adjustable to change aggregate proportions,when required. Feed rate controls must maintain the established proportions of aggregate from each stockpile bin when the combined aggregate delivery is increased or decreased. • Cement and Pozzolan Material Storage. Supply separate and independent storage silos for portland cement and pozzolan. • Preblended Portland Cement and Pozzolan. If using on-site preblended portland cement and pozzolan (such as fly ash or slag),employ blending equipment acceptable to the Engineer and demonstrate,with a testing plan,the ability to successfully produce a uniform blended material meeting the mix design requirements. Perform testing on at least a daily basis to ensure both uniformity and proper quantities. ■ Cement and Pozzolan Feed Unit. Provide a satisfactory means of dispensing portland cement and pozzolan,volumetrically or by weight,to ensure a uniform and accurate quantity of cementitious material enters the mixer. • Water Control Unit. Use a water control unit capable of measuring the required amount of water for the approved mix by weight or volume. Ensure that the unit is equipped with an accurate metering device. Vary the amount of water to be used only with the approval of the Engineer. • Gob Hopper. For continuous operating pugmills,provide a gob hopper attached to the end of the final discharge belt to temporarily hold the RCC discharge in order to allow the plant to operate continuously. 3.1.2. Central Mixed Rotary Drum. Provide a rotary drum batch mixer capable of producing a homogeneous mixture,uniform in color,and having all coarse aggregate coated with mortar. Equip the mixer with batching equipment to meet the following requirements; • Weighing Equipment.Measure the amounts of cement,pozzolan,and aggregate entering into each batch of RCC by direct weighing equipment. Use only weighing equipment that is readily adjustable in order to compensate for the moisture content of the aggregate or to change the proportionate batch weights. Include a visible dial or equally suitable device that will accurately register the scale load from zero to full capacity. The cement and pozzolan may be weighed separately or cumulatively in the same hopper on the same scale,provided the cement is weighed first. • Weigh Hoppers.Use only bulk cement and pozzolan weigh hoppers that are equipped with vibrators to operate automatically and continuously while weighing hoppers are being dumped. Ensure that the weigh hopper has sufficient capacity to hold not less than 10 percent in excess of the cementitious material required for one batch. ■ Water Metering.Measure the amount of water entering each batch of RCC by weight or volume. Use only equipment capable of measuring the water to within a tolerance of plus or minus one percent and equipped with an accurate gauge or dial measuring device. Vary the amount of water to be used only with the approval of the Engineer. During batching,admit water to the mixer only through the water measuring device and then only at the time of charging. • Mixing Time.Use only drum mixers equipped with an accurate clock or timing device,capable of being locked,for visibly indicating the time of mixing after all the materials,including the water,are in the mixer. • Recharging. Discharge all material in the drum before recharging. Ensure that the volume of mixed material per batch does not exceed the manufacturer's rated capacity of the mixer. 3-10 03-15 OTU 3016 3.1.3. Alternate Plants. Obtain approval from the Engineer to use other type plants.Demonstrate that the mixing equipment has the ability to produce a consistent,well-blended,non-segregated RCC mix meeting capacity requirements and tolerances of this specification. Meet the requirements of Section 421.4.6,"Mixing and Delivering Concrete." 3.2. Paver. Place RCC with an asphalt-type paver manufactured with a high-density screed subject to approval by the Engineer. Use only pavers equipped with compacting devices capable of producing an RCC pavement with a minimum of 90 percent of the maximum density in accordance with Tex-451-A(ASTM C 1040,"Standard Test Methods for In-Place Density of Unhardened and Hardened Concrete,including Roller Compacted Concrete,By Nuclear Methods")prior to any additional compaction. Ensure that the paver is of suitable weight and stability to spread and finish the RCC material,without segregation,to the required thickness,smoothness,surface texture,cross-section,and grade. 3.3. Compactors.Use self-propelled steel drum vibratory rollers having a minimum static weight of 10 tons for primary compaction. For final compaction,use either a steel drum roller,operated in a static mode,or a rubber-tired(pneumatic)roller of equal or greater weight. Use walk-behind vibratory rollers or plate tampers for compacting areas inaccessible to large rollers. 3.4. Haul Trucks.Use trucks for hauling the RCC material from the plant to the paver fitted and equipped with retractable protective covers for protection from inclement weather or excessive evaporation. To ensure adequate and continuous supply of RCC material to the paver,have a sufficient number of trucks. If the number of trucks is inadequate to prevent frequent starts and stops of the paver,cease production until additional trucks are obtained. 3.5. Water Trucks.Keep at least one water truck,or other similar equipment,on-site and available for use throughout the paving and curing process. Equip such equipment with a spreader pipe containing fog spray nozzles capable of evenly applying a fine spray of water to the surface of the RCC without damaging the final surface. 4. CONSTRUCTION REQUIREMENTS. 4.1. Submittals for Proposed RCC Mix Design and Paving/Jointing Plan 4.1.1. Proposed RCC Mix Design.Submit a proposed mix design to the Engineer for review. If accepted by the Engineer,prepare and test a trial batch mixture at the Contractor's facilities to verify that the design criteria for strength are met in accordance with 421.4.3,"Concrete Trial Batches." Perform batch mixture preparation and testing in the presence of representatives of the Engineer. Make no production until the mix design has been reviewed and the Engineer has given authorization to proceed. 4.1.2. Proposed Paving/Jointing Plan.Submit a paving plan that includes paving sequence,hand pour areas, locations of cold joints,transverse contraction joints,and joints at structures. Use following guides when develop the Paving/Jointing Plan. is Avoid odd-shaped RCC slabs • Avoid joint intersection angles less than 60° • Space transverse contraction joints at 20 ft.spacing ■ Saw cut the transverse contraction joint through the curb when RCC has curb. • Appropriately make field adjustment for joint locations to meet the inlets and manholes 4.2. Storage of Materials.Meet the requirements of 421.2.8,"Storage of Materials." 4.3. Sampling and Testing of Concrete.Unless otherwise specified,all fresh and hardened concrete is subject to testing as follows: 4.3.1. Sampling Fresh Concrete.Provide all material to be tested.Fresh concrete will be sampled for testing at the discharge end if using belt conveyors or pumps.When it is impractical to sample at the discharge end,a 4-10 03-15 OTU 3016 sample will be taken at the time of discharge from the delivery equipment and correlation testing will be performed and documented to ensure specification requirements are met at the discharge end. 4.3.2. Testing of Fresh Concrete. • Temperature.Tex-422-A. • In-Place Field Density Testing.Tex-451-A(ASTM C-1040) • Making and Curing Strength Specimens.ASTM C-1435 and ASTM C-31 (for cast-in-place concrete). 4.3.3. Testing of Hardened Concrete.Only compressive strength testing in accordance with Tex-418-A will be used unless otherwise specified or shown on the plans. 4.3.4. Quality Control Test Specimens.For each day's production,up to 1500 cubic yards of mix produced, prepare at least two sets of test specimens in accordance with ASTM C-1435 and ASTM C-31 under the direct observation of the Engineer or Engineer's representative. A set of specimens consists of three cylinders. Make an additional two sets for each additional 1500 cubic yards or fraction thereof. Cure and transport the specimens to the Contractor's curing tank. The Engineer will test two cylinders for compressive strength in accordance with Tex-418-a at 7 days. If the measured compressive strength between two cylinders varies by more than 10 percent of the stronger cylinder,the Engineer will test the third cylinder and average the results of the three cylinders. Otherwise,the Engineer will average the measured compressive strengths of the two cylinders tested at 28 days to determine the compressive strength of the lot. The Engineer may adjust compressive strength targets at 7 days as production continues based on field experience. 4.4. Mixing Process.Use the same mixture for the entire project unless otherwise stated in the project documents. If,during production,the source of hydraulic cement,pozzolan,or aggregates is changed,then suspend production and submit a new mix design to the Engineer for approval. Do not exceed the manufacturer's rated capacity for dry concrete mixtures in the mixing chamber. Keep the sides of the mixer and mixer blades free of hardened RCC or other buildups. Routinely check mixer blades for wear and replace if wear is sufficient to cause inadequate mixing. 4.4.1. Mixing Time.Use a mixing time adequate to ensure a thorough and complete mixing of all materials. Do not allow the mixing time,after all materials including water are in the mixer,to be less than 1/2 minutes for one cubic yard and 20 seconds for each additional cubic yard. 4.4.2. Mixture Ingredient Tolerances. Measure mixing water,consisting of water added to the batch,ice added to the batch,water occurring as surface moisture on the aggregates,and water introduced in the form of admixtures,by volume or weight.Measure ice by weight.Correct batch weight measurements for moisture. Ensure that the mixing plant receives the quantities of individual ingredients to within the tolerances shown in Table 2. Table 2 Tolerances for Mixture Ingredients Material Variation Cementitious Materials,wt. ±2.0% Water,wt or volume ±3.0% Aggregates,wt ±4.0% Admixtures,wt.or volume ±3.0% 4.4.3. Plant Calibration.Prior to commencement of RCC production,carry out a complete and comprehensive calibration of the plant in accordance with the manufacturers recommended practice. Provide all scales,containers,and other items necessary to complete the calibration. For volumetric mixers, provide test data showing mixers meet the uniformity test requirements of Tex-472-A. 5-10 03-15 OTU 3016 4.4.4. Daily Reports.Supply daily plant records of production and quantities of materials used that day to the Engineer. These records may be used as a check on plant calibration. 4.5. Transportation.Transport the RCC pavement material from the plant to the areas to be paved in dump trucks equipped with retractable protective covers for protection from rain or excessive evaporation. Ensure that the trucks are dumped clean with no buildup or hanging of RCC material in the corners. Have the dump trucks deposit the RCC material directly into the hopper of the paver or into a secondary material distribution system that deposits the material into the paver hopper. Dump truck delivery must be timed and scheduled so that RCC material is spread and compacted within the specified time limits. 4.6. Placing. 4.6.1. Subbase Condition.Prior to RCC placement,meet the requirements of the pertinent Item for the underlying layer and ensure that the surface of the subbase is clean and free of foreign material,ponded water,and frost. Ensure that the subbase is uniformly moist at the time of RCC placement. If sprinkling of water is required to remoisten certain areas,ensure that the method of sprinkling will not form mud or pools of freestanding water. 4.6.2. Weather Conditions. • Cold Weather Precautions.Meet the requirements of Section 360.4.7.3,"Temperature Restrictions." • Hot Weather Precautions.During periods of hot weather or windy conditions,take special precautions to minimize moisture loss due to evaporation. Cooling of aggregate stockpiles by shading or the use of a fine mist may be required. Protective covers may be required on dump trucks. Keep the surface of the newly placed RCC pavement continuously moist. • Rain Limitations.Conduct no placement of RCC pavement during rain conditions sufficient to be detrimental to the finished product. Placement may continue during light rain or mists provided the surface of the RCC pavement is not eroded or damaged in any way. Use dump truck covers during these periods. The Engineer may suspend paving when,in the Engineer's judgment,the rain is detrimental to the finished product. 4.6.3. Paver Requirements.Place all RCC with an approved paver in accordance with in Section 3.2,"Paver"and the following: • Filling the Paver.Do not allow the quantity of RCC material in the paver to approach empty between loads. Maintain the material above the auger at all times during paving.Material transfer devices are allowed at the option of the contractor. • Stopping the Paver.Ensure that the paver proceeds in a steady,continuous operation with minimal starts and stops,except to begin a new lane. Maximum paver speed during laydown is 10 feet per minute. Higher paver speeds may be allowed at the discretion of the Engineer if the higher speeds may be obtained without distress to the final product or cause additional starts and stops. • Surface Condition.Ensure that the surface of the RCC pavement is smooth,uniform,and continuous without excessive tears,ridges,or aggregate segregation once it leaves the paver. 4.6.4. Inaccessible!Transition Areas. When approved by the Engineer,inaccessible areas to either the rollers or the paver,or other areas such as transitions may be paved with cast-in-place concrete in accordance with the requirements of Item 360 and CPCD-14 standard sheet or as shown in the plans. 4.6.5. Adjacent Lane Pavement.Place adjacent paving lanes within 60 minutes. If more than 60 minutes elapses between placement of adjacent lanes,the vertical joint must be considered a cold joint and prepared in accordance with Section 4.8.2,"Cold Vertical Joints". At the discretion of the Engineer,this time may be increased or decreased depending on ambient conditions of temperature,wind,and humidity. Multiple pavers may be used in tandem to reduce the occurrence of cold joints. 6-10 03-15 OTU 3016 4.6.6. Hand Spreading. Broadcasting or fanning the RCC material across areas being compacted is not permissible. Such additions of materials may only be done immediately behind the paver and before any compaction has taken place. Remove segregated coarse aggregate from the surface before rolling. 4.6.7. Segregation.Suspend placement if segregation occurs in the RCC during paving operations until the cause is determined and corrected to the satisfaction of the Engineer. If the segregation is judged by the Engineer to be severe,remove and replace the segregated area at no additional cost to the Department. 4.7. Compaction. 4.7.1. Time to Compaction.Ensure that compaction begins with the placement process and is completed within 60 minutes of the start of the mixing at the plant and in compliance with the previously submitted paving plan. The time may be increased or decreased at the discretion of the Engineer depending on ambient conditions of temperature and humidity and the use of chemical admixtures. Do not delay rolling unless approved by the Engineer. 4.7.2. Rolling.Establish the sequence and number of passes by vibratory and non-vibratory rollers to obtain the specified density and surface finish. Only operate rollers in the vibratory mode while in motion. Rubber-tire rollers may be used for final compaction. Use additional rollers if specific density requirements are not obtained or if placing operations outpace the rolling operations. 4.7.3. Rolling Longitudinal and Transverse Joints.Do not operate the roller within 2 feet of the edge of a freshly placed lane until the adjacent lane is placed. Upon placement,roll both edges of the lanes simultaneously within the allowable time. If a cold joint is planned or expected,roll the complete lane and follow cold joint procedures as specified in Section 4.8.2,"Cold Vertical Joints". 4.7.4. Inaccessible Areas.Compact areas inaccessible to large rollers using walk-behind rollers or hand tampers. 4.7.5. Density Requirements.Perform field density tests at a frequency of 2 for 1500 cubic yards placed as soon as possible,but no later than 30 minutes after the completion of the rolling. Only wet density is used for evaluation. The required minimum density is 98 percent of the maximum laboratory density obtained according to Tex-451-A(ASTM C 1040). The in-place density and moisture content may be determined with a nuclear moisture-density gauge. Calibrate the gauge for moisture content at the beginning of the work and at any time during the work. RCC properly placed and compacted,but not meeting the density requirements, shall be cored and tested at the Contractor's expense. If the tested area achieves 28-day design strength,it will be paid at the full unit price. If the tested area indicates strength less than 4,000 psi but greater than 3,650 psi,payment will be made in accordance with Table 3. If the cores indicate strengths less than 3,650 psi at 28 days or longer,the Department will evaluate the results and may reject the affected area and require removal and replacement or elect to pay at an appropriate reduced rate.The Engineer may allow areas with strengths less than 3,650 psi to remain in place with no pay. The area for pay adjustment will be determined by the Engineer and may be further defined by their direction for additional cores. Table 3 Price Reduction Compressive Price Reduction Strength (percent of unit bid (psi) price) 3999-3800 5 3799-3650 15 4.8. Joints.Multiple pavers may be used in tandem to reduce the occurrence of cold joints. 7-10 03-15 OTU 3016 4.8.1. Fresh Vertical Joints.A joint is considered a fresh joint when an adjacent RCC lane is placed within 60 minutes of placing the previous lane or as specified by the Engineer based on ambient conditions. The time may be increased or decreased at the discretion of the Engineer depending on ambient conditions of temperature and humidity and the use of chemical admixtures. Other than rolling procedures,fresh joints do not require special treatment. 4.8.2. Cold Vertical Joints.Any planned or unplanned construction joints that do not qualify as fresh joints are considered cold joints. Prior to placing fresh RCC mixture against a compacted cold vertical joint,thoroughly clean the cold joint of loose or foreign material. Wet the vertical joint face and maintain it in a moist condition immediately prior to placement of the adjacent lane. For uncompacted surfaces or slopes more than 15 degrees from the vertical,cut the joint vertically for the full depth. Within 2 hours of final compaction,the edge of a cold joint may be cut with approved mechanical equipment. For edges cut after 2 hours,saw-cut to the full depth of the pavement. Demonstrate any modification or substitution of the saw-cutting procedure to the Engineer for approval prior to use. In no case allow cutting of the edge to cause raveling or tearing of the surface. Moisten the cut edge immediately prior to placement of the adjacent lane. For all longitudinal cold joints,route the joint%inch wide and seal in accordance with Section 360.2.7,"Joint Sealants and Fillers." 4.8.3. RCC Pavement Joints at Structures.Line structures such as manholes,valves,or concrete curb and gutter with preformed joint filler in accordance with DMS-6310,"Joint Sealants and Fillers"for Class 6 Preformed Seals. Provide preformed joint fillers with a thickness equal to the width of the joint required and furnish in lengths equal to the width of the slabs in which they are installed.Use preformed joint filler shaped so that, after installation,the upper and lower surfaces conform to the shape of the slab and subbase surfaces. Position the lower surface of the preformed joint filler on or below the surface of the base while the upper surface is 1/2 inch below the surface of the slab unless otherwise specified. 4.8.4. Control Joints.Construct transverse contraction joints in the RCC pavement by sawing. Green-cut shall be utilized as soon as possible behind the rolling operation to prevent random cracking,typically one(1)to four (4)hours. Cut all joints to 1/4 the depth of the RCC pavement to a single saw blade width. Joints should be spaced at intervals of 20 ft for all pavement thicknesses and follow the guides in Section 4.1.2.Control joints shall be sealed in accordance with Section 360.2.7,"Joint Sealants and Fillers." 4.9. Multi-lift Placements. Do not exceed 60 minutes between the start of moist mixing and the end of compaction of any load of RCC in multi-layer construction.Where two or more layers are to be constructed consecutively,do not exceed 120 minutes between the start of moist mixing of the material for the bottom layer and completion of finish,grading,and compaction of the top layer.Grading or operating graders, compacting,or finishing is not allowed after the specified times have elapsed,however,the time may be increased or decreased at the discretion of the Engineer depending on ambient conditions of temperature and humidity and the use of chemical admixtures.Multiple pavers may be used in tandem to reduce the occurrence of cold joints.Keep the surface of the underlying layers moist by fog-spray until covered by the next layer. 4.10. Finishing.Ensure that the finished surface of the RCC pavement,when tested with a 10-foot straightedge or crown surface template,does not vary from the straightedge or template by more than 1/4 inch at any one point and shall be within 5/8 inch of the specified finished grade. When surface irregularities are outside these tolerances,diamond-grind the surface to meet the tolerance. Corrective measures are at the Contractor's cost and will not be reimbursed. For final surfaces,provide a uniform diamond grind texture on all areas under traffic prior to opening to traffic. Target a diamond grind texture of 0.04 in.as measured by Tex-436-A. Correct any location with a texture less than 0.03 in.by performing additional diamond grinding. 8-10 03-15 OTU 3016 For surfaces where an overlay is the final riding surface,unless otherwise directed,correct grade deviations greater than 1/2 in.in 16 ft.measured longitudinally or greater than 1/2 in.over the entire width of the cross- section. 4.11. Curing.Immediately after final rolling and compaction testing,keep the surface of the RCC pavement continuously moist until an approved curing compound,a suitable prime coat,or a layer of asphalt concrete is applied or for 72 hours after placement,whichever comes first.Apply water cure by water trucks equipped with fog spray nozzles,soaking hoses,sprinkling system,or other means such that a uniform moist condition on the surface of the RCC is ensured. Apply this moisture in a manner that will not erode or damage the surface of the finished RCC pavement.Use either water cure or curing compound methods in Sections 4.11. 1 and 4.11.2. 4.11.1. Water Cure.The use of wet mat curing is allowed in accordance with Section 420.4.10."Curing Concrete" using interim Type 1-D curing compound and wet mats. 4.11.2. Curing Compound.Do not use curing compounds when the RCC material is to be promptly covered with asphalt. Apply curing compound conforming to DMS-4650,"Hydraulic Cement Concrete Curing Materials and Evaporation Retardants"in accordance with Section 360.4.9,"Curing"with the exception of application will be prior to texturing.Provide SS-1 emulsified asphalt conforming to Item 300,"Asphalts,Oils,and Emulsions,"for concrete pavement to be overlaid with asphalt concrete under this Contract unless otherwise shown on the plans or approved. Do not use emulsified asphalt when the RCC is the final surface. 4.12. Opening to Traffic.Protect the RCC from vehicular traffic during the curing period. Completed portions of the RCC pavement may be opened to light construction traffic as soon as the strength is sufficient to prevent visible damage to the RCC but no sooner than 24 hours. Water trucks will be allowed on the surface after compaction for the purposes of maintaining moisture. The pavement may be opened to unrestricted traffic after 72 hours and when the strength exceeds 2,500 psi. However,if the temperature drops below 400 F, then the period of time the temperature is below 400 F will be added to the minimum time to opening. Temperature will be based on the hourly ambient air temperature reported by the nearest National Weather Service station. 4.13. Maintenance.Maintain the RCC pavement in good condition until all work is completed and accepted at no additional cost to the Department. 4.14. Thickness and Thickness Tolerance. Provide and operate equipment capable of extracting a small (approximately 1 inch diameter or greater)core to determine the pavement thickness. Extract samples in the presence of the Engineer or Engineer's representative unless otherwise directed. Repair the core holes using a packaged quick set repair mortar such as SikaQuick 1000 or approved equivalent or a Class 4000 or better ready mix concrete. Rod and neatly strike off the repair material. Measure the thickness in the travel lanes of the completed RCC at staggered intervals not to exceed 500 feet in length for two-lane roads. Measure the core to the nearest 0.10 inch at three different,evenly spaced locations and record the average. Where the RCC is deficient in depth by more than 0.75 inch,take an additional core within 3 feet of the original core.If the average of the 2 cores is in excess of 0.75 inches, correct the area by removal and replacement. The extent of the area of correction will be determined by the Engineer and may be further defined by their direction for additional cores. The Engineer may allow areas in excess of 0.75 inches deficient to remain in place with no pay. Where the thickness of a core shows to be deficient by more than 0.2 inches but 0.75 inches or less,a pay adjustment will be made in accordance with Section 6,"Payment"and Table 4.The area for pay adjustment will be determined by the Engineer and may be further defined by their direction for additional cores. 9-10 03-15 OTU 3016 Table 4 Deficient Thickness Price Adjustment Factor Deficiency in Thickness Proportional Part of Contract Price Determined by Allowed Cores(in.) (adjustment factor) Not deficient 1.00 Over 0.00 through 0.20 1.00 Over 0.20 through 0.30 0.80 Over 0.30 through 0.40 0.72 Over 0.40 through 0.50 0.68 Over 0.50 through 0.75 0.57 4.15. Ride Quality.Unless otherwise shown on plans,measure the ride quality in accordance with Item 585,"Ride Quality for Pavement Surfaces,"Surface Test Type B,with Pay Adjustment Schedule 2. 5. MEASUREMENT RCC will be measured by the square yard completed and accepted in place. Pavement constructed outside the area designated to be paved will be not be measured for payment. 6. PAYMENT RCC will be paid for at the unit price for RCC Pavement,of the thickness specified,which price and payment will be full compensation for furnishing all materials,equipment,tools,labor,and incidentals necessary to satisfactorily complete the work. Pavement that is deficient in thickness addressed in Section 4.14, "Thickness and Thickness Tolerance"and density/strength deficiencies addressed in Section 4.7.5,"Density Requirements,"but is permitted to be left in place,will be paid at the reduced unit price as provided in Tables 3 and 4 or no pay in accordance with this Item.No compensation will be made for the materials or labor involved in the removal or replacement of defective material and for diamond grinding or other corrective measures to meet requirements. Cast-in-place concrete placed in areas as allowed under Section 4.6.4., Inaccessible/Transition Areas,will be paid as roller compacted concrete. Concrete curbs required will be for paid for under Item 529,"Concrete Curb,Gutter,and Combined Curb and Gutter." 10-10 03-15 OTU intertek• A COMPLETE BUILDING SOLUTION Os, Everything you need from start to finish-Assurance,Testing,Inspection,and Certification Building Systems Environmental Consulting Consulting & Geotechnical Services Industry professionals provide Assuring site and subsurface a variety of acoustic,fire,AV, conditions meet the criteria for roofing system and enclosure purchase,development and consulting services to ensure construction. proper design and installation of a building's critical systems. 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BASS WELSH ENGINEERING 3054 S.Alameda St. Email:NixMW@aol.com TX Registration No.F-52 Survey Registration No.100027-00 P.O.Box 6397 Corpus Christi,TX 78466-6397 18068-PCE- OVERWIDTH1 07/22/2022 KING'S LANDING UNIT 1 PRELIMINARY COST ESTIMATE C-3 COLLECTOR STREETS IN LIEU OF 28'RESIDENTIAL STREETS COST OF 50'BB STREET NEGLECTING WALKS ITEM DESCRIPTION QUANTITY UNIT UNIT PRICE AMOUNT 1 8"PCCP/RCCP TO LIP OF GUTTER 26077 SY 72.00 1,877,544.00 2 8"LIME STABILIZED SUBGRADE TO 2'BC 30612 SY 8.00 244,896.00 3 8"PORTLAND CEMENT STABILIZED SUBGRADE TO 2'BC 30612 SY 7.00_ 214,284.00 4 EXCAVATION TO 2'BC 30612 SY 2.50 76,530.00 5 6"CURB&GUTTER 10204 LF 13.50 137,754.00 SUBTOTAL $2,551,008.00 DEVELOPER PORTION OF COST OF 28'BB STREET NEGLECTING WALKS ITEM DESCRIPTION QUANTITY UNIT UNIT PRICE AMOUNT 1 2"HMAC TO LIP OF GUTTER 13605 SY 18.00 244,890.00 2 6"CRUSHED LIMESTONE BASE TO 2'BC 18140 SY 15.00 272,100.00 3 8"LIME STABILIZED SUBGRADE TO 2'BC 18140 SY 8.00 145,120.00 4 6"CURB&GUTTER 10204 LF 13.50 137,754.00 4 EXCAVATION TO 2'BC 18140 SY 2.50 45,350.00 SUBTOTAL $845,214.00 qv% CITY PORTION EQUALS DIFFERENCE IN CONSTRUCTION COST 1,705,794.00 A. Di-Tf,f* *10''��• '• ~'--# 7.5%ENGINEERING,SURVEYING,&TESTING 127,934.55 • AMI..... ;INo.ELSfi,.r TOTAL AMOUNT REIMBURSABLE $1,833,728.55 C/STE!A� TOTAL AMOUNT CITY REIMBURSEMENT PER AGREEMENT $1,570,206.65 bNa►t'/, / , Page 1 of 1 Exhibit 6 Concrete Repair Manual * 0 Texas ADepartment of Transportation March 2021 ©2021 by Texas Department of Transportation (512)463-8630 all rights reserved Manual Notice 2021-1 From: Graham A.Bettis,P.E.,Director,Bridge Division Manual: Concrete Repair Manual Effective Date: March 25,2021 Purpose This manual includes step-by-step repair procedures for use on new and existing concrete members cast for the Texas Department of Transportation(TxDOT). Changes Revisions to this manual include various editorial changes including: various reference to patch revised to repair; incorporated language on following manufacturer's material and procedure requirements; incorporated definition of SSD(saturated surface dray);adjusted the duration of water blasting requirement to achieve SSD;incorporated detail for concrete repair with mechanical anchors,and added steps and photos of a typical full-depth deck repair. Contact Please contact the Bridge Division with comments or questions. Archives Past Manual Notices are available in a PDF archive. Table of Contents Chapter 1 —Introduction Section 1 —Overview 1-2 Section 2—Using the Concrete Repair Manual 1-5 Section 3—Standard Specification References to the Concrete Repair Manual 1-6 Section 4—Repairs and Repair Manual 1-7 Section 5—Repair Procedure Submission and Approval 1-8 Section 6—Quality Control/Quality Assurance 1-9 Section 7—Definitions and Abbreviations 1-12 Chapter 2—Damage Assessment and Repair Types Section 1 —Defining Concrete Spalls 2-2 Description 2-2 Notes 2-2 Spall Categories 2-2 Selecting an Appropriate Repair Procedure 2-3 Section 2—Voids Due to Honeycombing 2-5 Description 2-5 Investigating Honeycombed Regions 2-5 Repairing Honeycombed Regions 2-5 Section 3—Damage over Traffic 2-6 Description 2-6 Section 4—Prestressed Concrete Piling 2-7 Description 2-7 Reference 2-7 Notes 2-7 Damage Prior to Driving(e.g. in the Fabrication Yard) 2-7 Damage During Driving 2-8 Lifting Strands 2-9 I Section 5—Taking Cores and Patching Core Holes 2-10 Description 2-10 Selection Criteria 2-10 Taking Cores to Check Compressive Strength 2-10 Taking Cores to Investigate Specific Defects 2-10 Marking Cores 2-10 Patching Core Holes 2-11 Section 6—Trimming or Cutting Prestressed Concrete Girder Ends 2-12 Description 2-12 Concrete Repair Manual i TxDOT 3/2021 Provisions for Acceptance 2-12 Repair Procedure 2-13 Section 7—Recessing Prestressed Strands 2-14 Description 2-14 Repair Procedure 2-14 Section 8—Rail Damage Due to Vehicular Impact 2-15 Description 2-15 Assessment 2-15 Repair Procedure 2-15 Chapter 3—Repair Materials and Procedures Section 1 —Minor Spall Repair 3-2 Description 3-2 Material 3-2 Repair Procedure 3-3 Commentary 3-5 Section 2—Intermediate Spall Repair 3-6 Description 3-6 Material 3-6 Repair Procedure 3-7 Commentary 3-17 Section 3—Major Spall Repair and Concrete Replacement 3-18 Description 3-18 Material 3-18 Repair Procedure 3-18 Commentary 3-22 Section 4—Bridge Deck Repair 3-23 Description 3-23 Selecting an Appropriate Repair Material 3-24 Repair Procedure 3-24 Commentary 3-32 Section 5—Crack Repair–Pressure-Injected Epoxy 3-34 Description 3-34 Material 3-34 Repair Procedure 3-34 Commentary 3-36 Section 6—Crack Repair–Gravity-Fed Sealant 3-37 Description 3-37 Material 3-37 Concrete Repair Manual ii TxDOT 3/2021 Repair Procedure 3-37 Commentary 3-38 Section 7—Crack Repair–Surface Sealing 3-39 Description 3-39 Method 1: Rout-and-Seal Cracks 3-39 Method 2: Surface Sealing 3-39 Concrete Repair Manual iii TxDOT 3/2021 Chapter 1 — Introduction Contents: Section 1 —Overview Section 2— Using the Concrete Repair Manual Section 3—Standard Specification References to the Concrete Repair Manual Section 4—Repairs and Repair Manual Section 5 —Repair Procedure Submission and Approval Section 6—Quality Control/Quality Assurance Section 7—Definitions and Abbreviations Concrete Repair Manual 1-1 TxDOT 03/2021 Chapter 1—Introduction Section 1—Overview Section 1 — Overview This manual includes step-by-step repair procedures for use on existing and new concrete members cast for the Texas Department of Transportation(TxDOT). It includes a comprehensive list of com- mon concrete distresses and repair methods.The methods adhere to industry standards and the provisions from applicable documents by the American Concrete Institute (ACI) and American Society for Testing and Materials (ASTM) .This manual was developed in collaboration with vari- ous repair material manufacturers to ensure that the procedures meet common proprietary requirements. In general, repairs to TxDOT concrete structures should be implemented in accordance with the methods outlined in this manual. However, unusual circumstances occasionally arise.Engineers may determine that methods differing from those outlined here are more appropriate in those circumstances. Updates to the manual are summarized in the following table. Table 1-1:Manual Revision History Version Publication Date Summary of Changes 2015-1 April 2015 New manual. 2017-1 January 2017 Revision adding manual revision history to Chapter 1;revision breaking Chapter 1 into seven sections with no changes to content; revision adding Section 8,discussing rail damage due to vehicular impact,to Chapter 2;revisions for consistency with current DMS- 4655;revised maximum application for neat product to 2";various revisions to Chapter 3,Section 4,"Bridge Deck Repair"and Section 6,"Crack Repair—Gravity-Fed Epoxy"for improved performance of repairs;minor formatting and editorial revisions in various sections. Concrete Repair Manual 1-2 TxDOT 03/2021 Chapter 1—Introduction Section 1—Overview Table 1-1:Manual Revision History Version Publication Date Summary of Changes 2019-1 January 2019 Various editorial revisions including: • Reference to CST revised to MTD • Reference to epoxy anchors revised to adhesive anchors. • Various references to patch revised to repair. Ch 1,Section 6: • Incorporated visual and non-destructive evaluation of repair material as part of Contractor's Responsibilities(QC). Ch 2 Section 4: • Added procedure to recess and coat lifting strands on pre- stressed piling after installation of piling. Ch 2,Section 8: • Referenced Item 445,"Galvanizing"for repair material to galvanized rail components. • Added language that tests on new railing adhesive anchorage may be required by the Engineer. Ch 3,Section 1 • Incorporated storage,temperature,humidity controls,and document controls to ensure material quality. Ch 3,Section 2: • Incorporated typical repair detail and photos showing steps for typical intermediate spall repair. • Incorporated language for temperature controls for mixing and using chilled water. • Added inspection prior to finishing Ch 3,Section 3: • Added inspection prior to finishing Ch 3,Section 6: • Gravity-Fed Epoxy revised to Gravity-Fed Sealant to include other acceptable sealants. • Incorporated language to follow product specifications for maximum working time. Concrete Repair Manual 1-3 TxDOT 03/2021 Chapter 1 —Introduction Section 1 —Overview Table 1-1: Manual Revision History Version Publication Date Summary of Changes 2021-1 February 2021 Various editorial revisions including: • Various references to patch revised to repair. Ch 1, Section 6: • Incorporated language about agreement on location of nondestructive testing. Ch 2, Section 3: • Incorporated that repair plans need to be sealed and signed by professional engineer. Ch 2, Section 5: • Removed discussion on taking cores to investigate material problems • Included requirement of marking top and bottom surface of full depth cores Ch 3, Section 1 • Incorporated language about following man- ufacturer's material and procedure requirement. Ch 3, Section 2: • Removed `other approved techniques' to remove rust from exposed steel surfaces. • Incorporated detail for concrete repair with mechanical anchors. • Included definition of SSD (saturated sur- face dry) • Adjusted the duration of water blasting to at least 15 minutes to achieve SSD. Ch 3, Section 3: • Removed 'other approved techniques' to remove rust from exposed steel surfaces. Ch 3, Section 4 : • Adjusted the duration of water blasting to at least 15 minutes to achieve SSD • Added steps and photos of typical full- depth deck repair. • Removed "other approved techniques" to remove rust from exposed steel surfaces. Concrete Repair Manual 1-4 TxDOT 03/2021 Chapter 1—Introduction Section 2—Using the Concrete Repair Manual Section 2—Using the Concrete Repair Manual When developing repair or rehabilitation plans,the Engineer should specifically include which sections of this manual will be enforced. Chapter 2 includes information on assessing damage, distress limits,and common types of concrete repair. Chapter 3 includes information on various repair materials and procedures for implementation. Typically concrete repair work will include categorizing the type of distress as outlined in Chapter 2 and selecting a type of repair material from Chapter 3. In some cases,the material section includes enough information that choosing a corresponding type of repair is not necessary.For instance,the sections on crack repair do not require that corresponding repair types be selected Each section in this manual is written as a stand-alone document,and individual sections contain all necessary information on material selection and application. It is not necessary to read the manual from start to finish. Rather,the intention is that Inspectors and Contractors will need only to reference the applicable section or sections.The sections are kept as concise as possible since they are intended for field use. This manual does not address post-tension strand,duct,or anchorage repairs.Repairs or defects associated with post-tension work should be addressed by the Bridge Division Construction& Maintenance Branch on a case-by-case basis. Concrete Repair Manual 1-5 TxDOT 03/2021 Chapter 1—Introduction Section 3—Standard Specification References to the Concrete Repair Manual Section 3 —Standard Specification References to the Concrete Repair Manual The Concrete Repair Manual is referenced in several 2014 Standard Specification Items.This section includes a list of each of those references,along with the corresponding Section to reference within this Manual. Standard Specification References Spec Item Item Title Spec Reference Repair Manual Reference 409 Prestressed Concrete 3.1 (Defects and Refer to Section 2.4 for limits and repair Piling Breakage) procedures when assessing damage to pre- stressed concrete piling. 420 Concrete Substructures 4.13(Ordinary Surface Spalls are defined per Section 2.1,and Finish) repaired(based on severity)per Section 3.1,3.2,or 3.3.Most spalls in this category will be defined as minor and repaired per Section 3.1. 424 Precast Concrete Struc- 4.3(Workmanship) Recess prestressed strands per Section 2.7. tural Members (Fabrication) 4.3.1 (Defects and This item covers damage or surface defects Breakage) that occur during fabrication,handling, storage,hauling,or erection of precast concrete members.Any of the sections in this manual could apply depending on the situation. 429 Concrete Structure 2(Materials) Severity of the unsound,delaminated,or Repair 3(Construction spalled concrete is defined per Section 2.1. Methods) After defining,select materials and imple- ment repair per Section 3.1 (Minor),3.2 (Intermediate),or 3.3(Major). 780 Concrete Crack Repair 2(Materials) Select materials and perform repair work in 3(Construction accordance with the applicable section in Methods) this manual.Section 3.5 covers pressure- injected epoxy,3.6 covers gravity-fed seal- ant,and 3.7 covers both routing and sealing and surface sealing. 788 Concrete Beam Repair 2(Work Methods) Concrete Beam Repair is a plan-specific item.Provide materials and perform work in accordance with the applicable sections of this Manual and as defined in the project plans. Concrete Repair Manual 1-6 TxDOT 03/2021 Chapter 1—Introduction Section 4—Repairs and Repair Manual Section 4 — Repairs and Repair Manual It is critical that repair crews use appropriate repair materials and installation methods. Even the best materials will not work effectively unless each aspect of the repair work is considered. Proper proportioning,mixing, surface preparation,application,and curing are all vital to the long-term success of a repair. TxDOT maintains Departmental Material Specifications and corresponding preapproved Material Producer Lists for most of the materials outlined in the manual. It is vital that Engineers, Inspectors,and Contractors select and use only preapproved materials when applicable.The Engineer may select or Contractors may propose to use material not included on an MPL if it will provide for the best repair in a specific application. The Engineer will review such requests from the Contractor on a case-by-case basis, but in almost all cases a preapproved material should be selected. Notify the Engineer before proceeding with the repairs if there are discrepancies between TxDOT's requirements and industry standards or manufacturers'instructions. Maintain up to date copies of the manufacturers'technical literature to ensure the proper procedures are followed. Concrete Repair Manual 1-7 TxDOT 03/2021 Chapter 1—Introduction Section 5—Repair Procedure Submission and Approval Section 5 — Repair Procedure Submission and Approval When the Engineer prepares repair or rehabi I i tation plans that include reference to this manual,the Contractor must prepare and submit formal procedures outlining repair plans and which proprietary materials they plan to utilize.The Engineer must approve in writing any procedures that differ from those in this manual or materials that are not included in one of TxDOT's MPLs. For damage that occurs in precast concrete fabrication yards or on construction sites in which Contractor is required to prepare a Nonconformance Report or Request for Information,the Contractor should propose repair methods and materials outlined in this manual. Contractors may also propose to use a procedure that differs from those outlined in this manual, in which case TxDOT will consider on a case-by-case basis. For minor defects in which the Engineer is not preparing repair documents and the Contractor is not issuing a Nonconformance Report or Request for Information,the Contractor and Inspectors should work collaboratively to determine an appropriate repair solution and then follow the appli- cable sections from this manual. Documentation of this communication should be retained in the project files. Concrete Repair Manual 1-8 TxDOT 03/2021 Chapter 1—Introduction Section 6—Quality Control/Quality Assurance Section 6 — Quality Control/Quality Assurance In addition to providing step-by-step procedures for Contractors and Fabricators,this manual is also meant to provide Quality Control(Contractor)and Quality Assurance(Owner)inspectors with the knowledge needed to ensure that appropriate repair solutions are selected and implemented. Each procedure in Chapter 3 of this manual includes detailed instructions on each individual facet of repair solutions. Proper attention to and implementation of each step in the repair process is critical to successful application.The first step is ensuring that the contractor is using approved materials. Correct proportioning and mixing is also critical.A common mistake is for Contractors to"eyeball"or guess at proper proportions when using multi-part mixes.Inspectors should verify that Contractors are measuring,either by volume or weight,all individual components prior to mixing.In almost all cases the Contractor should utilize an acceptable form of mechanical mixing;hand mixing is not acceptable.It is not possible to put a sufficient amount of energy into mixing when doing so using a shovel,trowel,or by hand. In small applications a small"jiffy"type paddle and mixer are often sufficient. When using larger quantities of cementitious repair material a mortar or volumetric mixer is more appropriate. Application varies significantly with repair type and material. Refer to the applicable section in Chapter 3. Another frequent problem leading to premature failure of repairs,especially cementitious materials, is inadequate curing.Improper curing often leads to cracking very early in the life of the repair.The best(and easiest)curing method is to leave the forms in place when using form-and- pour applications. In those cases only a small amount of moist curing is required in the small areas used to place the concrete. Ponding is also an excellent method of curing but is typically impractical in most repair scenarios. Many manufacturers include instructions for application of curing membranes.However,continuous moist curing is typically preferable to curing membranes. When using wet mats it is imperative that the mats be kept moist during the entire curing interval. In cases where membrane curing is approved,the Contractor must use material that is preapproved by TxDOT and is recommended for use by the repair material manufacturer. Since curing requirements vary significantly depending on the type of material and the manufac- turer, it is important that curing methods adhere to the technical product literature for the specific material being utilized.As noted above,moist curing is the preferred method for most cementitious repair materials. However,moist curing can actually harm some repair materials, such as those that contain magnesium phosphate.Again,the Contractor must adhere to the requirements for the specific material being applied. Contractor's Responsibilities(QC): Concrete Repair Manual 1-9 TxDOT 03/2021 Chapter 1—Introduction Section 6—Quality Control/Quality Assurance • It is the Contractor's responsibility to use repair materials specified in the Contract Documents and this manual.For materials in which there are lists of available through TxDOT's MPL,the Contractor should only use products that have been preapproved.Any deviation from the originally proposed and approved materials must be approved by the Engineer in writing. When in doubt,contact the Bridge Division or Materials and Tests Division for guidance on whether a proposed material is acceptable. • Shelf life of repair materials is critical, store materials on jobsite according to material manufacturer's requirements,preventing direct exposure to sunlight and moisture. Materials exceeding their shelf life shall not be used. • When required by the Contract,perform a trial repair or mockup to demonstrate acceptable performance and installation methods. • Ultimately, quality is the Contractor's responsibility. If the Contractor feels that any of the procedures outlined in this manual or in the contract plans could lead to unacceptable performance,they must inform the Engineer of those concerns in writing prior to commencing work. In such cases,the Engineer will work collaboratively with the Contractor to come to an agreeable solution. • Confirm that repair material performance is acceptable through visual observations and nonde- structive testing of all repaired locations.Repair material should not exhibit cracking.One of the easiest and most effective tests is to sound the repair material using firm (but not destruc- tive)blows with a hammer.When repair material has debonded from the substrate there is generally a distinctive hollow sound when the material is struck. Defective repair material must be removed and replaced at no extra costs to the Department. Owner's Responsibilities (QA): • Check materials to ensure that they are appropriate for the given application.Material should either be on one of TxDOT's preapproved lists or approved by the Engineer prior to use. • Ensure that the Contractor is following the procedures outlined in this manual and as shown on the plans for material selection,preparation, implementation,curing,and any other steps crucial to the performance of the concrete repair. Procedures may need to be altered for varying weather conditions(excessive heat or cold,rain,high wind,etc.). • Verify that all damaged material has been removed and that the remaining surface is clean and sound before the Contractor proceeds with repair material installation. • Confirm that repair material performance is acceptable through visual observations and nondestructive testing. See Contractor's Responsibilities(QC)for acceptance criteria.QA may be performed jointly with the contractor's QC or separately at the discretion of the Engineer. • In some cases,the Contractor may opt to perform nondestructive or destructive testing when there is a question about whether a repair is performing adequately. Often such testing will involve taking cores for petrographic analysis.Though a Contactor may use an independent consultant or lab for performing forensic or petrographic investigations,ultimately TxDOT Concrete Repair Manual 1-10 TxDOT 03/2021 Chapter 1—Introduction Section 6—Quality Control/Quality Assurance will decide whether a repair is acceptable. The location of the destructive testing should be agreed upon by the owner and the Contractor. Concrete Repair Manual 1-11 TxDOT 03/2021 Chapter 1—Introduction Section 7—Definitions and Abbreviations Section 7 — Definitions and Abbreviations The terms"Engineer,""Inspector,""Contractor,"and"Fabricator" are used regularly throughout this manual."Engineer"typically refers to the Engineer of Record that signed and sealed the repair plans,the Area Engineer or the Area Engineer's authorized representative where the work is being performed,or in the case of precast fabrication one of the licensed Professional Engineers at TxDOT Materials and Tests Division Headquarters in Austin. "Inspector"refers to the person, usually a Department employee,assigned by the Engineer to check compliance with the Contract. "Contractor"refers to the entity responsible for implementing the repair work."Fabricator"refers to a manufacturer that produces precast concrete structures for TxDOT.When not specifically stated,requirements for Contractors also apply to Fabricators. The following abbreviations are used in the manual: • CFRP: Carbon Fiber Reinforced Polymer • MTD:TxDOT Materials and Test Division • DMS: Departmental Material Specification • MPL: Material Producer List • NCR:Nonconformance Report(typically prepared by Precast Fabricators) • QA: Quality Assurance • QC: Quality Control • RPM: Revolutions per Minute • SSD: Saturated Surface-Dry • NDE: Nondestructive Evaluation Concrete Repair Manual 1-12 TxDOT 03/2021 Chapter 2 — Damage Assessment and Repair Types Contents: Section 1 —Defining Concrete Spalls Section 2—Voids Due to Honeycombing Section 3—Damage over Traffic Section 4—Prestressed Concrete Piling Section 5 —Taking Cores and Patching Core Holes Section 6—Trimming or Cutting Prestressed Concrete Girder Ends Section 7—Recessing Prestressed Strands Section 8—Rail Damage Due to Vehicular Impact Concrete Repair Manual 2-1 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 1—Defining Concrete Spalls Section 1 —Defining Concrete Spalls Description Spalls are categorized based on severity of damage per the definitions in this Section. Once a spall has been categorized,then an appropriate repair material and installation procedure can be selected. Reference: TxDOT Standard Specification Item 429,"Concrete Structure Repair." Notes Based on severity, spalls can be categorized as minor, intermediate,or major.Appropriate repair materials and methods differ significantly depending on the spall depth, size(area),cause(s)and configuration(horizontal,vertical,or overhead). The guidelines in this section help define various spall types.These are general definitions;depending on the circumstances,the Engineer may define spall severity differently than these definitions,on a case-by-case basis. This section does not apply to spalls in the riding surfaces of bridge decks. Refer to the Chapter 3 sections on Bridge Deck Repair when addressing such damage. Spall Categories • Minor Spall: • Damage is less than 1 inch deep and it covers an area less than 12 square inches.However, if the majority (more than 50%)of a reinforcing bar or strand circumference is exposed due to inadequate cover then the spall would be classified as Intermediate even if it is less than 1"deep. • The Inspector may elect to designate repairs that cover areas larger than 12 square inches as minor depending on the location and extent of the damage. • A deeper spall(2" maximum)can be categorized as minor as long as it does not progress beyond the outer layer of reinforcement. • Intermediate Spall: • The damage exposes a majority (more than 50%)of the outer cage of reinforcing bar or strand circumference,or the damage is greater than 2"deep. • The maximum depth of an intermediate spall is 6 inches. • No significant stresses are likely to develop in or immediately around the repair mate- rial due to service loads. • Major Spall: • Damage extends well beyond the outer layer of reinforcement. Concrete Repair Manual 2-2 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 1—Defining Concrete Spalls • Significant stresses are likely to develop in or immediately around the repair material due to service loads. Selecting an Appropriate Repair Procedure Beyond categorization of spalls,repair procedures depend on location to be repaired and volume of work.The following is only a brief overview of repairs. See Chapter 3 for detailed discussion on repair materials and procedure. • Minor Spall: • Regardless of configuration(vertical,overhead,or horizontal),the best repair method for minor spalls is typically neat epoxy or epoxy mortar.Epoxy that is formulated for concrete repair has very tenacious bond and performs well in thin applications. • Excavating the concrete to expose all corroded sections of the bar is an effective way to mitigate corrosion,but that typically requires the removal of sound material. Such measures are usually unnecessary unless the minor spalling is occurring over a large area. • Applying epoxy over thin spalls in which a small amount of steel is exposed will not typically stop corrosion. However, it provides an excellent waterproof barrier and can significantly slow down the rate of corrosion if properly applied. • Building up thin spalls with epoxy mortar is generally an aesthetic decision.Mortar should not be applied if the repair will occur over vehicular or pedestrian traffic.In those cases only neat epoxy should be applied. • Intermediate Spall: • Proprietary,bagged concrete repair materials are typically used to repair intermediate spalls.Use only preapproved materials meeting the requirements of DMS-4655,"Con- crete Repair Materials." • A common mistake when choosing bagged cementitious concrete repair materials is to select those with compressive strengths far higher than needed. Materials with lower com- pressive strengths typically perform better since they also have a lower modulus of elasticity,and therefore greater ductility. For intermediate spalls it is typically desirable not to redistribute loads into the repair material.Limiting compressive strength and modulus of elasticity are the best ways of achieving that. • Vertical and Overhead Repairs: • In most cases a Contractor will opt to use a trowel-applied repair material in vertical and overhead applications.The maximum lift thickness of trowel-applied materials is 2 inches or the maximum permitted by the repair material supplier,whichever is less. • In deeper applications the Contractor may propose to repair using pneumatically applied cementitious material, in which case they should follow the provisions set forth in Item 431. Pneumatically placed concrete is not addressed in this manual.The Concrete Repair Manual 2-3 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 1—Defining Concrete Spalls Engineer must approve use of pneumatically placed concrete in lieu of the repair methods outlined in this manual. • The Contractor may opt to use form-and-poured bagged material or batched concrete, which is often a better option since it can be extended with coarse aggregate.Most trowel-applied materials do not include coarse aggregate,which can lead to drying shrinkage cracking if not applied or cured properly. • Horizontal Repairs: Form-and-pour materials are typically the best option in horizontal applications because they can be extended with coarse aggregate,which significantly reduces the potential for shrinkage cracking. • Precast Concrete Production Yards: Batched concrete is readily available in precast concrete plants.Therefore,fabricators should typically use batched concrete(same mix design)as that used to fabricate the damaged member,even when the spall is classified as intermediate. • Major Spall: • Major spalls typically involve deep repairs to members in which capacity has been reduced as a result of damage and deterioration.The repair is meant to restore capacity of the damaged member. The best option in such applications is to use batched concrete with properties similar to the parent material. • When the mix design is unknown,the Engineer and Contractor should select an approved concrete mix that meets the requirements of the anticipated service loads. • In smaller applications it is often not practical to specify batched concrete when rehabilitating or repairing existing structures.The Engineer should determine when a preapproved bagged material is more appropriate and offer that as an alternative to batched concrete. • In some cases, additional anchoring may be required as directed by the repair details. Concrete Repair Manual 2-4 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 2— Voids Due to Honeycombing Section 2 —Voids Due to Honeycombing Description Honeycombing in concrete members can result from either of the following: • Forms not being sufficiently secured or tight,allowing mortar to leak out during casting operations.The mortar leakage can lead to voids between coarse aggregates. • Insufficient consolidation due to poor workability of concrete mixes or inade- quate vibration. Investigating Honeycombed Regions The biggest cause for concern when voids occur on the exterior portions of members is that additional,unseen defects could exist on the interior portions.Honeycombing due to lack of proper consolidation is of particular concern,especially in the portions of precast concrete members that are highly congested with prestressing strands and mild reinforcement. Prior to considering repair options,explore the voids to check for additional damage.The areas around the voids should be chipped to sound, undamaged concrete. However,do not chip out concrete around prestressed strands before discussing with the Engineer. Occasionally Contractors ask to use Nondestructive Evaluation(NDE)to investigate the severity of honeycombing when it appears to be severe and the Engineer is considering rejection.Most of the available technology(e.g. Impact Echo and Pulse Velocity)cannot effectively show whether small voids exist along congested prestressing strands or mild reinforcement.Although the Contractor may propose to use NDE, it is up to the Engineer to determine whether it is acceptable. Generally NDE requires destructive verification testing,which is oftentimes not an option in highly congested concrete, such as the bottom flanges of prestressed girders. Repairing Honeycombed Regions After the honeycombed regions have been removed,the damaged area should be evaluated and defined per Section 1 of Chapter 2 unless the damage is too severe to consider acceptance of the member.An appropriate repair material and method can be selected once the damage is categorized as minor, intermediate,or major. At a minimum,remove defective material, repair and finish as required in Section 420.4.13 of the Standard Specifications for Ordinary Surface Finish. Concrete Repair Manual 2-5 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 3—Damage over Traffic Section 3 — Damage over Traffic Description This section applies to damage that occurs or could occur over vehicular or pedestrian traffic.Dam- age consists of any spall,delamination,honeycombing, or other unintentional void.The Engineer will typically require additional measures to help ensure the repair material will not fall into traffic in the case of a repair failure. The most frequent damage that occurs over roadways is overhead vehicular impact. In addition to whatever necessary structural and waterproofing repairs,the Engineer should typically also require confinement or other acceptable means to prevent spalling or to catch portions of the repair mate- rial that become detached. Wire netting often works as a temporary solution.More permanent solutions should be included when the member or members are repaired.In almost all cases the best option for preventing damaged concrete from falling onto traffic is to confine the repair material with Carbon Fiber Reinforced Polymer wraps. Perform the CFRP work in accordance with Item 786,"Carbon Fiber Reinforced Polymer." In the case of precast concrete fabrication,damage that will occur over traffic may not be repaired unless approved by the Engineer. When feasible,members should be reassigned or rotated to move the damage to an area where damage will not occur over traffic in its final configu- ration.Minor damage may be coated with neat Type VIII epoxy but should not be built up with repair mortar.When the Engineer does permit more extensive repair,the repair material must be confined using CFRP or other approved method. There is no standard repair procedure for repairing damage over traffic. A repair plan must be signed and sealed by a professional engineer licensed in Texas. Do not proceed with such repairs without authorization from the Engineer. Concrete Repair Manual 2-6 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair 1jipes Section 4—Prestressed Concrete Piling Section 4— Prestressed Concrete Piling Description This section includes limits and repair procedures when assessing damage to prestressed concrete piling. This section also includes a procedure to recess and coat lifting strands after installation of piling. Reference Standard Specification Item 409, "Prestressed Concrete Piling." Notes Piling damage is divided into two categories: (1)damage that occurs prior to driving(during fabrication,handling, storing, or hauling),and(2)damage that occurs during driving operations (lifting or driving).When assessing damage to exposed portions of prestressed piling in an existing structure,treat it as a typical concrete substructure element.No special limits apply. The acceptance and rejection criteria for prestressed piling are more severe than with most other structural elements because the consequences of a failure are also very severe. Foundation distress is typically very difficult to remedy and can lead to shortened service life of an entire bridge. Therefore,damage that could potentially hinder performance or reduce durability will typically lead to rejection of the piling. Damage Prior to Driving(e.g. in the Fabrication Yard) • Minor damage. • Only thin spalls may be repaired.The Engineer will determine what constitutes an acceptable spall,but in general the limits are 1-inch in depth and 6 square inches in area.If either of those limits is exceeded,or if the damage exposes any reinforcing steel or prestressing strand,the damage will render the piling unacceptable unless specifically deemed otherwise by the Engineer. • Smooth out the perimeter of the damaged area to eliminate jagged edges. • Minor spalls deemed acceptable for repair should be cleaned and coated with neat epoxy in accordance with Section 1 of Chapter 3 of this manual. • Do not build up the spalled areas with repair material other than neat epoxy since it is likely to debond during driving operations. Concrete Repair Manual 2-7 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 4—Prestressed Concrete Piling • The Engineer may allow for repair when damage is deeper than 1 inch but does not progress beyond the outer layer of steel reinforcement. In those cases the damaged areas should be built up with epoxy mortar and confined by CFRP wrapped completely around the piling for a distance not less than six inches beyond the damaged area. • Damage to one end. • If one end of a piling is damaged beyond the limits outlined above,but the damage extends less than 6 inches from the end,then the fabricator or contractor may remove(cut) up to 6 inches from the end to eliminate the damaged portion. • Clearly mark the altered side as the"Tip End." • After cutting,recess the prestressing strands 3/8-inch minimum and fill the voids with epoxy mortar(typical strand end treatment). I • Re-form the chamfers after completing the cutting and repairing operations. • Damage to both ends. • There are no standard criteria for acceptance or rejection when both ends of a piling are damaged,but generally the member will be rejected since it would not be possible to avoid hammering a damaged end. • Engineer must approve any repairs when damage occurs on both ends of a piling. Damage During Driving • Horizontal cracks(transverse to longitudinal reinforcement or strand)greater than 1/16 inches wide. • Piling will be rejected if crack occurs in a portion that will be below ground or water level after driving. • If crack occurs in a portion that will be above grade or water level,the Contractor may opt to cut back beyond the crack and rebuild to required elevation. • Horizontal cracks less than 1/16 inches wide. • Inject the cracks with epoxy in accordance with Section 3.7 of this manual. • If cracks develop that will be inaccessible in final configuration,cease driving operations and repair cracks before continuing. • Vertical or diagonal cracks. • In most cases a piling member will be rejected if vertical or diagonal cracks form during driving operations. • If the Engineer approves repair of vertical or horizontal cracks, inject with epoxy in accordance with Section 3.7 of this manual. • Fine hairline cracks(less than 0.006 inches)or surface checks that do not extend to the plane of the nearest reinforcing steel will not require repair and will not be cause for rejection. Concrete Repair Manual 2-8 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 4—Prestressed Concrete Piling Lifting Strands • Recess lifting strands to help prevent corrosion due to exposure to the elements. • Recess the prestressing strands a minimum 3/4-inch using a torch,grinder,or other approved method.Do not overheat or damage the surrounding concrete. • Abrade the concrete and the end of the steel strand with a needle gun,steel brush,or other suitable means to ensure that no slag remains on the steel or concrete surfaces. • Coat the inside of the recessed area, including the strand,with 10 mils(minimum)of neat Type VIII epoxy and repair the recess with epoxy mortar. Concrete Repair Manual 2-9 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 5—Taking Cores and Patching Core Holes Section 5 Taking Cores and Patching Core Holes Description Cores may be taken from concrete members for a variety of reasons, including verification of compressive strength, investigation of potential concrete material problems (e.g. segregation or bleeding),or examination of specific defects(e.g.cracks or cold joints).This section covers proper taking and marking of cores,and patching of the core holes. Selection Criteria Select core locations and have them approved by the Engineer. Check fabrication sheets so,cores are taken with minimum impact to mild reinforcement. Check design sheets or shop drawings to ensure that cores are not taken through prestressing strands unless specifically approved by the Engineer. For prestressing strands use GPR and other NDE methods to locate the strands. Take four-inch outside diameter cores when feasible.When approved by the Engineer,take smaller cores in highly congested areas to avoid impact to mild reinforcement or prestressed strands. Taking Cores to Check Compressive Strength • Take at least two cores from a member if companion cylinders reveal a potential deficiency in the required 28-day compressive strength. • Evenly space the cores along the member(s) in question.Typically,take the cores through the webs or sidewalls of prestressed concrete girders. • There can be no mild reinforcement or prestressed strands in the cores if they will be used for testing compressive strength. Taking Cores to Investigate Specific Defects • Take cores directly through the problem areas when investigating specific damage or defects.It typically will not be necessary to take control cores in these types of situations. • If investigating a cold joint,take the sample such that approximately half the core is above the joint and half is below the joint. Marking Cores When cores are not taken from a horizontal surface,draw two arrows on the core locations BEFORE a core is taken.Point both arrows straight up,and draw them on each side(left and right) Concrete Repair Manual 2-10 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 5—Taking Cores and Patching Core Holes of the core. In most cases the petrographer will need to cut in the vertical orientation,so it is important that the core be marked such that both sides will indicate the"up"direction after cutting. After a core has been taken,write additional information on each side(left and right)of the sample. Include the following information: • Structure No. (existing structure)or CSJ(new construction). • For new construction,name of Prime Contractor if at jobsite or Fabricator if in Precast Concrete Plant. • Member ID and location. • Core number.Also,take photographs and notes indicating from where in the member the core was taken and why. • Top and bottom surfaces for full depth cores . Again,most cores are cut vertically.Write all of the above information on both sides of the core so each part of the sample can be properly identified if it is cut. Include a standard TxDOT Form 202 for each set of cores taken from a member.Request that the TxDOT Inspectors fill out Form 202 as needed so hard copies of the completed forms can be sent directly with the samples.Also send copies of applicable concrete mix design worksheets, batch tickets, and strength data with the cores when they are available. Patching Core Holes As with all large patches,utilize preapproved bagged cementitious repair material or batched concrete to patch core holes when feasible.Follow the requirements set forth in the section on Intermediate Spall Repair for implementing the work. Concrete Repair Manual 2-11 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 6—Trimming or Cutting Prestressed Concrete Girder Ends Section 6—Trimming or Cutting Prestressed Concrete Girder Ends Description This section includes allowances and repair procedures for trimming or cutting the ends of prestressed concrete I-beams. • Removal of more than 1 inch of a beam end is considered cutting. • Removal of 1 inch or less from a beam end is considered trimming. Cutting beam ends requires preparation of an NCR from the Fabricator.The TxDOT Inspector determines whether an NCR is required when a beam end will be trimmed. NOTE: Standard provisions for cutting beam ends apply to Tx Girders(bulb tees)only.Cutting the ends of prestressed members other than Tx Girders requires a detailed analysis by a Professional Engineer and authorization from TxDOT MTD Headquarters or the Bridge Division.There is no standard repair for such alterations;proposals will be considered on a case-by-case basis. Provisions for Acceptance No more than 12 inches may be removed from either girder end. If more than 6 inches is removed from a girder end, include in the modification proposal stamped calculations from a Professional Engineer indicating the viability of the proposed modification. Calculations must include: • Required moment and shear capacity. • Actual moment capacity of the modified member, obtained using PGSuper or another acceptable analysis program. • Actual shear capacity. In most cases equal amounts should be removed from each end if the total length to be cut exceeds 6 inches.However,that would not be a viable solution if a beam end is being cut in order to eliminate damage or when a beam end contains an anchor slot. The Area Engineer and MTD Engineer must approve modifications.All parties, including the Fabricator,Contractor, and Engineer,must agree that trimming will not result in any unacceptable issues related to deck forming, slab or haunch thickness,camber,or plan profile deck geometry. The girder must be modified as required for use in its new configuration, including but not limited to blockouts, inserts,hangers,and bevels. Concrete Repair Manual 2-12 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 6—Trimming or Cutting Prestressed Concrete Girder Ends When the strand pattern differs from the destination design,or if more than 6" is cut off one or both beam ends,a replacement shop plan for the permanent record must be provided that indicates all characteristics of the candidate girder that differ from the originally specified girder. Include dual girder identification by permanently marking the inside face of the girder, clearly indicating which is the previous girder I.D.and which is the current I.D. Fabricator or Contractor must send written notification to the Area Engineer informing them of the circumstances of the dual marked girder for their information and records. Repair Procedure After the beam has been trimmed or cut,re-measure the member(length, skew, and batter)to ensure that the altered dimensions are acceptable. Once the dimensions have been checked and found to be acceptable, remove all vertical reinforcement that has less than 3/4-inch concrete cover.Recess longitudinal reinforcing steel and prestressing strands approximately 3/8-inch. • Locate the steel using shop drawings, exploratory drilling,and whatever other means is necessary to ensure that all reinforcement with inadequate concrete cover is identified. • Remove the steel using a torch or other approved method. Do not overheat or damage the surrounding concrete and steel that will remain in place. • If steel is removed using a torch,abrade the steel and concrete surfaces with a needle gun,steel brush,or other suitable means to ensure that no slag remains. Apply a silane penetrating sealer and neat Type VIII epoxy to every portion of the member that was trimmed or cut.Wait at least 48 hours after applying the penetrating sealer before applying neat epoxy. Do not extend the neat epoxy material with sand except to fill in the voids where the steel has been recessed or removed. Concrete Repair Manual 2-13 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 7—Recessing Prestressed Strands Section 7 — Recessing Prestressed Strands Description Recess prestressed strands to help prevent corrosion due to exposure to the elements. Repair Procedure Recess the prestressing strands a minimum 3/8-inch using a torch or other approved method. Do not overheat or damage the surrounding concrete. Abrade the concrete and the end of the steel strand with a needle gun, steel brush, or other suitable means to ensure that no slag remains on the steel or concrete surfaces. Coat the inside of the recessed area, including the strand,with 10 mils(minimum)of neat Type VIII epoxy and repair the recess with epoxy mortar. Do not coat the beam end away from the recessed strands with epoxy mortar. Concrete Repair Manual 2-14 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 8—Rail Damage Due to Vehicular Impact Section 8 — Rail Damage Due to Vehicular Impact Description Traffic rails frequently sustain damage from vehicular impact,often resulting in reduced structural capacity. It is imperative to implement repairs to railing that restore capacity, in the event that the same section of rail is impacted again. Many rail types include steel components mounted to concrete parapets.Although this manual addresses concrete repairs,damage to steel elements must also be considered when rail damage is assessed and repaired. Assessment Damage to railing can be categorized as minor, intermediate,or major.Damage should be assessed on a case-by-case basis. Minor rail damage is defined as spalling or cracking that does not extend beyond the outer reinforcing steel cage,with no loss in structural capacity,and that covers an area of less than 12 square inches.Additionally,there is no deformation of any steel components. Intermediate damage extends beyond the outer cage of reinforcement but based on the Engineer's assessment hasn't significantly reduced rail capacity.The maximum depth of an intermediate spall is 6 inches. Major rail damage occurs from any impact that necessitates restoration of structural capacity. Damage is typically greater than 6 inches deep and results in plastic deformation of reinforcing steel,anchor bolts, or other steel elements. The Engineer may evaluate slight deformations in steel elements or reinforcement to determine whether they can be reused. Deformations in galvanized steel can severely limit its long-term viability in preventing corrosion; therefore,damaged galvanized elements should typically be replaced rather than repaired or touched-up. In no case should damaged anchor bolts be reused. Repair Procedure Minor rail damage: Repair spalls in accordance with Section 1 (epoxy mortar)or Section 2 (proprietary,bagged concrete repair materials)of Chapter 3 in this manual. Seal cracks in accordance with Section 6(gravity-fed sealant)or Section 7 (surface seal)of Chapter 3.Touch up any scrapes or other minor damage to steel elements in accordance with standard District Concrete Repair Manual 2-15 TxDOT 03/2021 Chapter 2—Damage Assessment and Repair Types Section 8—Rail Damage Due to Vehicular Impact maintenance practices.If any galvanized elements are impacted,then the Engineer should evaluate to determine appropriate repair procedures,such as touch-up using zinc-rich paint or other process. See Item 445, "Galvanizing"and the Department Material Producer List for Galvanizing Repair Paints for more information. Intermediate rail damage: Repair spalls in accordance with Section 2 (proprietary,bagged concrete repair materials)or Section 3(batched concrete)of Chapter 3.Ensure there is a mechanical bond by completely excavating around exposed reinforcing steel. Major rail damage:When damage is severe enough to reduce the structural capacity of a rail,the best option for full restoration is to remove the rail to the level of the concrete deck and retrofit in accordance with the TxDOT Bridge Standards Retrofit Guide for concrete rails or curbed structures.All damaged components should be replaced or supplemented, and structural class batched concrete should be used to cast the new section of concrete railing. If the Engineer determines that major rail damage can be repaired rather than retrofitted to suffi- ciently restore capacity,perform work in accordance with Standard Specification Item 778, "Concrete Rail Repair."When feasible,utilize batched concrete rather than proprietary,bagged material to repair the damaged rail. Installation of new anchors and reinforcement is critical to ensuring adequate capacity of the con- crete railing and steel-mounted components.When using an adhesive to anchor steel bars,install in accordance with Standard Specification Item 450,"Railing."Note that anchorage testing of installed adhesive anchorages may be required as directed by the Engineer. Concrete Repair Manual 2-16 TxDOT 03/2021 Chapter 3 — Repair Materials and Procedures Contents: Section 1 —Minor Spall Repair Section 2—Intermediate Spall Repair Section 3 —Major Spall Repair and Concrete Replacement Section 4—Bridge Deck Repair Section 5 —Crack Repair–Pressure-Injected Epoxy Section 6—Crack Repair–Gravity-Fed Sealant Section 7—Crack Repair–Surface Sealing Concrete Repair Manual 3-1 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 1—Minor Spall Repair Section 1 —Minor Spall Repair Description Most minor concrete spalls are repaired using neat Type VIII epoxy(no sand)to help protect against deterioration caused by exposure to the water,chlorides,and other contaminants. Minor spalls are defined in Section 2.1 of this Manual. Minor spalls can be built up using Type VIII epoxy mortar. Generally building up minor spalls with mortar provides no additional corrosion protection or capacity vs.neat epoxy only.Filling the voids removes the appearance of spalling and is typically done based on aesthetic concerns. Material TxDOT Type VIII neat epoxy compound(ASTM C 881 Type I or IV) is produced by mixing two proprietary liquid components in the ratio required by the manufacturer. • Refer to DMS 6100, DMS 6110,and the MPL for Epoxies and Adhesives for additional information. • Use materials from TxDOT's preapproved list for Type VIII epoxy. Contractor may use other materials only if specifically authorized by the Engineer in writing. • Follow manufacturer's published recommendations for storage including temperature and humidity controls. Retain manufacturer lot tags with packaged date and shelf life for inspection prior to product use. • Follow manufacturer' s material requirements. TxDOT Type VIII epoxy mortar is produced by combining the neat epoxy compound and an aggregate(usually silica sand)approved by the epoxy producer and TxDOT. • Ratio by Volume: • Adhere to the requirements from the manufacturers'technical data sheets when proportioning the sand to add to the neat epoxy. • Silica Sand: • Most manufacturers recommend that 20/40 mesh sand be used to produce epoxy mortar.It is acceptable to use sand that passes a No. 16 sieve but is retained by a No. 50 sieve(16/50 mesh). • Use sand other than 16/50 mesh or 20/40 mesh only if authorized by the epoxy manufacturer and the Engineer. Concrete Repair Manual 3-2 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 1—Minor Spall Repair • If the repair will remain visible after a member has been erected,the Engineer may require use of a combination of gray and white sand to make the epoxy mortar material closely resemble the surrounding concrete. Do not exceed 130°F if heating any of the epoxy liquid components to ease mixing or application. NOTE: Keep a separate container that is protected from rain and other water for storing sand used to mix Type VIII epoxy mortar.Sand from a stockpile is typically far too wet to be used for mixing epoxy mortar. Do not exceed 230°F when heating sand to dry it.Allow sand to cool to a maximum temperature of 130°F before mixing with the neat epoxy. Repair Procedure • Surface preparation. • Remove any damaged or loose concrete. • Avoid damage to sound concrete that is to remain in place by saw cutting the perimeter of the repa i r area or taking other appropriate measures acceptable to the Engineer. • Unless otherwise approved by the Engineer,use only hand tools or power-driven chipping hammers(15-lb. class maximum)to remove concrete. • If the damage occurs at the end of a member and prestressing strand is exposed,recess the strands a minimum 3/8-inch using a torch or other approved method. Do not overheat or damage the surrounding concrete. NOTE: In the past some Contractors and Fabricators opted not to recess prestressing strands in spalled areas so the protruding sections could serve as dowels for the repair material. While the strands would serve well as dowels in those circumstances,they could be exposed to moisture and chlorides if the repair fails over the life of the structure. For that reason it is more important that the strand be completely recessed. • Ensure substrates are clean and sound. Remove any contaminants, including laitance,oil, dust,debris, or other foreign particles. • Just prior to coating or repa i r i ng,blast the repair area using a high-pressure air com- pressor equipped with filters to remove all oil from the compressed air. • For minor spalls in which a short longitudinal section(less than 4 inches)of mild reinforcement or prestressing strand is exposed,the steel should NOT be removed.Nor should sound material behind the steel be excavated unless more than half the bar circumference is exposed, in which case the spall should be classified as Intermediate. • It is not necessary to install dowels or provide other mechanical anchorage in applications less than 1 %2 inch thick.The Engineer may require dowels,typically stainless steel expan- Concrete Repair Manual 3-3 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 1—Minor Spall Repair sion anchors, in thicker applications to help tie the repair material to the parent material in case of a delamination. • Mixing. Measure the proper quantity of each component per the manufacturer's requirements,then dispense into a clean container.Do not estimate the proper amounts while adding the different components. Mix the liquid components thoroughly using a low-speed electric drill (400–600 rpm)and a clean"Jiffy"type mixing paddle.Do not mix Type VIII neat epoxy or epoxy mortar by hand. • If utilizing whole batches,mix the liquid components for a minimum of 3 minutes or in accordance with the manufacturer's instructions. • If using partial batches, mix for at least 1 minute or until the material is well-blended and uniform,whichever is longer. Slowly add the sand or other approved aggregate to the epoxy compound while mixing with an electric drill and paddle. Mix the material until the epoxy mortar is well-blended and all sand particles are coated(1 minute minimum after the sand is added). Mix an adequate amount of additional neat epoxy compound for use as a waterproofing and bonding layer. Set times vary significantly depending on type of epoxy and ambient conditions(temperature, wind,humidity). In hot weather(greater than 90°F)place a partial batch in a cup to determine set-up time, and adjust production volumes accordingly.Adhere to manufacture' s storage and shelf life recommendation. • Neat Epoxy Application. • Surface must be dry and clean prior to application of the repair material. • Brush,roll,or scrub the material into the prepared substrate to ensure that all small voids are filled. • Cover the entire damaged area, including exposed steel reinforcement and dowels when applicable,with at least 10 mils of the neat epoxy compound. NOTE: Members of the repair crew should have a wet-film thickness gauge to periodically check that neat epoxy is being installed in adequate application depth. Inspectors should also carry wet-film thickness gauges so they can verify adequate minimum thickness. • Epoxy Mortar Application. • Apply a layer of neat epoxy compound to the substrate as outlined above to serve as a bond coat layer for the repair mortar. • Trowel-apply the epoxy mortar into the repair area while the bonding layer is still tacky.If the bonding layer loses its tackiness prior to repairing,clean the epoxy surface and apply additional neat epoxy before proceeding. Concrete Repair Manual 3-4 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 1—Minor Spall Repair • Limit repair depth to 1 inch when using epoxy mortar unless otherwise approved by the Engineer. In multiple lift applications wait until previous lift has cured sufficiently to prevent sagging prior to applying the next lift.Apply a bonding layer of neat epoxy between each lift. • Finishing. The Contractor should consult the Engineer before repairing minor spalls in which an aes- thetic treatment will later be applied. As noted above,the Engineer may require that white or gray sand be used to produce epoxy I mortar if a repair will remain visible in its final configuration. Such repair should not be easily discernible if viewed from more than 25 feet away.The Engineer will review other methods proposed for blending repairs. • Curing. The required time for the material to cure properly can increase significantly when the ambient temperature is below approximately 50°F. If artificial means are used to heat the in-situ neat epoxy or epoxy mortar,ensure that the air around the repair material does not exceed 130°F. Moist curing is not required. Commentary The high bond strength of properly mixed and applied Type VIII epoxy mortar makes it a good option for use in thin applications where inclusion of dowels is not practical and excavation behind partially exposed steel would unnecessarily necessitate removal of sound material. Do not use Type VIII epoxy mortar for structural repairs or in other areas where significant movement from loading or temperature variations are anticipated. Stress caused by differential movement at the bond line can develop because the coefficient of thermal expansion of Type VIII I epoxy mortar varies significantly from the concrete substrate.This problem can occur even in thin applications if the damage covers a large area. Concrete Repair Manual 3-5 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair Section 2 — Intermediate Spall Repair Description I Most intermediate spalls,as defined in Section 1 of Chapter 2,are repaired using proprietary, bagged concrete repair materials. Extending bagged cementitious repair material with coarse aggregate can significantly reduce the potential for shrinkage and cracking. When feasible,the Contractor should either use a pre- I extended repair material or add coarse aggregate(typically pea gravel) as allowed by the manufacturers.Using extended material is often not practical when using trowel-applied materials in vertical and overhead applications. It is a common misconception that higher compressive strength equals a better repair. In reality, excessively high compressive strength can lead to early failure as a result of excessive loads being I transferred into the repair material. Engineers and Contractors should typically select materials that have only enough strength for the intended use.In most cases intermediate spall repairs will be non-structural in nature,and therefore compatible or lower compressive strengths are beneficial. In general, slower strength development means better long term performance. Often, Contractors select rapid strength-gaining repair materials even when it is not necessary to do so.When it is practical, standard(non-rapid)strength-gaining materials should be selected. Batched concrete should generally be used when repairing intermediate spalls in precast fabri- cator yards since it is readily available. Likewise,batched concrete should be used on construction sites when practical.Although bagged mixes can work well when applied correctly, batched con- crete is typically a better alternative since the material properties will very closely match those of the parent concrete.Follow the provisions in Section 3 of Chapter 3 when using batched concrete to repair intermediate spalls. Ensure maximum aggregate size is no larger than 1/3 of the clear space between reinforcement or the cover. For small repair area,the largest of the coarse aggregate can be removed using a sieve to allow the material to flow adequately in the confined repair spaces. Material Proprietary,cementitious repair mortars and concretes(pre-extended with coarse aggregate) typically consists of a mixture of the following: • Prepackaged dry material,and • Either water or a proprietary liquid component supplied by the manufacturer. Concrete Repair Manual 3-6 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair Only preapproved materials listed on the MPL for DMS 4655, Concrete Repair Materials, should be used on TxDOT projects.The MPL includes several repair categories.The Engineer should specify on the plans which category or categories are acceptable in specific applications. Use neat materials for applications up to 2 inches thick.Use extended materials for repairs exceed- ing 2 inches. Some neat materials may be extended in the field with appropriate aggregate. Consult the manufacturer' s recommendation for aggregate properties and extension proportions . The repair material MPL differentiates between materials that may be extended in the field, those that are pre-extended, and those that are only approved neat. Minimum application thickness can vary depending on the material and size of coarse aggregate(if applicable). Consult the manufacturer's technical data to determine minimum thicknesses when determining minimum acceptable thickness,especially when working with extended materials. For vertical and overhead repairs, limit lift thickness to 2 inches or the maximum permitted by the repair material supplier,whichever is less. Roughen the surface of materials that will receive subsequent lifts,and ensure substrate is clean and saturated surface dry prior to placing additional repair material. Shelf life of repair material is critical, follow manufacturer's published recommendations for storage including temperature and humidity controls.Do not expose material to the environment for extended periods of time.For projects with greater than 1000 square feet of concrete repair, store material off-site.For short durations,not to exceed three days,prepackaged material may be stored on-site but must be raised off the ground and covered in waterproof tarps. Material exposed to the environment and showing signs of packaging wear should not be used until tested and approved by Materials and Tests Division. Retain manufacturer lot tags with packaged date and shelf life for inspection prior to product use. Repair Procedure • Surface preparation. • Remove any damaged or loose concrete. • Avoid damage to sound concrete that is to remain in place. • Unless otherwise approved by the Engineer,use only hand tools or power-driven chipping hammers (15-lb. class maximum)to remove concrete. • If more than 1/2 the perimeter of any mild reinforcement is exposed or if the exposed bar exhibits significant corrosion,remove the concrete from around the entire bar. • Provide'-inch clearance or 1.5 times the largest sized aggregate in the repair mate- rial,whichever is greater,between the steel and surrounding concrete to permit adequate flow of the repair material. Concrete Repair Manual 3-7 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair NOTE: A good rule of thumb is that adequate clearance is attained when you are able to wrap your fingers around the bar. Ensuring that you can grab the bar is a simple but highly effective method of ensuring there is adequate clearance to permit the repair material to flow around the exposed bar. • Do not chip around prestressing strand that is exposed anywhere away from the I immediate end of the member. Consult the Engineer when repairing an area in which prestressing strands have been exposed. When repair dictates that chipping occur around exposed strands,the Contractor must avoid striking the strands directly or otherwise causing damage that could lead to wire or strand breaks. • Use abrasive blasting to remove rust from exposed steel surfaces. • Saw-cut the repair perimeters to eliminate feathered edges and to ensure that the repair material will be applied in depths no less than 1/2 inch. • Handheld grinders or saws may be used to square the repair perimeters. • Do not over-cut the repair perimeters at the corners of the repair areas. • When practical,undercut the repair perimeter at an approximate angle of 30 degrees such that the profile will help hold the repair material in place. • Roughen the substrate to ensure that there will be a mechanical bond between the repair material and the parent concrete.Though difficult to quantify and measure,Con- tractor should attempt to attain a minimum surface roughness profile of 1/8 inch or CSP (Concrete Surface Profile)6 per ICRI. • If the damage occurs at the end of a member and prestressing strand is exposed,recess the strands a minimum 3/8 inch using a torch or other approved method. Do not overheat or damage the surrounding concrete. Concrete Repair Manual 3-8 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair Remove damaged or deuaaunared concrete DAMAGED CONDITION Roughen concrete substrate to promote Pond of catch material. See Concrete Rem,- Manual epanManual PREPARATION ats -Square patch perimeters 1/2 dccc mrmmom. Apply patch meter d)to clean 550 substrele.-- PATCHING lonnommi �..sneofdl,kaarr,._. Contort,patch material In satendod repair area Do not smear onto adjacent surfaces. CONCRETE REPAIR DETAILS Figure 3-1. Typical Repair Details I Figure 3-2. Preparation (saw-cutting)straight and squared edges to contain repa i r material. Concrete Repair Manual 3-9 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair {j r , Figure 3-3. Chipping hammer used to remove unsound concrete. Figure 3-4. Verging adequate clearance around reinforcing. .41 { Figure 3-5. Abrasive blasting to clean reinforcing of rust/active corrosion. Concrete Repair Manual 3-10 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair Figure 3-6. Reinforcing cleaned and free of rust. Figure 3-7. Pressurized water to clean and prepare surface (saturated surface dry). NOTE: In the past some Contractors and Fabricators opted not to recess prestressing strands in spalled areas so the protruding sections could serve as dowels for the repair material. While the strands would serve well as dowels in those circumstances,they could be exposed to moisture and chlorides if the repair fails over the life of the structure.For that reason it is more important that the strand be completely recessed. Install anchors to hold the repair material in place. • Mechanical,ties that bind repair material to the substrate can greatly decrease the risk of future delamination and spalling. For most intermediate repairs, exposed steel serves that purpose.However,there are scenarios in which no reinforcement is exposed and thickness of the spall dictates that cementitious repair material be utilized. In such cases it is neces- sary to install anchors to help mechanically tie the repair material to the parent concrete.When no mild reinforcement is exposed, install anchors at no more than 6 inches on center each way or as required by the Engineer. Refer to Standard Specification Item 449 - anchor bolts.The anchors must consist of one of the following and Figure 3-8 shows detail for concrete repair with mechanical anchors: Concrete Repair Manual 3-11 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair • Stainless steel expansion anchors. The Contractor may propose to use other anchors, such as galvanized or zinc-painted metal.The Engineer will review on a case-by-case basis. • Rebar or threaded stainless steel pins(1/2-inch diameter minimum)anchored in place using TxDOT Type III anchoring adhesive.Remove any epoxy that leaks onto the patch substrate after the anchor is placed. Mechanical Anchors with minimum Existing Concrete embedment (specified by the Manufacturer)into the existing concrete install anchors no —Mechanical more than 6 inches Anchors ° I '' • Existing Concrete on center each way ENC., or as required by the Repair " Min Cover for stainless Engineer Material steel anchors and 1" Min Cover Repair Material for non-stainless steel anchors PLAN SECTION Figure 3-8. Concrete repair with mechanical anchors • If installing expansion anchors: • Drill and clean the holes as required by the anchor manufacturer.Do not use a drill bit • that has a larger diameter than that required. • Embed the anchor the minimum amount required by the manufacturer.However,the anchor should not be driven further than necessary. In order to function as intended the head of the anchor must protrude into the repair material. • If installing dowels using anchoring adhesive: • Drill a hole 1/8 to 1/4 inch greater than the dowel diameter. Make the hole deep enough to permit a minimum 4-inch embedment of the dowel. • Remove any contaminants from the hole using a brush or other mechanical cleaner. • Just prior to installing the anchor,clean the hole using a high-pressure air compressor equipped with filters to remove all oil from the compressed air. • Dry the concrete surface inside the hole prior to installing the dowel. • Fill the hole approximately 1/3 full with the adhesive.Twist the dowel as it is inserted. Ensure that the space between the dowel and the concrete is completely filled with the adhesive. Remove all adhesive from the concrete surface that leaks from the hole after the dowel is inserted. NOTE: When using anchoring adhesives it is critical to properly drill and clean the anchor holes and to place a proper amount of material to keep the anchors in place. The drilled holes must be thoroughly cleaned which should include the use of clean high pressure air and mechanical brushing.Also, if there is too little adhesive,the anchor will not have enough pullout resistance. If there is too much adhesive,the material can leak out of the anchor hole and create a bond breaker on the repair substrate.It is imperative that the Contrac- tor follow the manufacturer's instructions and the above guidelines. Concrete Repair Manual 3-12 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair • Where anchors are installed,ensure that there will be a minimum cover of 1/2 inch for stainless steel and 1 inch for non-stainless steel after the repair material is applied. Oftentimes anchors or dowels do not protrude far enough from the concrete substrate, leaving large depths of repair material unanchored to the parent concrete. Contractor should install anchors with the exposed edge of the repair in mind,not the outside sur- face of the parent material. • Substrates must be clean and sound. Remove any contaminants, including laitance,oil, dust,debris,or other foreign particles. • Just prior to repairing,blast the repair area using a high-pressure air compressor equipped with filters to remove all oil from the compressed air. • Mixing. For small applications(less than 1 cubic yard total)use graduated measuring cups or con- tainers to determine the proper quantity of each component per the manufacturer's require- ments,then dispense into a clean container. Thoroughly mix the components by mechanical means (electric drill or mortar mixer) per the manu- facturer's requirements. Do not mix repair mortar or concrete by hand. • Do not estimate the proper amounts while adding the different components. • For vertical and overhead applications Contractors often need to limit the amount of water or liquid component in order to achieve a stiff mix. Consult the manufacturer's literature for minimum requirements. • If extending the mortar to produce concrete,add aggregate and mix in accordance with the manufacturer's requirements. When mixing more than 1 cubic yard use a mortar mixer,volumetric mixer,or other method approved by the engineer. Contractor must submit detailed procedures on equipment type, proportioning methods,minimum mixing time, and placement. Many cementitious repair materials have relatively short working times(15 to 30 minutes). • Do not mix materials until the surface preparation is complete and the substrate is ready for application of the repair material. • Mix only the amount of material necessary for immediate application. • Review water requirements and temperatures. If the dry materials are left out in the environment,they can easily reach 90°F or higher. In cases where dry materials have elevated temperature,use cooled mix water to ensure workability.When performing repairs between the months of April and September,having ice to add to the mix water or using chilled water should be normal. It is much easier to use cooler repair material.Note that all the material set time and workability time shown on the material's product datasheet is based on a laboratory room temperature of 70°F. • Do not attempt to make the material workable by over-mixing or adding additional liquid after it has begun to set. Over-mixing material that has begun to set can reduce the com- Concrete Repair Manual 3-13 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair pressive strength and increase the permeability of the material. Exceeding maximum water content is bad for long term performance of repair material. • The beneficial properties of bagged mixes are often lost when the repair material is retempered. Retempering of bagged mixes will not be permitted. • Application. Hot and cold weather application. • The temperature of the repair material and the concrete substrate at the time of application must be between 40°F and 95°F. Contractor must also adhere to manufacturer limits if they are more stringent. • Do not apply repair material when the ambient temperature in the shade is below 40°F and falling. Repair material may be placed when the ambient temperature in the shade is 35°F and rising or above 40°F. • Shade the repair material components and the repair substrate if the ambient temperature is above 100°F. In almost all cases, the repair material should be applied over a Saturated Surface Dry (SSD) substrate. ACI CT-13, ACI concrete Terminology, defines sat- urated surface-dry (SSD) as condition of an aggregate particle or other porous solid when the permeable pores are filled with water and no water is on the exposed surfaces . In other words, SSD is achieved when the surface of concrete substrate is saturated with water to a depth of about 1/8 to 1/4 inches, but the exposed sur- face is devoid of free water, as if it had been dried with a towel. Surfaces that will be repaired with a cementitious repair material should be in a saturated surface dry (SSD) condition immediately prior to material application. This condition is achieved by soak- ing the surfaces with water for 2 to 24 hours or pressure water jetting for at least 15 minutes just before repair material appli- cation. Concrete can be visualized like a sponge; when the substrate concrete material can no longer take on water like a sponge that is full, SSD condition has been achieved. Immediately before material application, the repair surfaces should be allowed to start drying. The surface should appear slightly damp, with no standing water. Obtain an SSD condition using the following method: • Several minutes before repairing, apply pressure water blast to the surface for a brief period(at least 15 minutes depending on the porosity of the concrete).An SSD condition is achieved if the surface remains damp until the repair material is applied. Concrete Repair Manual 3-14 TxDOT 03/2021 4 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair Surface may be damp, but must be free of standing water. Do not use a proprietary epoxy bonding layer in lieu of an SSD substrate unless approved by the Engineer. If use of a proprietary bonding agent is authorized,mix it in accordance with the manu- facturer's requirements. Use only TxDOT approved Type V or Type VII material(refer to DMS 6100-Epoxies and Adhesives). If trowel-applying the repair material: • Apply over a bonding layer,which typically consists of a scrub coat brushed into the SSD substrate. • The scrub coat consists of a thin layer of repair mortar that is pushed into the surface using a stiff brush,completely covering the substrate and filling all voids. Ensure that there is not an excess amount of water on the brush used to apply the scrub coat. • Do not dilute the scrub coat material with additional liquid. • Apply the repair material while the bonding layer is still wet(scrub coat)or tacky (proprietary bonding layer). • Apply in minimum 1/2-inch and maximum 1 1/2-inch lifts unless otherwise approved by the Engineer. • For multiple lift applications,roughen the surface of the preceding lift before it has reached initial set. I • Wait until the preceding lift has reached initial set(refer to the product data sheet for estimated time frame)to prevent sagging prior to applying the next lift. • Wet the surface just prior to applying the subsequent lift. I If repairing,using a form-and-pour method: • Prepare and install the forms prior to mixing the repair material. • Ensure that forms are tight enough to prevent grout leakage. • Place the repair material in the forms while the bonding layer is still wet(scrub coat)or tacky (epoxy). • Consolidate the material adequately. Refer to the product data sheet for consolidation instructions . Do not over-vibrate the mix. Do not vibrate self-consolidating concrete products. If required by the Engineer,determine the compressive strength of the repair material by making concrete test cylinders. • Curing. Failures often occur in cement-based repair materials due to inadequate curing. • Large plastic shrinkage cracks can develop if rapid moisture loss occurs before the I repair has the capacity to resist tensile loads that develop as a result of the shrinkage. Concrete Repair Manual 3-15 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair • Drying shrinkage can lead to elevated stress levels that cause cracking within the repair material or at the bond line between the repair and the parent concrete. • It is paramount to the long-term success of the repair that proper moist curing commence as soon as possible after application of the repair material,and that it continue for a sufficient amount of time thereafter. After placing repair material,moist cure exposed repair material surfaces for a minimum of 72 hours using wet mats,water spray,or ponding.Do not use a curing compound in lieu of moist cur- ing unless approved by the Engineer. Curing compound will only be considered for use when water curing will be unnecessarily burdensome and when allowed by manufacturer literature. If use of a curing compound is authorized,any remaining residue must be completely removed after the required curing period. In form-and-pour applications, leave forms in place for a minimum of 72 hours after placing the repair material. Place wet mats on exposed sections and over the openings used to place the material. The Engineer may reduce required curing time in some cases,such as when there is a need to return the member to service quickly or when CFRP will be placed over the repair material. Do not allow concrete surfaces to become dry during the specified moist curing period.Ensure that wet mats are kept wet during the entire cycle. Insulate the repair material to ensure that there is adequate heat for curing if ambient tempera- ture is expected to fall below 50°F.If using artificial heating methods,do not heat the air around the repair material to above 130°F. After curing,the repair area will be inspected visually for cracking and sounded by the inspector with firm hammer blows to ensure the repair has adequate bond without cracking and is free of soft or other unsound material.Acceptance of the repair will be based on the findings of this inspection. • Finish. Ensure that the repairs closely resemble the surrounding concrete.Finish repair work as outlined in Item 427, Section 4.3.4 for Off-the-Form Finish. • Blend in the repair area if after completing the work the repair material does not closely resemble the surrounding concrete. Perform blending or slurry coat finish after measurement of repair location has been com- pleted. The Contractor may use a slurry coat finish in accordance with Item 427 to blend in the repair.The Engineer will review other methods proposed for blending repairs. • Repairs should not be easily discernible if viewed from more than 25 feet away. • Measurement will be make prior to blending repair edges with parent material. Concrete Repair Manual 3-16 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 2—Intermediate Spall Repair Commentary When feasible, batched concrete is typically the best option for repairing intermediate spalls. However,it is often not practical to use batched concrete when working on existing structures or,in some cases,on construction sites.Using bagged mixes is also necessary when either trowel-applied or flowable form-and-pour mortar is needed in highly congested or thin applications.Proprietary cementitious repair materials can work effectively if applied correctly. Each step in the repair process(preparation,proportioning, mixing,application,and curing) is crit- ical in the overall performance of the repair material.The requirements set forth in DMS 4655, Concrete Repair Materials, ensure that only high quality materials will be added to TxDOT's pre- approved list. It is imperative that Contractors only use concrete repair materials that have been preapproved for the given application. Concrete Repair Manual 3-17 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 3—Major Spall Repair and Concrete Replacement Section 3 — Major Spall Repair and Concrete Replacement Description Use batched concrete for repairing large spalls and defects in concrete members,or when removing and replacing large concrete components. Using batched concrete ensures that the repair material properties will be the same or similar to the parent concrete. Batched concrete is required in structural applications because it becomes more critical that the repair material have similar material properties as the parent concrete. Proprietary bagged mixes may only be used in structural applications if specifically authorized by the Engineer. Material For new construction,make the repair material using the same concrete mix design that was utilized when the damaged member was originally cast.This applies to precast fabrication yards and construction sites where new structures are being built. In remedial applications,the Engineer will specify which class of concrete should be utilized per Item 421.For repairs,the Engineer should select concrete mixes that closely match the parent material when such information is available via design documents or construction records. Repair Procedure • Surface preparation. • Remove any damaged or loose concrete prior to proceeding. • Avoid damage to sound concrete that is to remain in place. • Unless otherwise approved by the Engineer,use only hand tools or power-driven chipping hammers (15-lb. class maximum)to remove concrete. • If more than 1/2 the perimeter of any mild reinforcement is exposed or if the exposed bar exhibits significant corrosion,remove the concrete from around the entire bar. • Provide 3/4-inch clearance or 1.5 times the largest sized aggregate in the repair material, whichever is greater,between the steel and surrounding concrete to permit adequate flow of the repair material. NOTE: A good rule of thumb is that adequate clearance is attained when you are able to wrap your fingers around the bar. Ensuring that you can grab the bar is a simple but highly effective method of ensuring there is adequate clearance to permit the repair material to flow around the exposed bar. Concrete Repair Manual 3-18 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 3—Major Spall Repair and Concrete Replacement • The Engineer may require that the steel be coated or that corrosion inhibitor be added to the repair material when reinforcing steel has been exposed. • Do not chip around prestressing strand that is exposed anywhere away from the immediate end of the member. Consult the Engineer when repairing an area in which prestress- ing strands have been exposed. When repair dictates that chipping occur around exposed strands,the Contractor must avoid striking the strands directly or otherwise causing dam- age that could lead to wire or strand breaks. • Use abrasive blasting to remove rust from exposed steel surfaces. • Square the repair perimeters to eliminate feathered edges and to ensure that the repair mate- rial will be applied in depths no less than 1/2 inch. • Handheld grinders or saws may be used to square the repair perimeters. • Do not over-cut the repair perimeters at the corners of the repair areas. • When practical,undercut the repair perimeter at an approximate angle of 30 degrees such that the profile will help hold the repair material in place. • Roughen the substrate to ensure that there will be a mechanical bond between the repair material and the parent concrete.Though difficult to quantify and measure,Contractor should attempt to attain a minimum surface roughness profile of 1/8 inch or CSP(Concrete Surface Profile)6 per ICRI. • If the damage occurs at the end of a member and prestressing strand has been exposed,recess the strands a minimum 3/8 inch using a torch or other approved method. Do not overheat or damage the surrounding concrete. NOTE: In the past some Fabricators have opted not to recess prestressing strands in spalled areas so they can serve as dowels for the repair material.While the strands would serve well as dowels in those circumstances,they could be exposed to moisture and chlorides if the repair fails over the life of the structure.For that reason it is more important that the strand be completely recessed.Anchors should be installed to hold the repair material in place. • For practically all batched concrete repairs there will be an adequate amount of exposed steel to provide sufficient mechanical anchorage to the parent material.If the Engineer requires that Contractor install additional ties or dowels, select material and install in accordance with the requirements in Section 3.2 for Intermediate Spall Repair. • Adhesive Anchors. • The Engineer will identify anchor or reinforcing steel type in plans. • Anchor the bars using a preapproved Type III anchoring adhesive. Ensure the Con- tractor has either small volume anchoring adhesive cartridges or an injection system for bulk volume anchoring adhesive. Concrete Repair Manual 3-19 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 3—Major Spall Repair and Concrete Replacement • Drill a hole 1/8 to 1/4 inch greater than the bar diameter. Make the hole deep enough to permit a minimum 6-inch embedment of the bar. • Remove any contaminants from the hole, including laitance,oil,dust,debris,or other foreign particles. • Just prior to installing the anchor, clean the hole using a high-pressure air compressor equipped with filters to remove all oil from the compressed air. • Dry the concrete surface inside the hole prior to installing the dowel. • Fill the hole approximately 1/3 full with anchoring adhesive.Twist the bar as it is inserted. For u-shaped bars that cannot be twisted fill the holes approximately %z full with adhesive prior to insertion. • Ensure that the space between the dowel and the concrete is completely filled with adhesive. • Remove all adhesive from the concrete surface that leaks from the hole after the dowel is inserted. • Where supplemental reinforcement is installed,ensure minimum cover of 1 'A inch. • Substrates must be clean and sound.Remove any contaminants, including laitance,oil, dust,debris,or other foreign particles. • Just prior to repairing,blast the repair area using a high-pressure air compressor equipped with filters to remove all oil from the compressed air. • Mixing. Produce repair material in accordance with the approved methods for batching concrete. In order to ensure an adequate mix, batch a minimum of one cubic yard of concrete to repair the damaged area even if less volume is required to complete the repair. Ensure that concrete is workable enough when it is placed that it can be adequately consolidated around reinforcing steel,anchors,and other tight places inside the forms. Ensure the maximum coarse aggregate does not exceed 1/3 of the smallest dimension, including reinforcement clearance . Remove large aggregate by wet sieving when necessary. • Application. Hot and cold weather application. • The temperature of the repair material and the concrete substrate at the time of application must be between 40°F and 95°F. • Do not apply repair material when the ambient temperature in the shade is below 40°F and falling.Repair material may be placed when the ambient temperature in the shade is 35°F and rising or above 40°F. • Shade the repair material components and the repair substrate if the ambient temperature is above 100°F. Concrete Repair Manual 3-20 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 3—Major Spall Repair and Concrete Replacement Convey the material to the repair area using approved concrete delivery equipment. Apply the repair material over an SSD substrate. Obtain an SSD condition using the following methods: • Several minutes before repairing,apply high-pressure water blast to the surface for a brief period(15 minutes depending on the porosity of the concrete).An SSD condition is achieved when the surface remains damp after being exposed for 15 minutes. Surface may be damp, but must be free of standing water.Remove all free(ponded)water just before placing repair material. Do not use a proprietary epoxy bonding layer in lieu of an SSD substrate unless approved by the Engineer.If use of a proprietary bonding agent is authorized,mix it in accordance with the manufacturer's requirements.Use only TxDOT approved Type V or Type VII material (refer to DMS 6100-Epoxies and Adhesives). • Forms. Prepare and install the forms prior to mixing the repair material. Ensure that forms are tight enough to prevent grout leakage. Place the repair material in the forms while the concrete substrate is still SSD. If the parent concrete is no longer SSD,remove the forms and re-spray the surface with a high-pressure water blast. Consolidate the material adequately. Do not over-vibrate the mix. Do not vibrate self-consolidating concrete. If required by the Engineer,make concrete test cylinders to determine the compressive strength of the repair material. If the same concrete mix is being used for production work in another location,the results of compressive strength testing for that work may be used. • Curing. Cure batched concrete repairs for a minimum of 72 hours.For most batched concrete applications,the material should be cured by leaving the forms in place during the entire curing period. Place wet mats on exposed sections and over the openings used to place the material. Do not allow concrete surfaces to become dry during the specified moist curing period.Ensure that wet mats are kept wet during the entire cycle. Insulate the repair material to ensure that there is adequate heat for curing if ambient temperature is expected to fall below 50°F. If using artificial heating methods,do not heat the repair material to above 130°F. After curing,the repair area will be inspected visually for cracking and sounded by the inspector with firm hammer blows to ensure the repair has adequate bond without cracking and Concrete Repair Manual 3-21 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 3—Major Spall Repair and Concrete Replacement is free of soft or other unsound material.Acceptance of the repair will be based on the findings of this inspection. Commentary Batched concrete is typically the best choice when repairing deep spalls and in structural applications. Particularly in new construction,mix designs can be selected to ensure that the material properties will closely match the substrate. Failures at the bond line between the repair material and parent concrete are a common problem due to stresses that develop as a result of loading, differential thermal expansion, drying shrinkage and contraction between the repair and parent material. To that end,using repair material that has a comparable coefficient of thermal expansion and a comparable or lower modulus of elasticity is critical for the long-term success of a repair when significant stresses are likely to develop. Typically, it is not feasible to determine the modulus of elasticity and coefficient of thermal expansion in a member that has already been cast.The best solution is to use the same mix design for the repair material as that used when the damaged member was originally cast,ensuring that the material properties will be similar. Concrete Repair Manual 3-22 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair Section 4 — Bridge Deck Repair Description This section covers bridge deck repairs over relatively small areas.Large-scale deck repair or replacement work should typically include project-specific plans and be in accordance with Item 422,"Concrete Superstructures."The primary use of this section is to address unanticipated localized bridge deck damage that typically must be repaired quickly. The work covered here can be categorized in two ways. First,by depth: (1)partial depth deck repairs,(2)deck repair over precast deck panels (PCP),and(3)full-depth bridge deck repair. Second,by speed: (1)ultra-rapid,(2)rapid,(3)accelerated,and(4)normal. • Defining Bridge Deck Repairs by Depth: • Partial-depth bridge deck repairs are typically performed on full-depth cast-in-place bridge decks. Damage in the top of the deck only(not progressing full depth)is due to initial slab defects such as improper consolidation or insufficient concrete clear cover over the reinforcing steel; abrasion;wear; or top reinforcing mat steel corrosion. • Distress can also occur in the cast-in-place sections of deck above precast concrete panels (PCP's).Regardless of the severity,when performing deck repairs in such cases the cast- in-place portion should be removed to expose the top of the PCP,which then becomes the bonding interface for the repair material.When spalling is occurring above a precast panel,the underside of the panel should be checked for distress. If there is substantial staining on the girder side faces indicating roadway drainage passing through the haunch concrete,panels likely should be replaced with a full depth repair. • When damage extends into the PCP portion of the deck,exhibited by visible cracking on the panel soffit,then it should be treated as a full-depth deck repair. • Full depth repairs are typically performed when partial depth distress has gone untreated and has progressed to full depth distress as discussed in the commentary of this section and when required to perform expansion joint replacement. • Defining Bridge Deck Repairs by Speed(Required Return to Service): • Often,the factor that trumps all others in bridge deck repair work is the need to return a structure to service quickly.Bridge deck failures and consequent lane closures can have hugely detrimental impacts on traffic,particularly in urban environments. Over the years, repair material suppliers and contractors have become accustomed to the need for extraordinarily quick turnaround,and have catered their services around that need. However, it has been observed that re-repair of previously repaired decks occurs frequently when the rapid strength gaining materials are used.This is further expanded upon in the commentary of this section. Concrete Repair Manual 3-23 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair • In this section there are four categories of repair material based on the needed return to service time. Ultra-rapid repair material can attain sufficient compressive strength for return to service in 2 to 4 hours.Rapid repair materials can generally be returned to service in 6 to 8 hours. Class K material is batched concrete designed specifically in deck repair applications for accelerated strength gain and return to service, usually in less than 12 hours(not including moist curing time).Class S concrete is the best long term solution but can take several days to achieve sufficient strength. Follow the plan requirements related to required strength prior to opening to traffic. If no guidance is provided,provide concrete able to obtain a minimum of 3,600 psi compressive strength prior to opening to traffic. Selecting an Appropriate Repair Material An appropriate repair material can be selected once a project has been categorized based on the needed return to service.For depths exceeding 3 inches use material extended with coarse aggregate. • 3 hours: Use a preapproved Type B Ultra-Rapid Repair Material meeting the requirements of DMS 4655, Concrete Repair Materials. • 6 hours: Use a preapproved Type A Rapid Repair Material meeting the requirements of DMS 4655, Concrete Repair Materials. • 24 hours: Use Class K concrete.These are typically specialty mix designs supplied by a Ready-Mix plant. Mix design requires review and approval from the Engineer. Depending on the capabilities of local Ready-Mix plants this option may or may not be available. • 2 to 4 days: Class S concrete mixes,which are used to cast new bridge decks,offer the best likelihood of long term serviceability. However, it can take several days before the concrete has sufficient strength for return to service.Engineer should review the history of the proposed Class S mix to ensure that relatively fast strength gain(less than 4 days)is likely to occur.Even with rapid strength gain,Class S mixes should be moist cured for 72 hours(absolute minimum 48 hours). For batched concrete,provide mixes meeting the requirements of Item 421,Hydraulic Cement Concrete.Note that typical Class HES mixes may not be classified as structural concrete, and should not be used,unless otherwise approved. Repair Procedure • Mixing. • Except in very small applications(less than 1 cubic yard),use a mortar or volumetric mixer.Ready-Mix suppliers and trucks should typically provide batched concrete(Class K or Class S),though the Engineer may approve volumetric mixers on a case-by-case basis. Concrete Repair Manual 3-24 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair • For small applications(less than 1 cubic yard total), mix the components thoroughly by mechanical means (electric drill or mortar mixer) per the manufacturer's requirements.Do not mix repair material by hand. • Regardless of the mixer type, carefully proportion the water to ensure water-to-cement ratio falls within manufacturer limits.Do not guess at proper quantities or add water to attain a desired consistency. NOTE: Contractors often use"5-gallon"buckets to proportion water.The actual volumes of these buckets can vary significantly.The Contractor and Inspector should verify actual volumes rather than assuming the buckets actually hold exactly 5 gallons. • Do not mix material until surface preparation is complete. Ensure that there are sufficient amounts of material,mixing equipment,and labor to provide a continuous supply of mixed concrete until the placement is complete.Take sufficient steps to prevent cold joints between lifts,keeping in mind that many proprietary materials set up very rapidly(less than 15 minutes) in hot weather. • Removal of Concrete. • Saw-cut the perimeter of the proposed repair approximately 1/2 to 3/4 inches but do not cut existing reinforcing steel.Adjust depth as necessary to avoid damaging deck steel. • Use power-driven chipping tools or hydro-demolition equipment to remove concrete. Avoid damage to sound concrete to remain. Contractor may use up to 30-1b. hammers for the bulk of the work.However, 15-lb.hammers or smaller must be used at the base and perimeter of the repair area to avoid damaging the surrounding concrete. • Remove additional concrete as necessary to keep the repair area to a reasonably uniform depth. • Partial-Depth Deck Repair • Remove a sufficient amount of damaged concrete to ensure that the remaining deck is sound.Provide a uniformly rough surface with a chipped appearance (1/4 inch minimum surface profile or ICRI Concrete Surface Profile 9). • Even if defective material does not extend beyond top layer of reinforcement,remove enough concrete to ensure there is minimum 3 inch clearance below the top layer of steel in order to provide mechanical bond for new patch material. • Repairs over precast deck panels (PCPs) : Completely remove cast-in-place concrete to expose roughened PCP surface.Ensure that demolition operations do not dam- age the PCPs. • Full-Depth Deck Repair: Square or slightly undercut the repair perimeter. • The Engineer or the Inspector may sound the perimeter of the repair area to determine whether concrete removal operations caused damage beyond the intended perime- ter. If that is the case the repair area must be extended to include the unintentionally damaged area. Concrete Repair Manual 3-25 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair • For full-depth repairs, remove the concrete and place forms in accordance with Item 422, Concrete Superstructures,or as approved by the Engineer. • Obtain approval from the Engineer of the completed concrete removal before proceeding with surface preparation. • Reinforcing Steel. • Remove all rust and other deleterious material from reinforcing steel. • For non-epoxy coated reinforcing and for epoxy coated steel bars with coating failure, abrasive blast clean steel. Inspect cleaned steel for damage. Replace bars when cross- section is reduced greater than 25 percent. • Apply an approved epoxy coating to repair minor damage to existing epoxy coated bars. • When the original epoxy coating on the bars was removed by abrasive blasting,apply an epoxy coat around the entire circumference of the bars extending a minimum of 3 inches from the repair perimeter into the repair area. • Install reinforcing steel as indicated on the plans or as directed by the Engineer.Place reinforcement parallel to the finished surface.Lap adjacent sheets or bars at least 6 inches and tie them together securely at a spacing of at most 18 inches. • Pre-bend reinforcing steel fabric to fit around corners and into re-entrant angles before installing it.Place and secure reinforcement to prevent displacement due to repair material application. • Surface Preparation. • Just prior to repairing,thoroughly clean the concrete surfaces (bottom and sides). • Clean the area to be repaired by high-pressure water blasting,or other approved methods. Remove all loose particles,dirt, deteriorated concrete,or other substances that would impair the bond of the repair material. Follow this with a high-pressure air blast for final cleaning. • Ensure the surface of the existing concrete is in a saturated surface-dry (SSD)condition but remove all free(ponded)water just before placing repair material.Achieve an SSD condition by high-pressure water blasting at 1 ea s t 15 minutes before placing the repair material. • Formwork. • Formwork should be tight to prevent leakage of grout or mortar. • Formwork surfaces should not be too hot,preferably not higher than 90°F,to avoid flash set of fresh concrete. • Placement. • Place the repair material onto the prepared surfaces. Consolidate using immersion-type vibrators or other methods acceptable to the Engineer. Concrete Repair Manual 3-26 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair • Curing. Moist curing is often neglected in deck repairs due to the need to return the bridge to service quickly. However, lack of adequate curing leads to problems on deck repair materials just as it does on any other cementitious repair.Bridge deck repairs should be moist cured for as long as possible.Although 72 hours of curing time is ideal,that is seldom practical in deck repair applications. Even a few hours of moist curing can be beneficial. Steps for full-depth deck repair • Define repair boundary areas • Sound the concrete to determine the boundary of repair area. • Typically add 3 in. in both directions unless otherwise noted on plans. • Delineate straight edges for repairs. • Saw cut the repair boundary repair boundary areas • Square or slightly undercut the repair perimeter. • Do not cut reinforcement steel • Remove deteriorated/unsound concrete • Use power-driven chipping tools or hydro-demolition equipment to remove concrete. Avoid damage to sound con- crete to remain. Contractor may use up to 30-lb. hammers for the bulk of the work. However, 15-lb. hammers or smaller must be used at the base and perimeter of the repair area to avoid damaging the surrounding concrete. • Installation of formwork • Formwork should be tight to prevent leakage of repair material. • Prepare repair area • Clean the area to be repaired by high-pressure water blasting, or other approved methods. • Use abrasive blasting to remove rust from exposed steel surfaces . • Remove all loose particles, dirt, deteriorated concrete, or other substances that would impair the bond of the repair material. Follow this with a high-pressure air blast for final cleaning. • Mixing Concrete Repair Manual 3-27 TxDOT 03/2021 • Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair • Prepare repair material in accordance with the approved methods for batching concrete. • Place and finish concrete • Place the repair material onto the prepared surfaces . Consolidate using immersion-type vibrators or other meth- ods acceptable to the Engineer. • Distribute the concrete evenly to avoid the need of excessive shoving. Use vertical penetrations of an approved vibrator to adequately consolidate the concrete. Do not drag the vibrator through the mix as this may cause segregation and loss of entrained air. • Cure and insulate concrete • Curing is important to help the concrete achieve intended strength and durability. tF �� i• . y :. :Y. Figure 3-9. Saw-cutting along defined repair boundaries Concrete Repair Manual 3-28 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair rA.,_ . , • -4i' , s 1.....- . . *4,,,,,,,i_ • '"..: _ L 1 ti� x.A „ �r �t• a'e [. . .. - --_ s "Y. a .P a N"- te •, `? spa' N Figure 3-10. Remove deteriorated/unsound concrete ti f. Figure 3-11. Installation of formwork Concrete Repair Manual 3-29 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair \ ,; 4 afr „Air Ik1. C • r ;.fie; Figure 3-12. Repair area preparation(high-pressure water blasting,or other approved methods to remove dust and debris.Abrasive blasting to remove rust from exposed steel surfaces) Concrete Repair Manual 3-30 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair 1,,,IP 'i 1.''• - N tt,, •' -- VT ' ,,.1. • /it . . •, 4 t ..e... .,,,. 1‘,••,, ,, - . ,.. 'A ,-7 •rigttlf,,,,, . . ., ,II 8 Ili' 1:114- ...,.. 14 ,/'• . i„.„. , ,, ..i •&L•i.,...,N.4z. '-, • • • 74.'' 7' .. •• .c 4.*)' 1,1V . •N”, •'-.'itt:1,•:' ,'.4t•• , . '''• _. 1114, "0 .(4., 'um:A,:,c* .-' ‘ , - e. >,..,....6 .0, .•'44- .41W7 V A' ' •( . • i-rs.,..... - vit-i0 . ,,,, • ,,, 4.,,(Iv°F . ,_ .„ , . • , . • , Figure 3-13. Placing the concrete 4i‘IF , laigitrib,- ,. ......_ , ...... • . . .. .1.40).•...V.A..,, . . 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"'1::.'--.•i' ... 4A..2 ,eni.4$.-.,-;,..,1-, • ,„,-.---;.f" -,-.474w • /... ,..,,,,,, „,,„, , „,,,, ' 1*'-,,,,, ,,S, S. , - 0r •'t - ' ,•"-.4"-s.::,7:4-:,''' 4:st ' ' ; "-v,,,p7.'..1%.%).1',;1***534.1.1.14.V.,,f,iik,404. .• . , .',';i.•.!:4...•!;.");.-,-.7,.%-.).44:4;40 .:... .,/,,,e,,,,s::,,f/,r!,.‘•f .14.,,/ W .,,•... - ..-id."5147/31,?&„fr , 40, -.41it• -1:,,,.. :Pri.',4iii ,- ',4, •'• ''''''',7!•.:(.:?..;•;$'*• , .%Ar A q-:-.--,%.:00.?4,1it,.'f,:".:;"..,.'40-1- .,'„? •-,, -, ,.24,-". - '--"*... ..",,,4,..-:;-""!,,,.1.71.f.6'..;`•-,•.// f-Af•&11-f:',1!-...P.,',:j.".; ...,•'-•••:': :•-•:.'c " % OppilIV ... i• ,,,...A4,, ,„. ,....,i,yr' ._. . . -, ' •", o' ,..',,4::.,„,:f-4v.tt4;";,...1%.,,,,,,-;.14,r.$t '1„.. v,- Figure 3-14. Finishing the c ;: - Concrete Repair Manual 3-31 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair - ! 1 r` ti yN. Figure 3-15. Cure and insulate concrete Commentary Shallow deck repairs are notorious for exhibiting poor performance. One common cause of early failure is debonding between the repair material and the substrate. Repair material applied over large areas but in thin applications tend to build up very high stresses at the bond line, leading to premature failure.To remedy this the Contractor should excavate below the top layer of steel, which serves two purposes. First,the reinforcing cage provides a mechanical tie for the repair material to the rest of the deck. Second, it helps to prevent overly thin applications that have little chance of performing well. Another common cause of premature failure is that partial-depth repairs are often implemented when full-depth would have been more appropriate.The deck soffit should be inspected at partial Concrete Repair Manual 3-32 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 4—Bridge Deck Repair depth repair locations looking for areas of distress that could be weak and fail when the upper surface is being removed. Partial-depth repairs are typically easier to perform because they do not require installation of formwork or road closures under the bridge.Bridge deck distress oftentimes progresses full depth,as evidenced by cracking in the deck soffit.If map pattern cracking is visible, or if there is widespread cracking with efflorescence and rust staining,then full depth repairs should usually be implemented in lieu of partial-depth. Intended partial-depth deck repairs can unintentionally become full-depth repairs if the Contractor utilizes equipment too heavy for the application. Contractors should not use equipment larger than necessary to perform the required demolition work, and must stay within the applicable limits outlined in the"Surface Preparation"item below, unless specifically allowed otherwise by the Engineer.No additional compensation for full depth repairs caused by contractors operations will be made. While rapid strength gain is beneficial for returning a bridge to service, it typically has detrimental effects for the repair material. Short duration curing of the cementitious material can prevent even distribution of the hydration products.Also,early return of ser- vice induces stresses into concrete that can create microcracking and other defects even when the compressive strength is high. Because deck repairs must usually be performed quickly,Engineers and Contractors often select rapid methods even when they are not necessary. It is imperative that,when feasi- ble, slower-hydrating materials and longer curing cycles be utilized.The faster the return to service,the shorter the anticipated service life of the repair. Concrete Repair Manual 3-33 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 5—Crack Repair–Pressure-Injected Epoxy Section 5 — Crack Repair– Pressure-Injected Epoxy Description Pressure-inject TxDOT Type IX low-viscosity epoxy resin into concrete cracks to restore structural integrity of damaged members or to prevent water and chloride infiltration. Depending on the epoxy resin material,cracks as narrow as 0.002 inches can be injected with epoxy resin. However, it is often difficult to effectively fill cracks that are narrower than 0.005 inches. It is important to use a crack gauge to get accurate readings on crack widths. Material Crack Injection Material:TxDOT Type IX low-viscosity epoxy resin(ASTM C 881 Type IV, Grade 1)typically consists of two liquid components that are combined automatically during the pressure injection process. Epoxy for Sealing the Surface of Cracks:TxDOT Type V or VII concrete epoxy adhesive.Use only material that is approved by TxDOT and the crack injection material manufacturer. Refer to DMS 6110 and MPL for Epoxies and Adhesives for additional information.Also refer to approved manufacturers and products list. Use material not included in the approved MPL only if authorized by the Engineer. Repair Procedure • Surface Preparation. • Drill holes to permit installation of the injection ports or mount the ports on the surface as required by the manufacturer. Space the ports at appropriate intervals as outlined in the Application section that follows. • Clean the interior of vertical cracks from bottom to top using either com- pressed air or vacuum systems to remove all loose materials entrapped in the cracks. • In some cases, it may be difficult or impossible to sufficiently remove dust or debris from inside the cracks. • If the debris is only near the surface,drill holes for the injection ports away from the exposed portion of the crack.Drill the holes at an angle so the injection ports intersect the crack beneath the surface away from the dust and debris. • When using compressed air ensure that the debris is not being forced deeper into the crack. Concrete Repair Manual 3-34 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 5—Crack Repair–Pressure-Injected Epoxy • Consult the Engineer if it appears that debris in the crack could hinder proper injection of the epoxy resin. • Remove contaminants where the surface seal will be applied,including laitance,oil,dust, debris,or other foreign particles. • Unless the manufacturer or the Engineer specifically requires otherwise, do not grind the concrete around the crack to remove contaminants or provide a V-shaped groove along the crack. • Grinding can force dust into the crack and consequently hinder proper flow of the epoxy resin. • If a V-shaped groove is cut into place along the crack,carefully remove the dust using compressed air and/or high-pressure water blasting.Do not commence the surface sealer application or injection work until the crack and concrete surface have dried. • Mixing. Mix the epoxy surface seal as required in the manufacturer's technical literature. Epoxy Injection Resin: Use portable injection equipment capable of automatically mixing the liquid components at the proper proportion during the pressure injection operation. • Application. Install the injection ports. • Place the ports directly on the crack or in drilled holes that intersect the crack. • Install the injection ports at appropriate intervals along the crack. • The port spacing should not exceed the depth of the crack. If the depth of the crack is not known,space the ports as recommended by the resin manufacturer. • If the crack projects through the entire concrete section,the intervals between ports should not exceed the section depth. • Ensure that the ports are placed in locations where the crack is not too narrow or clogged with debris to permit adequate flow of the epoxy resin. • Anchor the injection ports and seal the surface of the crack between ports using a sealer as required by the resin manufacturer. • Allow sufficient time for the sealer to cure before commencing the resin injection. • The sealer must have adequate strength to hold the injection ports in place and withstand the pressure along the crack during the injection operations. • Apply sealer over the surface of the crack on the backside if the crack extends completely through the concrete section. • Pressure-inject the epoxy resin into the crack through the ports. • Use a positive displacement pump,air-actuated caulking gun,or paint pressure pot as rec- ommended by the epoxy resin manufacturer and approved by the Engineer. Concrete Repair Manual 3-35 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 5—Crack Repair–Pressure-Injected Epoxy • If working on a vertical surface,start injecting at the lowest port and work upwards. • Maintain adequate pressure until resin emerges from the adjacent port. • If resin does not emerge from the adjacent port, stop the work and reevaluate the crack. • Ports may need to be placed more closely together or debris cleared from under the existing ports. • As noted above,ports should be installed at an angle so they intersect the crack at a deeper point if debris is clogging the crack near the concrete surface. • Inadequate flow of the epoxy resin may be a sign that the crack is either too shallow or too narrow for pressure injection to serve its purpose. • If the epoxy begins to flow out of a nonadjacent port,temporarily plug that port until the epoxy begins to flow out of the adjacent port. • Once the resin appears in an adjacent port,remove the injection nozzle,seal the port,and begin injecting in the adjacent port. • Move the equipment to the adjacent port and proceed with the epoxy resin pressure injection. • Remove the injection ports and surface sealer after the epoxy resin has been given adequate time to cure.Resin material should not flow from the crack after the surface sealer is removed. • Finishing. • Grind away any epoxy resin or surface sealer residue that is left on the concrete surface after the injected material has had sufficient time to cure. Commentary Injection of concrete cracks with epoxy resin takes a great deal of skill and expertise.The repair crew should receive hands-on training from a technical representative from the resin manufacturer before proceeding with the work, or the Contractor should retain a specialty firm to perform the work. Concrete Repair Manual 3-36 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 6—Crack Repair-Gravity-Fed Sealant Section 6 — Crack Repair—Gravity-Fed Sealant Description Use TxDOT Type IV low-viscosity, gravity-fed sealant to fill cracks to help prevent water and chloride infiltration into concrete. Depending on the type of sealant used,cracks with widths as narrow as 0.004 inches can be filled using gravity-fed material. Use a crack gauge to get accurate readings on crack widths. Material TxDOT Type IV low-viscosity,gravity-fed sealant typically is made by combining two proprietary liquid components in the ratio required by the manufacturer. Refer to DMS 6110 and MPL for Epoxies and Adhesives for additional information.Also refer to approved manufacturers and products list. Use material not included in the approved MPL when specified on the plans or if authorized by the Engineer. Provide dry,coarse sand to apply to deck surface when flood coating with sealant is specified.The sand should be able to provide long-term skid resistance, with min- imum 60% acid insoluble residue per Tex-612-J. Repair Procedure • Surface Preparation. • Remove contaminants where the epoxy will be pooled around the crack, including laitance,oil,dust,debris,or other foreign particles. • The epoxy will not work effectively in cracks that are filled with contaminants.Use compressed air to remove debris and other foreign particles from inside the crack. • Ensure that concrete is sufficiently dry prior to applying the epoxy. • For cracks that extend completely through the concrete section,seal the crack on the back or underside of the concrete to prevent the epoxy material from flowing out. Remove the surface sealer after the gravity-fed epoxy has had adequate time to cure. • Mixing. • Measure the quantity of each component per the manufacturer's requirements,then dispense into a clean container. Do not estimate the proper amounts while adding the different components. Follow the product specifications for maximum time allowed for Concrete Repair Manual 3-37 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 6—Crack Repair–Gravity-Fed Sealant use after mixing.These materials have short pot life when left in a container and if left too long they will flash set. • Mix the components thoroughly for 3 minutes using a low-speed electric drill(400–600 rpm)and a clean"Jiffy"type mixing paddle.Ensure that the material is well-blended after mixing. • Do not mix gravity-fed epoxy material by hand. • Application. • Pour sealant directly on cracks within the treatment area. Distribute the sealant over the surface to be treated within the lot size that can be accommodated for the particular sealant being sealed.Brush grooved cracks with heavy nap roller.Pull additional sealant material onto crack using squeegee or broom and then re-brush crack with heavy nap roller. • If applying on grooved surface,remove excess sealant from deck surface and brush or broom out epoxy from texture grooves.Do not allow the ponded sealant to stiffen,and do not allow sealant to remain in the grooves on the bridge deck. • Broadcast or spread sand onto the still tacky sealant within 10 to 20 minutes of the last application of sealant.Apply the sand at a rate of 15 to 20 lb.per 100 sq. ft. of area. • Contractor may propose alternate application techniques that meet manufacturer requirements. • When sealing isolated cracks and flooding the surface will not be done, install temporary dams around the crack so the pressure head of the gravity-fed epoxy will build up. Install the dams using a material that will prevent the epoxy from spreading over the concrete surface,and that can be removed after the repairs have been completed. Leave the pooled epoxy in place for at least one hour. Refill the dammed area as necessary if the epoxy drains completely into the crack. NOTE: Although a wide variety of materials will work for constructing temporary dams for pooling gravity-filled epoxy,plumbers putty is a good option because it does not require any curing time and it can be very easily removed after use. Commentary Gravity-feeding epoxy is an effective method for filling the tops of cracks. However,the depth of penetration can be variable.Limit its use to shallow cracks or locations where deeper cracks are acceptable,but protection from water and chloride infiltration is necessary. Gravity-feeding sealant is an effective method for filling the tops of cracks. However,the depth of penetration can be variable and often times it will not penetrate the cracks more than 1/4".The pri- mary use of gravity-fed sealants is to address relatively shallow bridge deck cracking, which when used correctly,will provide a barrier keeping water and chloride from reaching the reinforcing steel. Concrete Repair Manual 3-38 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 7—Crack Repair–Surface Sealing Section 7 — Crack Repair— Surface Sealing Description Occasionally there is a need to seal cracks to prevent infiltration of water,chlorides,and other contaminants. While other crack sealing techniques can restore capacity or provide for complete filling of a crack,the methods outlined in this section only cover sealing the cracks at the outer surface of the concrete. Method 1: Rout-and-Seal Cracks • Routing and sealing cracks can be an effective way to prevent water infiltration in cracks in which a small amount of movement is anticipated due to service loads,thermal effects,or other causes. • When routing a crack,the Contractor should use a grinder to create a V-shaped groove,with the crack centered in the groove.Though it can vary depending on the application,the grooves should typically be about 3/8 inch deep. • For cracks in which a significant amount of movement is anticipated,bond breaker tape should be placed at the bottom of the groove prior to sealing.The tape must stay at the bottom of the groove in order to be effective.The bond breaker allows for 2-sided rather than 3-sided adhesion,which permits much greater elasticity of the sealant. NOTE: Although good in principle, it is difficult to place bond breaker tape in the bottoms of the grooves such that the tape will not move during application of the sealant. If the bond breaker moves up it can reduce or eliminate the bonding surface on one side of the joint, eliminating their effectiveness. When used,the Contractor must take great care to ensure that tape stays in its intended location. • After grooving,ensure substrates are clean and sound.Remove any contaminants, including laitance,oil, dust,debris, or other foreign particles. • Fill the groove using a preapproved Class 4 low-modulus silicone meeting the requirements of DMS 6310,Joint Sealants and Fillers or Type V adhesive meeting the requirements of DMS 6100,Epoxies and Adhesives as specified on the plans. Method 2: Surface Sealing • Sealing the surfaces of cracks simply involves applying an adhesive directly over the crack to prevent infiltration of water, chlorides,and other contaminants. • Sealing the surfaces of cracks should only be employed when no significant crack movement is anticipated.This can apply to minor cracks in compression members,or in cracks that occur in prestressed members as a result of fabrication,detensioning, or handling issues. Concrete Repair Manual 3-39 TxDOT 03/2021 Chapter 3—Repair Materials and Procedures Section 7—Crack Repair–Surface Sealing ♦ For sealing cracks at the outer concrete surface,apply a preapproved Type VIII or Type X epoxy that meet the requirements of DMS 6100,Epoxies and Adhesives.Work the epoxy into the crack,then remove any excess epoxy from the surface before it sets. Concrete Repair Manual 3-40 TxDOT 03/2021 Exhibit 7 INSURANCE REQUIREMENTS CONTRACTOR'S LIABILITY INSURANCE A. Contractor shall not commence work under this agreement until all insurance required herein has been obtained and approved by the City's Risk Manager or designee. Contractor must not allow any subcontractor to commence work until all similar insurance required of the subcontractor has been so obtained. B. Contractor shall furnish to the Risk Manager or designee two (2) copies of Certificates of Insurance, with applicable policy endorsements showing the following minimum coverage by an insurance company(s) acceptable to the Risk Manager or designee. The City must be listed as an additional insured for the General Liability policy and Business Auto Liability policy, and a waiver of subrogation is required on all applicable policies. TYPE OF INSURANCE MINIMUM INSURANCE COVERAGE 30-Day Notice of Cancellation required on all Bodily injury and Property Damage certificates or by policy endorsement(s) Per Occurrence/aggregate COMMERCIAL GENERAL LIABILITY $1,000,000 Per Occurrence 1. Broad Form $2,000,000 Aggregate 2. Premises—Operations 3. Products/Completed Operations Hazard 4. Contractual Liability 5. Broad Form Property Damage 6. Independent Contractors 7. Personal and Advertising Injury 8. Professional Liability(if applicable) 9. Underground Hazard (if applicable) 10. Environmental (if applicable) BUSINESS AUTOMOBILE LIABILITY $1,000,000 Combined Single Limit 1. Owned 2. Hired&Non-owned 3. Rented &Leased WORKERS' COMPENSATION Which Complies With The Texas Workers' (for paid employees) Compensation Act And Paragraph II Of This Exhibit. EMPLOYER'S LIABILITY $500,000/$500,000/$500,000 PROPERTY INSURANCE Contractor shall be responsible for insuring all owned, rented,or leased personal property for all perils. C. In the event of accidents of any kind related to this project, Contractor shall furnish the Risk Manager with copies of all reports of such accidents within ten (10)days of the accident. Page 1 of 3 Exhibit 3 H. ADDITIONAL REQUIREMENTS A. Contractor must obtain workers' compensation coverage through a licensed insurance company in accordance with Texas law.The contract for coverage must be written on a policy and endorsements approved by the Texas Department of Insurance. The coverage provided must be in amounts sufficient to assure that all workers'compensation obligations incurred will be promptly met. An"All States endorsement shall be included for Companies not domiciled in Texas. B. Contractor shall obtain and maintain in full force and effect for the duration of this Contract,and any extension hereof,at Contractor's sole expense,insurance coverage written on an occurrence basis,by companies authorized and admitted to do business in the State of Texas and with an A.M.Best's rating of no less than A-VII. C. Contractor shall be required to submit replacement certificate of insurance to City at the address provided below within 10 days of the requested change. Contractor shall pay any costs incurred resulting from said changes. All notices under this Article shall be given to City at the following address: City of Corpus Christi Attn: Risk Management P.O.Box 9277 Corpus Christi,TX 78469-9277 D. Contractor agrees that with respect to the above required insurance,all insurance policies are to contain or be endorsed to contain the following required provisions: • List the City and its officers,officials,employees,volunteers,and elected representatives as additional insured by endorsement, or comparable policy language, as respects to operations, completed operations and activities of,or on behalf of,the named insured performed under contract with the City. • The "other insurance" clause shall not apply to the City of Corpus Christi where the City is an additional insured shown on the policy; • Workers'compensation and employers'liability policies will provide a waiver of subrogation in favor of the City;and • Provide thirty (30) calendar days advance written notice directly to City of any suspension, cancellation, non-renewal or material change in coverage, and not less than ten (10)calendar days advance written notice for nonpayment of premium. E. City shall have the option to suspend Contractor's performance should there be a lapse in coverage at any time during this contract.Failure to provide and to maintain the required insurance shall constitute a material breach of this contract. F. In addition to any other remedies the City may have upon Contractor's failure to provide and maintain any insurance or policy endorsements to the extent and within the time herein required,the City shall have the right to order Contractor to stop work hereunder, and/or withhold any payment(s) which become due to Contractor hereunder until Contractor demonstrates compliance with the requirements hereof. Page 2 of 3 Exhibit 3 G. Nothing herein contained shall be construed as limiting in any way the extent to which Contractor may be held responsible for payments of damages to persons or property resulting from Contractor's or its subcontractor's performance of the work covered under this agreement. H. It is agreed that Contractor's insurance shall be deemed primary and non-contributory with respect to any insurance or self insurance carried by the City of Corpus Christi for liability arising out of operations and completed operations and activities under this agreement. [. It is understood and agreed that the insurance required is in addition to and separate from any other obligation contained in this agreement. Page 3 of 3 w= EXHIBIT 8 City of CITY OF CORPUS CHRISTI Corpus Christi DISCLOSURE OF INTEREST Corpus Christi Code § 2-349, as amended, requires all persons or firms seeking to do business with the City to provide the following information. Every question must be answered. If the question is not applicable, answer with "NA". See next page for Filing Requirements, Certification and Definitions. COMPANY NAME: STREET ADDRESS: P.O. BOX: CITY: STATE: ZIP: FIRM IS: 1. Corporation ❑ 2. Partnership ❑ 3. Sole Owner ❑ 4. Association ❑ 5. Other ❑ If additional space is necessary, please use the reverse side of this page or attach separate sheet. 1. State the names of each "employee" of the City of Corpus Christi having an "ownership interest" constituting 3% or more of the ownership in the above named "firm." Name Job Title and City Department(if known) 2. State the names of each `official" of the City of Corpus Christi having an "ownership interest" constituting 3% or more of the ownership in the above named "firm." Name Title 3. State the names of each "board member" of the City of Corpus Christi having an "ownership interest" constituting 3% or more of the ownership in the above named "firm." Name Board, Commission or Committee 4. State the names of each employee or officer of a "consultant" for the City of Corpus Christi who worked on any matter related to the subject of this contract and has an `ownership interest" constituting 3% or more of the ownership in the above named "firm." Name Consultant FILING REQUIREMENTS If a person who requests official action on a matter knows that the requested action will confer an economic benefit on any City official or employee that is distinguishable from the effect that the action will have on members of the public in general or a substantial segment thereof, you shall disclose that fact in a signed writing to the City official, employee or body that has been requested to act in the matter, unless the interest of the City official or employee in the matter is apparent. The disclosure shall also be made in a signed writing filed with the City Secretary. [Ethics Ordinance Section 2-349 (d)]. CERTIFICATION I certify that all information provided is true and correct as of the date of this statement, that I have not knowingly withheld disclosure of any information requested, and that supplemental statements will be promptly submitted to the City of Corpus Christi, Texas, as changes occur. Certifying Person: Title: Signature of Date: Certifying Person: DEFINITIONS a. "Board member." A member of any board, commission, or committee of the city, including the board of any corporation created by the city. b. "Economic benefit". An action that is likely to affect an economic interest if it is likely to have an effect on that interest that is distinguishable from its effect on members of the public in general or a substantial segment thereof. c. "Employee." Any person employed by the city, whether under civil service or not, including part- time employees and employees of any corporation created by the city. d. "Firm." Any entity operated for economic gain, whether professional, industrial or commercial, and whether established to produce or deal with a product or service, including but not limited to, entities operated in the form of sole proprietorship, as self-employed person, partnership, corporation, joint stock company, joint venture, receivership or trust, and entities which for purposes of taxation are treated as non-profit organizations. e. "Official." The Mayor, members of the City Council, City Manager, Deputy City Manager, Assistant City Managers, Department and Division Heads, and Municipal Court Judges of the City of Corpus Christi, Texas. f. "Ownership Interest." Legal or equitable interest, whether actually or constructively held, in a firm, including when such interest is held through an agent, trust, estate, or holding entity. "Constructively held" refers to holdings or control established through voting trusts, proxies, or special terms of venture or partnership agreements. g. "Consultant." Any person or firm, such as engineers and architects, hired by the City of Corpus Christi for the purpose of professional consultation and recommendation.