Section 500 PDF

Section 500
Table of Contents
Contents
501 CONCRETE PAVEMENTS ............................................................................................................ 501-1

501.1 SCOPE ..................................................................................................................................... 501-1
501.2 EARTHWORKS ........................................................................................................................... 501-1
501.3 MATERIALS ............................................................................................................................... 501-1
501.3.1 Portland Cement and Fly ash ......................................................................................... 501-1
501.3.2 Aggregates ..................................................................................................................... 501-1
501.3.3 Admixtures...................................................................................................................... 501-2
501.4 WATER ..................................................................................................................................... 501-3
501.5 CONCRETE ............................................................................................................................... 501-3
501.5.1 Proportions: .................................................................................................................... 501-3
501.5.2 Trial Batches................................................................................................................... 501-4
501.6 REINFORCEMENT, TIE BARS AND DOWELS ................................................................................. 501-5
501.7 JOINT FILLERS .......................................................................................................................... 501-6
501.7.1 Joint Fillers...................................................................................................................... 501-6
501.8 CURING MATERIALS .................................................................................................................. 501-7
501.9 FIELD MATERIAL TESTS ............................................................................................................. 501-7
501.10 EQUIPMENT .............................................................................................................................. 501-7
501.10.1 General ........................................................................................................................... 501-7
501.10.2 Sub-Base Planer ............................................................................................................ 501-8
501.10.3 Batching Plant & Equipment........................................................................................... 501-8
501.10.4 Mixers ............................................................................................................................. 501-8
501.10.5 Transporting Vehicles..................................................................................................... 501-8
501.10.6 Slip-Form Paver.............................................................................................................. 501-8
501.10.7 Concrete Spreaders ....................................................................................................... 501-8
501.10.8 Forms.............................................................................................................................. 501-8
501.10.9 Finishing Equipment ....................................................................................................... 501-9
501.10.10 Transverse Groover.................................................................................................... 501-9
501.10.11 Curing Membrane Spray Equipment .......................................................................... 501-9
501.10.12 Rain Protection ........................................................................................................... 501-9
501.10.13 Concrete Saws ......................................................................................................... 501-10
501.10.14 Miscellaneous Equipment......................................................................................... 501-10
501.11 CONSTRUCTION REQUIREMENTS ............................................................................................. 501-10
501.11.1 Preparation of Sub-Base .............................................................................................. 501-10
501.11.2 Conditioning of Sub-Base or Base Course .................................................................. 501-10
501.11.3 Slip-Form Paving .......................................................................................................... 501-10
501.11.4 Fixed Form Paving ....................................................................................................... 501-11
501.11.5 Construction of Irregular Areas .................................................................................... 501-11
501.11.6 Handling, Measuring and Batching Materials for Concrete.......................................... 501-11
501.11.7 Weather and Lighting Conditions ................................................................................. 501-12
501.11.8 Mixing Concrete............................................................................................................ 501-12
501.11.9 Placing Steel................................................................................................................. 501-13
501.11.10 Placing Concrete ...................................................................................................... 501-15
501.11.11 Joints ........................................................................................................................ 501-16
501.12 FINAL STRIKE-OFF, CONSOLIDATION AND FINISHING ................................................................. 501-23
501.12.1 Consolidation and Strike-off ......................................................................................... 501-23
501.12.2 Floating ......................................................................................................................... 501-23
501.12.3 Checking and Surface Correction ................................................................................ 501-23
501.12.4 Final Finishing............................................................................................................... 501-24
501.12.5 Edging at Forms and Joints.......................................................................................... 501-24
501.13 CURING .................................................................................................................................. 501-24
501.14 SEALING JOINTS ..................................................................................................................... 501-26
501.15 RIDING QUALITY...................................................................................................................... 501-27
501.16 OPENING TO TRAFFIC.............................................................................................................. 501-27
501.17 CONFORMANCE CRITERIA........................................................................................................ 501-27
501.17.1 Compressive Strength of Concrete .............................................................................. 501-27
501.17.2 Compaction and Tolerances ........................................................................................ 501-28
Standard Specification for AACRA Road & Bridge Works
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Section 500
Table of Contents
501.17.3 Non-conforming Work - Removal of Non-conforming Concrete................................... 501-29

501.17.4 Replacement of Concrete Slab Pavement ................................................................... 501-30
501.18 MEASUREMENT AND PAYMENTS ................................................................................................ 501-30

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SECTION 500 RIGID PAVEMENT
DIVISION 501 CONCRETE PAVEMENT
501 CONCRETE PAVEMENTS

501.1 Scope
This Division covers the specification of materials for, and the construction of, un-reinforced and reinforced
concrete pavement slabs cast monolithically on a prepared sub-base or base course, in conformity with the
lines, grades, thickness, and typical cross sections shown on the plans or established by the Engineer.
501.2 Earthworks
Carry out earthworks and preparation of surfaces as specified in Section 200 of this Specification.
Unless otherwise permitted, excavated material shall not be deposited on existing grassed areas.
501.3 Materials
501.3.1 Portland Cement and Fly ash
Portland cement and fly ash shall follow requirements of Division 801 of this specification. The Contractor
shall furnish documentary evidence of the quality and source of the cement and the fly ash to the Engineer
upon request at any stage of the work.
501.3.2 Aggregates
(a) General
The maximum soluble sulphate salt content of aggregates, expressed as percentage SO4 by mass, shall not
exceed 0.1 %.
Aggregates containing more than the maximum permissible amount of sulphates or with visible encrustation
of salts, shall be washed and drained before being used in concrete. The Engineer may direct washing or re
washing of the aggregates until he is satisfied that harmful quantities of salts are not present.
(b) Fine Aggregate:
Fine aggregate can be natural sand, manufactured sand, or a combination of natural and manufactured
sand, meeting the following requirements:
(i) Natural Sand - shall be composed of clean, hard, durable, uncoated grains, free from
lumps or flaky particles, organic matter, loam, or other deleterious substances.
(ii) Manufactured sand- shall be made from stone meeting all the quality requirements for
coarse aggregates.
(iii) Mixtures of Natural Sand and Manufactured sand - when the blend is approved the two
materials shall be stored and batched separately.
(iv) Organic Impurities - all fine aggregate shall be free from injurious amounts of organic
impurities. Fine aggregates subjected to the colorimetric test of AACRA Test A-6 (ref:
Division 802 and AACRA Soils and Materials Manual; Section 6.6) for organic impurities
and producing a colour darker than 3 shall not be used unless the following criteria is met: A
fine aggregate with the colour darker than 3 may be used provided that the relative strength
at 7 and 28 days is not less than 95% when tested in accordance with AACRA Test A-7 (ref:
Division 802 and AACRA Soils and Materials Manual; Section 6.7).
(v) Soundness - When the fine aggregate is subjected to five alternations of the sodium sulphate
soundness test AACRA Test A-4 (ref: Division 802 and AACRA Soils and Materials
Manual; Section 6.4) the weight loss shall not exceed 10% by weight.
(vi) Gradation of Fine Aggregate- for all classes of Portland cement concrete and concrete
pavement shall conform to the following gradation:
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Table 501.1
Gradation of Fine Aggregate AACRA Test A-5

ISO Percentage by
Standard Sieve weight passing
Designation in (mm)
9.50 100
4.75 96-100
2.36 75-100
1.18 55-98
0.06 25-75
0.03 8-30
0.015 0-9
0.075 0-3
(c) Coarse Aggregate:
Coarse aggregate for Portland cement concrete shall conform to the following requirements
(i) Coarse aggregate shall be clean, tough, durable gravel, crushed gravel, hard durable
rock, metallurgical furnace slag or gravel. It shall be free from soft, thin, elongated or
laminated pieces. If necessary, coarse aggregate shall be washed to produce a clean
aggregate so the following properties are achieved:
- Los Angeles abrasion AACRA Test A-3 (ref: Division 802 and AACRA Soils and
Materials Manual; Section 6.3) shall not exceed 40%.
- Sodium sulphate soundness test AACRA Test A-4 (ref: Division 802 and AACRA Soils
and Materials Manual; Section 6.4), the weight loss shall not exceed 15%.
- Adherent coating in accordance with ASTM D5711-03 shall not exceed 1.0%.
- Gradation of Coarse Aggregate shall be No. 56, No. 57 or No. 67. Aggregate No. 78
may be used in thin sections and prestress panels when approved by the Engineer. The
various gradings of Coarse Aggregate are as follows:
Table 501.2
Gradation of Fine Aggregate AACRA Test A-5

ISO Percentage by
Standard Sieve weight passing
Designation in (mm)
No.56 No.57 No.67 No.78
37.50 100 100 - -
25.00 90-100 95-100 100 -
19.00 40-85 - 90-100 100
12.50 10-40 25-60 - 90-100
9.50 0-15 - 20-55 40-75
4.75 0-5 0-10 0-10 5-25
2.36 - 0 -5 0 -5 0 -10
1.18 - - - 0-5
501.3.3 Admixtures
(a) Accelerating, Retarding and Water-Reducing Chemical Admixtures shall comply with AACRA
Test C21 (ref: Division 802 and AACRA Soils and Materials Manual; Section 8.21).
When a retarding admixture is required it shall be Type D, a water -reducing -retarding admixture as
designated in the above specification.
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Care should be taken not to combine chemical admixtures together in to a mixture unless they are
compatible.
Chloride accelerators shall not be used. Admixtures shall not contain calcium chloride, calcium
formate, or triethanolamine. An air-entraining agent can be included in the mix if approved by the
Engineer.
The Contractor shall submit details of the nominated mix and the Contractor shall nominate the
proprietary source, type and name for each admixture to be used. Upon request at any stage of the
work, the Contractor shall furnish documentary evidence of the quality and chemical compatibility to
the Engineer.
(b) Air-Entraining Admixtures.
If the Contractor requests approval to use an air-entraining admixture, evidence based test results (a
Certified Affidavit and test result evidence based on tests made in an AACRA approved laboratory)
shall be submitted to the Engineer to show that the material complies with AACRA Test C-22 (ref:
Division 802 and AACRA Soils and Materials Manual; Section 8.22). The Contractor shall only use
an air-entraining admixture if required and allowed by the Engineer.
(c) Cement
Cement shall be ordinary Portland cement complying with the requirements of AACRA Test C-23
(ref: Division 802 and AACRA Soils and Materials Manual; Section 8.23) or blended hydraulic
cement complying with the requirements of AACRA Test C-24 (ref: Division 802 and AACRA Soils
and Materials Manual; Section 8.24).
501.4 Water
Water used in mixing or curing of Portland cement concrete shall be reasonably free from salt, oil, acid,
alkali, organic matter, sewage or other substances injurious to the finished product. If required by the
Engineer test for water quality shall be made in accordance with AACRA Test C-8 (ref: Division 802 and
AACRA Soils and Materials Manual; Section 8.8). Water from a public water supply may be accepted without
being tested. Water from other sources shall not be used until tested and approved.
501.5 Concrete
501.5.1 Proportions:
(a) Concrete shall be composed of Portland cement, fine aggregate, coarse aggregate, fly ash,
granulated blast furnace slag, water, and chemical admixtures. The Contractor shall submit, for
approval by the Engineer, a mix design that will produce concrete of the specified strength and
workability.
(b) Mix design, manufacture, placing, compaction and finishing of concrete shall be the responsibility of
the Contractor.
(c) Concrete Strength - the mix will be designed to produce concrete with a minimum job average
flexural strength of 3.5 MPa at 28 days. The concrete shall contain the amount of cement as directed
by the Engineer, but in no case shall the concrete contain less than 365 kg cement per cubic metre
(m3).
(d) Water cement ratio, including moisture on the aggregates, shall not be more than 0.53. This shall be
maintained by use of chemical admixtures and or additional cement, if necessary.
(e) Workability of Concrete -concrete shall be uniformly plastic and workable. The consistency of the
concrete shall be determined by the slump test in accordance with AACRA Test C-10 (ref: Division
802 and AACRA Soils and Materials Manual; Section 8.10). The slump shall be in the range of
25 mm to 60 mm or 37.5 mm +or- 25 mm for slip-form paving and 100 mm maximum for hand or
other means of paving.
(f) The percentage of entrained air voids in the mix shall be from 3 to 6 percent. Concrete shall have
properties within the limits prescribed in Table 501-3.
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Table 501.3
Concrete Properties
Property Requirement
Characteristic flexural strength at 90 days 4.0MPa
Compressive Strength 36 MPa at twenty eight (28) days
Air Content 3 - 6%
Slump on delivery – mechanically placed 30 -40 mm
Slump on delivery – hand placed 55 - 65 mm
Drying Shrinkage at 56 days (max.) 450 micro-strain (after 3 weeks air drying)
Water /cement Ratio (max.) 0.53
(g) Where concrete is to be cast between fixed forms the nominal maximum size of the mix shall be 40 mm.
(h) Where the Engineer has approved of the placement of concrete by means of a self propelled
slip-form-paving machine, the mix design, slump and workability shall suit the machine proposed for
use.
501.5.2 Trial Batches

(a) At least 40 days prior to the beginning of concrete placement, adequate quantities of proposed
materials and a proposed mix design with data shall be furnished by the Contractor to the Engineer
to allow preparation of trial mixes and for his subsequent approval.
(b) The concrete mix will first be batched with the proportioning as proposed by the Contractor. If the
proposed design does not give adequate strength and workability and meet all the physical
requirements, it will be redesigned to the satisfaction of the Contractor and the Engineer.
(c) Concrete from the trial batches will be moulded, cured, and tested in accordance with AACRA
Test C-25 (ref: Division 802 and AACRA Soils and Materials Manual; Section 8.25) to determine the
flexural strength of the concrete AT 14 days. From the trial batch tests, an approved mix design will
be established and furnished to the Contractor.
(d) A furnished mix design by the Engineer will not relieve the Contractor from producing quality
concrete and will not limit further negotiating of changes in the mix design if necessary. The
Contractor shall not make any changes to the approved mix, its method of production or source of
supply of constituents without the prior written approval of the Engineer.
(e) Where changes to an approved mix are proposed, the Contractor shall provide details of the
nominated mix and materials in accordance with this Clause. If the variations to the quantities of the
constituents in the approved mix are less than 10 kg for Portland cement and fly ash and 5 per cent
by mass for each other constituent, except admixtures, per yielded cubic metre of concrete the
Engineer may approve the changes without new trials being carried out.
(f) Details Required for each Nominated Mix:
Details required for each Nominated Mix of the concrete mix designed by the Contractor shall be
submitted for approval with the following itemised Information:
(i) Material Constituents:
Cement - brand and source.
Fly ash - powerhouse source.
Admixtures - proprietary source, type, name and dosage recommended by manufacturer.
Aggregates - source, geological type, moisture condition on which mix design is based
(oven dry, saturated surface dry or nominated moisture content).
Relevant test results for all constituents.
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Test results for soluble salt content.

(ii) Mix Design:
Quantity of each constituent in a cubic metre of concrete.
Nominated particle size distribution for fine, coarse and combined particle size
aggregates.
(iii) Test Results for each trial batch including:
Cement content and fly ash content per yielded cubic metre of concrete;
Water cement ratio;
Compressive strength at age 7 days; Compressive strength at age 28 days;
Flexural strength at age 7 days;
Flexural strength at age 28 days;
Drying shrinkage after 21 days air drying; and
Air content.
501.6 Reinforcement, Tie Bars and Dowels

(a) Reinforcing steel for concrete pavements shall be of the type, length, size, spacing, and quantity
shown on the drawings and shall meet the requirements specified in Division 604 of this
specification reinforcing steel and hereinafter specified. All steel shall be clean and free from mill
scale, loose rust or oil.
Tie bars and reinforcing steel shall be deformed steel bars conforming to AACRA Test M-9 (ref: Division
802 and AACRA Soils and Materials Manual; Section 9.9) for grade 40 or 60.
Dowel bars shall be plain, round bars conforming to AACRA Test M-10 (ref: Division 802 and
AACRA Soils and Materials Manual; Section 9.10) type A or B. They shall be free from burring or
other deformation restricting slippage in concrete.
Dowel bars shall be coated with an approved material to break the bond between the steel and
concrete.
Wire and wire mesh shall conform to the requirements specified in Division 801 of this specification
(b) Place dowels and tie bars across joints where indicated, correctly aligned, and securely held parallel
to the surface of the finished pavement, such that after placement they remain in their specified
location. The spacing and vertical location of dowels and tie bars shall be as detailed except where
the planned spacing cannot be maintained because of form length or interference with form braces.
In such cases, closer spacing with additional dowels or tie bars shall be used.
(c) All reinforcement, dowels and tie bars shall be clean and free of oil, grease, loose rust and other
foreign material when the concrete is placed. Paint free portions of dowels, including ends, with two
coats of bituminous emulsion. The unpainted portions of dowels shall be installed in the initially
placed concrete slab.
(d) Dowels installed in contraction joints during paving operations shall be held securely in position by
means of rigid metal frame cradles to prevent them from rising, sliding out or becoming distorted
under paving operations.
(e) Dowels and tie bars in fixed form paving shall be placed by the bonded-in-place method. Installation
by removing and replacing dowels and tie bars in preformed holes, including their withdrawal to
assist in form stripping, will not be permitted.

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501.7 Joint Fillers

501.7.1 Joint Fillers
Filler for preformed or sawed joints shall be the type specified and shall be placed in accordance with joint
details as shown in the plans. All materials shall be used in accordance with the manufacturer's
recommendations regarding preparation of joint walls, application temperatures, and necessary equipment
to ensure proper material placement.
Preformed expansion joint fillers shall conform to the requirements of AACRA Tests M-11and M-12 (ref:
Division 802 and AACRA Soils and Materials Manual; Section 9.11 and 9.12) for concrete paving. All
preformed joint fillers shall have a thickness equal to the width of the joint required and shall be furnished in
lengths equal to the width of the slabs in which they are to be installed.
Sawed joint fillers (transverse and longitudinal), unless otherwise specified, shall be filled with hot poured
material conforming to the requirements of ASTM D 6690.
(a) Preformed Elastomeric Joint Sealer:

(i) Preformed elastomeric joint sealers shall comply with the requirements of ASTM D2628.
The sealer shall have vertical sidewalls of adequate length to retain the sealer in the joint.
The overall depth of the sealer shall not exceed 50 mm when the sealer is compressed
laterally to 50% deflection. The sealers shall be marked durably at 300 mm intervals ±
2 mm on the top surface at the time of manufacture.
(ii) The sealer shall have vertical sidewalls of adequate length to retain the sealer in the joint.
The overall depth of the sealer shall not exceed 50 mm when the sealer is compressed
laterally to 50% deflection. The sealers shall be marked durably at 300 mm intervals ±
2 mm on the top surface at the time of manufacture.
(iii) The preformed elastomeric joint sealer shall comply with the force-deflection
requirements specified in Table 501-4.
Table 501.4
Force Deflection Requirement for preformed elastomeric joint sealer
Deflection Based on Nominal Width (%) Required Force
(a) 10 mm and smaller joint sealer:
20 350 N/m min
50 2,100 N/m max
(b) 12 mm and larger joint sealer:
20 525 N/m min
50 2,100 N/m max
(iv) The specimens used for determining the original force-deflection relationship will then be
heat aged in an oven for 70 hours at 100°C at 50% deflection. After heat ageing the
specimens again will be subjected to force-deflection testing and shall comply with the
additional requirements specified in Table 501-5.
(v) The lubricant-adhesive used with preformed elastomeric sealers shall be a compound of
the same base polymer as the sealer, blended with suitable volatile solvents. It shall have
the following additional physical properties:
Average net mass per litre: 7.84% ± 5%.
Solids content % by mass: 25 ± 3.0 (ASTM D1084)
Film strength: tensile strength – 15 MPa min.
elongation 75% min. before breaking.
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The viscosity of the lubricant-adhesive shall be such that it will perform suitably with the
installation equipment.
Lubricant adhesive containers shall show date of manufacture. Adhesive shall be used
within nine months of manufacture.
Table 501.5
Additional deflection Requirement for preformed elastomeric joint sealer

Deflection Based on Nominal Width (%) Required Force
(a) 10 mm and smaller sealer:
20 175 N/m min
50 2,100 N/m max
(b) 12 mm and larger sealer:
20 260 N/m min
50 2,00 N/m max
(b) Preformed Self-Expanding Cork Joint Sealer - shall comply with the requirements of AACRA Test M-11
(ref: Division 802 and AACRA Soils and Materials Manual; Section 9.11).
(c) Silicone Sealant - shall meet the detailed requirements as stated in the special provisions or as
provided by the manufacturer. The test methods shall conform to ASTM-D-792, ASTM D 2240, and
ASTM C 794 & ASTM C793-7. The silicone joint sealant shall be grey in colour and shall be stored
and installed in accordance with the manufacturer’s written instructions.
501.8 Curing Materials

Curing materials shall conform to the following requirements as specified:
(a) Burlap cloth made from Jute or Kenaf. This material shall conform to AACRA Test M-13 (ref: Division
802 and AACRA Soils and Materials Manual; Section 9.13) for Class 3 (285 g) or Class 4 (343 g).
(b) Sheet Material for Curing Concrete. Waterproof paper, polyethylene film, and white burlap.
polyethylene sheet shall conform to AACRA Test M-14 (ref: Division 802 and AACRA Soils and
Materials Manual; Section 9.14).
(c) Liquid membrane forming compounds shall conform to AACRA Test M-15 (ref: Division 802 and
AACRA Soils and Materials Manual; Section 9.15).
501.9 Field Material Tests

The Contractor shall furnish the concrete materials necessary for making job control test specimens. The
Contractor also shall furnish the labour to assist the Engineer in obtaining samples, making of specimens,
and other testing of materials as required in the quality control process.
501.10 Equipment
501.10.1 General
All plant, equipment and tools necessary for the Work shall be on site sufficiently ahead of the start of
construction to allow thorough inspection and approval by the Engineer. The plant and equipment shall be
maintained in a satisfactory working condition at all times until completion of the work.
The Contractor shall furnish the following equipment specified below.

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501.10.2 Sub-Base Planer

The Sub-Base planer shall have a cutting edge, or edges, set to conform accurately to the specified sub-
base elevations. The planer shall be fully energised, self-propelled, and designed for the specific purpose of
planing the sub-base to the true grade and cross section.
Scratch planers with spikes or teeth will not be permitted.
501.10.3 Batching Plant & Equipment

The batching plant shall be fully equipped with bins, hoppers, scales, meters and dispensers.
501.10.4 Mixers
(a) Concrete shall be mixed in central batch plants, unless otherwise authorised by the Engineer.
(b) Each mixer shall have attached to it, in a prominent place, a manufacturer's plate showing the
capacity of the drum in terms of volume of mixed concrete and the recommended speed of rotation
of the mixing drum or blades.
(c) Mixers shall be examined daily for accumulation of hard concrete or mortar, and wear of blades.
The blades shall be repaired or replaced when they are worn down 25 mm or more.
501.10.5 Transporting Vehicles

Approved means for transporting concrete are non-agitator trucks, truck mixers, truck agitators and dry
batch trucks
501.10.6 Slip-Form Paver

(a) The Slip-form paving machine shall be self propelled and shall be so designed and operated as to
place the plastic concrete as it leaves the machine in a uniform layer over the width of the slab being
placed.
(b) When the mechanical paver rides on the edge of previously constructed concrete, precautions shall
be taken to prevent damage to the surface and edge of the existing concrete.
(c) The machine shall be equipped with the following:
(i) Electronic controls to control line and grade from either or both sides of the machine;
(ii) Vibrators to vibrate the concrete for the full width and depth of the strip of pavement being
placed; and
(iii) A positive interlock system to stop all vibration and tamping elements when the forward
motion of the machine is interrupted.
501.10.7 Concrete Spreaders

The spreaders shall be a self propelled machine, equipped with a power-driven device for spreading the
concrete uniformly between the forms without segregation, and provided with an adjustable blade or other
approved means for striking off the concrete to the required height and crown. The spreaders shall be
equipped with effective cleaning devices to ensure proper contact at all times between the wheels and the
contact surface.
501.10.8 Forms
Forms shall be of steel or seasoned dressed timber planks fitted with steel angle sections top and bottom,
constructed to finish flush with the face of the form and covering the full width of the top and bottom of the
forms. Forms shall conform to the following:
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(a) Forms shall be free of warps, bends or kinks;

(b) The forms shall be staked into position with not less than three steel stakes, each not more than 1.5 m
apart, so that the top of the form does not deviate by more than 5 mm from the required level;
(c) Lock joints between form sections shall be free from play or movement in any direction;
(d) Flexible or curved forms of proper radius shall be used for curves of 45 m radius or less;
(e) The top surface of the form shall not vary from a straight edge by more than 5 mm in 3 m. The face
of the form shall not vary more than 10 mm from a plane surface and, when erected, not more than
3 mm from vertical;
(f) Depth equal to edge of concrete pavement thickness without horizontal joint and a base width no
less than 200 mm;
(g) 3 m minimum length;
(h) Stabilising devices to withstand paving operations;
(i) Cleaned and oiled before each use;
(j) Repaired forms shall not be used until inspected and approved by the Engineer;
(k) Built-up forms shall not be used except where the total area of pavement of any specified thickness
on the project is less than 2,500 m2;
(l) Forms shall be in one piece for the concrete pavement thickness specified. Forming strips for the
key way of construction joints, where required, shall be of steel and accurately located on the form
face and securely fastened flush against the face of the forms so that the centre of the key is at the
mid-depth of the concrete slab;
(m) Forms shall remain in place at least 12 hours after the concrete has been placed. When conditions
on the work are such that the early strength gain of the concrete is delayed, the forms shall remain
in place for a longer period as directed but not longer than 48 hours;
501.10.9 Finishing Equipment

The Contractor shall furnish the following finishing equipment:
(a) Finishing Machine - equipped with at least 2 oscillating type transverse screeds;
(b) Vibrators - for full width vibration of concrete paving slabs may be either the surface pan type or the
internal type with either immersed tube or multiple spuds. They may be attached to the spreader or
the finishing machine or mounted on a separate carriage.
(c) Tube Finisher - a self-propelled machine of the type and design that will produce a satisfactory finish
to the concrete as determined by the Engineer; and
(d) Hand tools - appropriate straight edge tools to complete the finishing of the slab.
501.10.10 Transverse Groover

A mechanical device that is essentially a metal comb capable of spanning the width of the pavement shall be
available to produce the transverse grooves.
501.10.11 Curing Membrane Spray Equipment

A mechanical device capable of spanning the width of the pavement shall be provided to uniformly apply the
white pigmented curing compound.
501.10.12 Rain Protection

A mechanical device with an appropriate supply of rolled polyethylene sheet, capable of spanning the
pavement shall be available at all times along with the other paving equipment.

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501.10.13 Concrete Saws

The Contractor shall provide sawing equipment adequate in number of units and power to complete the
sawing to the required dimensions.
501.10.14 Miscellaneous Equipment

The Contractor shall provide other equipment and tools, such as kettles for placing hot poured elastic filler,
equipment to place silicone sealant, etc of approved design, necessary for the satisfactory completion of the
job.
501.11 Construction Requirements

501.11.1 Preparation of Sub-Base
The sub-base shall be brought to reasonably close conformity to the lines, grades and typical sections as
shown on the plans or as designated by the Engineer.
The sub-base shall include an area 900 mm wide extending beyond the edges of the base course or
pavement unless shown otherwise on the plans.
When curb and gutter is constructed contiguous with the pavement the sub-base shall include an area
600 mm wide extending beyond the back of the curb and gutter.
The sub-base shall be completed for at least 750 m in advance of concrete placing operations when this
distance is available.
501.11.2 Conditioning of Sub-Base or Base Course
(a) Compaction:
The entire sub-base or base layer shall be thoroughly compacted. Any portion of the sub-base that
is not accessible to a roller shall be compacted with hand tampers to obtain the density requirements
for the material.
(b) Protection:
Before placing any surfacing material on any section, ditches and drains along that section shall be
completed to drain the sub-grade effectively. Until the sub-base or base has been checked and
approved, no material shall be deposited thereon.
501.11.3 Slip-Form Paving

(a) Where practicable, a slip form-paving machine shall be used. No wheeled equipment will be allowed
in the paving train that disturbs the track lane for other equipment or otherwise does not perform
satisfactorily.
(b) No vehicular traffic or mixing equipment will be allowed on the completed grade without the prior
permission of the Engineer.
(c) Slump of the Concrete will not exceed 9.50 mm from any typical cross-section.
Slump at longitudinal construction joints shall not exceed 6.30 mm from any typical cross-section.
(d) The paving machine shall be operated with a continuous forward movement and the Contractor shall
co-ordinate mixing, delivering, and spreading concrete to provide uniform progress without stopping
and starting the paving machine. The paving machine shall all necessary tractive force. No external
force shall be applied to the machine.
(e) If for any reason it is necessary to stop the forward movement of the machine, the vibratory and
tamping elements shall also be stopped immediately.

Concrete Pavement
Final November 2004
Page 501-10
(f) Areas inaccessible to slip form-paving equipment shall be paved in accordance with the provisions
for fixed form paving.
501.11.4 Fixed Form Paving

(a) Base Support: The sub-base under the forms shall be hard and true to grade so that the form,
when set, will be firmly in contact for its whole length at the specified grade.
(b) Form Setting: After the forms have been set to correct grade, the sub-base shall be thoroughly
tamped, mechanically, or by hand, at both the inside and outside edges of the
base of the forms.
(c) No settlement or springing of forms under the finishing machine will be permitted.
(d) The Contractor shall set and maintain sufficient forms and shall conduct his operations so that the
final minor corrections, compaction of sub-base, and checking and approval of forms shall be
completed at least 240 m in advance of the point of depositing concrete when this distance is
available.
501.11.5 Construction of Irregular Areas

In irregular areas or areas inaccessible to paving equipment, the Contractor shall construct the pavement
using side forms. Screed, compact, float, and surface finish the concrete, as follows:
(a) Thoroughly and uniformly vibrate and compact the concrete during placement without segregating
the material;
(b) With templates or screeds, strike-off the concrete to shape it to the required cross-section between
the forms. Carrying a slight excess of concrete in front of the leading edge of the template or screed;
(c) Float the surface to the required grade and cross-section; and
(d) Finish the surface according to Clause 501.12 of this specification.
501.11.6 Handling, Measuring and Batching Materials for Concrete

(a) Stockpiling of aggregates, the location and preparation of the sites, the minimum size of pile and the
method adopted to prevent coning or other segregation of component sizes shall be subject to the
approval of the Engineer.
(b) Stockpiles shall be built up in layers of not more than 900 mm in thickness. Each layer shall be
completely in place before beginning the next and shall not be allowed to cone down over the next
lower layer. Under no circumstances will coning of stockpiles be permitted.
(c) Aggregates from different sources shall not be stockpiled together unless approved by the Engineer.
(d) The fine aggregate and coarse aggregate shall be separately weighed into the hopper in the
respective amounts set by the Engineer in the job mix approval.
(e) When mixing of the concrete is to be done at the job site, materials shall be transported from the
batching plant to the mixer in vehicles appropriate for this job. In the dry batch process, bulk cement
shall be transported to the roadside paver in watertight compartments carrying the full amount of
cement required for the batch unless otherwise permitted when it shall be between the fine and
coarse aggregates.
(f) Water for the mix may be measured by volume or by weight. The accuracy of the water-measuring
equipment shall be within a range of error of not over 1%, and shall be so arranged that the
measurement will not be affected by variations of pressure in the water supply line and will be
accurate under all construction conditions encountered.
(g) Methods and equipment for adding air-entraining agent or other admixtures into the batch shall be
as recommended by the manufacturer.

Concrete Pavement
Final November 2004
Page 501-11
Hold Point 501.1
Process Held: Production of concrete for concrete paving.

Submission Details: At least 20 working days prior to commencement of concrete paving,
the Contractor shall submit details of the proposed methods of
handling, storing and batching materials for concrete, details of
proposed mixers and methods of agitation, mixing and transport.
Release of Hold Point: The Engineer will review the submitted details, prior to authorising the
release of the Hold Point.
501.11.7 Weather and Lighting Conditions

(a) No concrete shall be placed when the atmospheric temperature is below 2ºC or when the
temperature threatens to drop below -4ºC within 48 hours, except upon written permission of the
Engineer, and such permission will not be granted until satisfactory provisions have been made to
protect the work.
The Contractor will be responsible for the quality and strength of the concrete placed during cold
weather, and any concrete damaged shall be removed and replaced without additional
compensation.
(b) Concrete shall not be mixed when either the coarse or fine aggregate contains frozen particles. No
more concrete shall be mixed than can be placed, finished, and covered during daylight, unless an
artificial lighting system is approved by the Engineer.
501.11.8 Mixing Concrete

The concrete shall be mixed in a central-mix plant. If specifically approved by the Engineer, concrete for
small works may be mixed at the site of the work in truck mixers or in a roadside paver.
(a) Central mix plant.

The plant shall be of an approved size and type which will ensure a uniform distribution of the
materials throughout the mass and meet the following requirements or changes:
(i) Mixing time for mixers having a rated capacity greater than 1.5 m3 shall not be less than
90 seconds. Charging time in excess of 20 seconds shall be added to the 90 seconds
mixing time. The Engineer may approve an increase in mixing time may to produce a
homogeneous mass.
An overload up to 10% above the mixers nominal capacity may be permitted provided
concrete test data for strength, segregation, and uniform consistency is satisfactory and
no spillage of concrete occurs.
(ii) Mixed concrete from the central mixing plant shall be transported in truck mixers, truck
agitators, or non-agitating trucks. The time elapsing from the time water is added to the
mix until the concrete is deposited in place shall not exceed 30 minutes when the
concrete is hauled in non-agitating trucks, nor 60 minutes when hauled in truck mixers or
truck agitators.
(b) Truck Mixers:
The use of truck mixers shall be according to the manufacturer's specifications and guide lines, and
the approval of the Engineer.

Concrete Pavement
Final November 2004
Page 501-12
501.11.9 Placing Steel

(a) Fixing of Reinforcement:
Placing and fastening of all reinforcement in the work shall be approved by the Engineer before
concrete is placed and adequate time shall be allowed for inspections and any corrective work that
may be required.
(i) Notice for inspection shall not be less than four working hours before the intended time of
commencement of concrete placement or such time as determined by the Engineer.
(ii) Load transfers shown on the plans shall be provided at bridge ends for the two approach
slabs at each bridge end, for successive slabs adjacent to the approach slabs at each
bridge end and at other locations indicated on the plans.
(iii) The spacing of the joints on the successive slabs adjacent to the reinforced approach
slabs may be varied to compensate for any added distances to accommodate the
reinforced approach slabs.
(iv) The minimum width of any slab shall be 4.80 m. The maximum length shall be 7.50 m.
(v) Laps in longitudinal reinforcing bars shall be not less than 35 bar diameters or 450 mm
whichever is greater. At laps between sheets of welded steel reinforcement, the first
transverse bar of one sheet shall lie within the last complete mesh of the previous sheet.
(vi) Laps in transverse reinforcement shall be a minimum of 300 mm. Where longitudinal and
transverse laps coincide, no lap is required in the transverse bars within the lap of the
longitudinal reinforcement. These transverse bars shall be cropped or fabricated shorter
so that the requirements for cover are met.
(vii) If the reinforcement is positioned prior to concreting, it shall be fixed on approved metal
supports and retained in position at the required depth below the finished surface and
distance from the edge of the slab so as to ensure that the required cover is achieved.
(b) Jointed Reinforced Concrete Slabs
(i) In jointed reinforced concrete slabs, the reinforcement shall be so placed that after
compaction of the concrete, the cover below the finished surface of the slab is 110 + or –
20 mm.
(ii) The vertical cover between the longitudinal joint groove forming strip and any
reinforcement or tie bars shall be a minimum of 30 mm.
(iii) Unless otherwise described in the Contract, any transverse bars described in the
Contract or used for spacing or for the rigidity of the longitudinal reinforcement, shall be at
right angles to the longitudinal axis of the carriageway.
(c) Dowel Bars:
Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to
construction of the slab or mechanically inserted with vibration into the plastic concrete by a method,
which ensures full re-compaction of the concrete around the dowel bars.
Unless otherwise stipulated in the Contract, dowel bars shall be positioned at mid-depth of the slab
to within a tolerance of + or – 20 mm and equally about the intended line of the joint to within a
tolerance of + or – 25 mm. They shall be aligned parallel to the finished surface of the slab, to the
centreline of the carriageway and to each other, within the following tolerances:
(i) For bars supported on cradles prior to construction of the slab:
All bars in a joint shall be within 3 mm per 300 mm length of bar.
Two thirds of the bars shall be within 2 mm per 300 mm length of bar.
No bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm
length of bar in either the horizontal or vertical plane.

Concrete Pavement
Final November 2004
Page 501-13
(ii) For all bars, after construction of the slab:

Twice the tolerances for alignment as in Sub-Clause 501.11.9(c)(i) of this Clause.
Cradles supporting dowel bars shall not extend across the line of the joint.
Dowel bars, supported on cradles in assemblies, when subjected to a load of 100 N
applied at either end and in either the vertical or horizontal direction (upwards and
downwards and both directions horizontally) shall not deflect by more than the following
limits:
(i) Two thirds of the number of bars of any assembly tested shall not deflect by more
than 2 mm per 300 mm length of bar.
(ii) The remainder of the bars in that assembly shall not deflect by more than 3 mm
per 300 mm length of bar.
(iii) The assembly of dowel bars and supporting cradles, including the joint filler board in the
case of expansion joints, shall have the following degree of rigidity when fixed in position:
(iv) For expansion joints, the deflection of the top edge of the filler board shall be not greater
than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical face of the joint
filler board and distributed over a length of 600 mm by means of a bar or timber packing,
at mid depth and midway between individual fixings, or 300 mm from either end of any
length of filler board, if a continuous fixing is used. The residual deflection after removal
of the load shall be not more than 3 mm.
(v) The joint assembly fixings to the sub-base shall not fail under the 1.3 kN load applied for
testing the rigidity of the assembly but shall fail before the load reaches 2.6 kN.
(vi) The fixings for contraction joint assemblies shall not fail under a 1.3 kN load but shall fail
before the load reaches 2.6 kN when applied over a length of 600 mm by means of a bar
or timber packing placed as near to the level of the line of fixings as is practicable. Failure
of the fixing shall be deemed to be when there is displacement of the assemblies by more
than 3 mm under the test load. The displacement shall be measured at the nearest part
of the assembly to the centre of the bar or timber packing.
(vii) For expansion joints, a closely fitting plastic cap 100 mm long shall be placed over the
sleeved end of each dowel bar. An expansion space at least equal in length to the
thickness of the joint filler board shall be provided between the end of the cap and the
end of the dowel bar.
(d) Tie Bars:
Tie bars projecting across the longitudinal joint shall be protected from corrosion for 75 mm on each
side of the joint by a protective coating of bituminous paint to the approval of the Engineer. The
coating shall be dry when the tie bars are used.
Tie bars in longitudinal joints shall be made up into rigid assemblies with adequate supports and
fixings to remain firmly in position during the construction of the slab. Alternatively, tie bars at
longitudinal joints may be mechanically inserted into the plastic concrete from above by vibration
using a method which ensures re-compaction of the concrete around the tie bars.
Tie bars shall be positioned and remain within the middle third of the slab depth, approximately
parallel to the surface and approximately perpendicular to the line of the joint, with the centre of each
bar on the intended line of the joints within a tolerance of plus or minus 50 mm, and with a minimum
cover of 30 mm below any top crack inducer or joint groove.

Concrete Pavement
Final November 2004
Page 501-14
Hold Point 501.3
Process Held: Placement of Reinforcement

Submission Details: At least 4 hours prior to commencement of concrete placement for
paving, the Contractor shall provide notification that the reinforcement
fixing is completed and ready for inspection.
Release of Hold Point: The Engineer may inspect the reinforcement prior to authorising the
501.11.10 Placing Concrete
(a) Procedures for Placing:

At least 28 days before commencing work under this Specification, for the information of the
Engineer, the Contractor shall submit as part of the Quality Plan full details of the equipment and
methods proposed for placing and finishing the concrete base and sub-base together with a paving
plan showing proposed paving widths, sequence, joint details and estimated daily outputs.
When the placing of concrete has started:
(i) The amount of equipment and supply of materials shall be sufficient to ensure that
placing will be continuous for any given working period;
(ii) Construction equipment shall not operate on the prepared sub-base after approval to
place concrete has been given;
(iii) The batches shall be deposited so as to require as little rehandling as possible.
(iv) Any necessary rehandling shall be with rakes;
(v) Workmen shall not walk on the fresh concrete with footwear coated with earth or other
foreign matter;
(vi) Concrete shall be placed over and against the joints in such a manner as to ensure joints,
dowel bars, and load transfer assemblies are retained in correct position;
(vii) Unless unavoidable, concrete placing shall be continuous between transverse joints
without the use of intermediate bulkheads;
(viii) Concrete shall be thoroughly compacted against the faces of all forms and joints,
including the face of concrete in a previously constructed lane of pavement, by means of
vibrators inserted in the concrete;
(ix) When concrete is placed the face of a previously constructed lane of pavement,
mechanical equipment will not be allowed to be operated on the existing lane, until the
lane has attained a minimum flexural strength of 35 MPa according to AACRA Test C-25
(ref: Division 802 and AACRA Soils and Materials Manual; Section 8.25) or compressive
strength of 36 MPa according to AACRA Test C-18 (ref: Division 802 and AACRA Soils
and Materials Manual; Section 8.18). The previously constructed lane shall be protected
from damage by the paving equipment;
(x) Unless otherwise approved, placement at each placing location shall proceed at a rate of
not less than 25 m/h;
(xi) Concrete shall be placed within one hour of the time of batching and before it has
attained initial set. The temperature of the concrete when deposited in the forms shall be
not less than l0°C or more than 32°C;
(xii) Concrete shall not be placed either during rain or when the air temperature in the shade
is below 5 °C or above 38°C;
(xiii) In order that the concrete may be properly protected against the effects of rain before the
concrete is sufficiently hardened, the Contractor is required to have available at all times
Concrete Pavement
Final November 2004
Page 501-15
satisfactory materials for the protection of the edges and surface of the un-hardened
concrete.
(xiv) The concrete slab shall be constructed by slip form or side form paving machines. Where
a paving machine is impractical, concrete is to be placed according to Clause 501.11.5 of
this specification. The paving machines shall be provided with approved covers to protect
the surface of the slab under construction from direct sunlight and rain.
(xv) The slab shall be constructed in one layer or two layers as approved by the Engineer.
(xvi) The spreading, compacting and finishing of the concrete shall be carried out as rapidly as
possible and the paving operation shall be so arranged as to ensure that the time
between the mixing of the first batch of concrete in any transverse section of the slab and
the application of the sprayed curing membrane to the surface of that section shall not
exceed the limits in Table 501-6. Work shall not proceed when the temperature of the
concrete exceeds 30º C.
Table 501.6
Time Between Mixing and Completion of Concrete Pavement Slabs

Temperature of Concrete Maximum Time Between
Mixing and Completion
Up to 25º C 2 hours
From 25º C to 30º C 90 minutes
Note: The temperature of the concrete shall be measured at the point of discharge from the
delivery vehicle.
The addition of water to the concrete to facilitate the finishing operations will
not be permitted unless approved by the Engineer when it shall be applied
as a spray by means of approved equipment.
Hold Point 501-3
Process Held: Placement of concrete paving.

Submission Details: (a) At least 20 working days prior to commencement of concrete
paving the Contractor shall submit details of the equipment
and methods proposed for placing and finishing the concrete.
(b) At least 30 working days prior to commencement of concrete
paving the Contractor shall submit details of the concrete mix
design, component materials and test results.
Release of Hold Point: The Engineer will review the submitted details, prior to authorizing the
501.11.11 Joints
(a) General
(i) Joints shall be constructed and located as detailed on the drawings. Joints shall be
straight and plumb. Unless otherwise detailed on the drawings, transverse expansion and
contraction joints shall be normal to the longitudinal joints and continuous from edge to
edge of the pavement throughout all paving slabs that are connected in a single paved
area.

Concrete Pavement
Final November 2004
Page 501-16
(ii) Where curbs are cast as part of the paving slab, joints of the same type shall continue
through the curb sections on the same alignment as those in the paving slab. When curbs
or medians are constructed integral with the pavement, transverse joints shall be
constructed continuous through the curb or median. All joints shall be protected from the
intrusion of deleterious matter until sealed.
(iii) Isolated joints shall be formed at structures by placing 12.50 mm expansion joint filler around
each structure that extends into or through the pavement before concrete is placed.
(iv) Newly placed concrete pavement shall be removed and replaced if uncontrolled cracking
occurs.
(d) Construction Joints
Transverse construction joints in jointed concrete slabs shall be either contraction or expansion joints.
Longitudinal construction joints in concrete slabs shall be tied warping joints.
(c) Longitudinal Joints

Longitudinal joints shall be tied warping joints constructed in the slab at the positions shown on the
drawings or as directed by the Engineer. Joints in the slab and sub-base shall be staggered so that
they are not coincident vertically and are at least 300 mm apart.
(i) Longitudinal joints shall be constructed by forming or sawing.
(ii) Sawed longitudinal joints (with tie bars) shall be constructed when the concrete pavement
placement width exceeds 4.50 m.
(iii) Longitudinal joints shall be constructed continuous with no gaps in either the transverse
or longitudinal directions at intersections.
(iv) Unless otherwise specified or directed, longitudinal joint shall be constructed parallel to
the pavement centreline.
(v) Tie bars of the specific length, size, spacing, and material shall be placed in all
longitudinal contraction and longitudinal construction joints.
(vi) Tie bars of the specific length, size, spacing and material shall be placed perpendicular to
the longitudinal joints with mechanical equipment or rigidly secured chairs without
damaging or disrupting the concrete.
(vii) Tie bars shall not be painted or coated with any material or enclosed in tubes or sleeves.
(viii) The longitudinal joint shall be constructed in the position shown on the drawings within
the following tolerances.
(ix) Deviations of the bottom crack inducer from the intended line of the joint, parallel to the
axis of the road shall be not greater than 10 mm.
(x) The best-fit line along the constructed joint groove shall be not more than 15 mm from the
intended line of the joint.
(xi) Deviations of the joint groove from the best-fit line through the joint shall be not greater
than 10 mm.
(xii) The joint groove shall be located vertically above the bottom crack inducer within a
horizontal tolerance of 35 mm.
(n) Types of Longitudinal Joints.
Formed Joints:
Construction grooves for sealer (where required) in formed joints shall be centred on the face of the
joint.

Concrete Pavement
Final November 2004
Page 501-17
(e) When forming the edge of the first placed slab, cast in a step recess of width equal to half
the nominal width of sealer groove and of depth equal to the depth of joint sealer + 5 mm.
The step recess shall be formed by fixing a metal strip of appropriate dimensions to the
top of the form such as to leave a clean straight edge in the concrete when the form is
stripped.
(f) After stripping and when concrete has cured sufficiently, clean arrises of step recesses
using a rotary concrete saw.
(g) Prior to placement of concrete adjacent to previously formed slab edges, fix an inert form
strip such as a "Fibre-board" or polystyrene foam to the edge using a suitable waterproof
adhesive. Do not place concrete until the adhesive has set.
Sawn Joints
(i) After placing concrete, Joints shall be sawn as soon as equipment can be supported and
before uncontrolled cracking occurs. The joints shall not be ravelled while sawing.
(ii) Longitudinal joints shall be sawn immediately after sawing transverse joints. The sawn
concrete faces shall be protected from drying during the curing period.
(iii) Sealant reservoirs shall be saw no sooner than 72 hours after placing the concrete. If
necessary, sawing shall continue day and night, regardless of weather conditions. The
saw cut and adjacent concrete surface of slurry residue shall be cleaned after sawing
each joint.
(iv) Sawing of a joint shall not be done if a crack occurs at or near the joint location before
sawing and shall be discontinued when a crack develops ahead of the saw.
If a crack develops in reinforced concrete pavement, at least a 3 m long full-width slab
shall be removed, replaced and properly attached to adjacent slabs.
If a crack develops in plain concrete pavement, a full slab shall be removed, replaced and
properly attached to adjacent slabs.
(v) Ribbon - Induced Joints
Ribbon-induced longitudinal tied joints shall be provided to the dimensions and details
shown on the drawings. The inducer ribbon shall be machine-inserted so that the top of
the ribbon does not protrude above the surface of the base, nor shall it lie below the
surface of the base by more than 3 mm. The inducer ribbon shall be a minimum of
0.5 mm thick. When placed, it shall be within 5o of the vertical plane. Inducer ribbon,
which curls on placement and when cut in the base is found to be curved in transverse
section by more than 3 mm from straight shall be rejected.
At transverse construction joints, the inducer ribbon shall be carried through the joint
sufficiently to allow a connection by strong stapling, or other method approved by the
Engineer, to the inducer ribbon to be used on the other side of the joint.
When a join is necessary in the inducer ribbon during paving, the inducer ribbon on the
new spool shall be similarly joined to the tail of the inducer ribbon on the old spool.
(g) Transverse Construction Joints
a. Transverse construction joints shall be installed at the end of each day's placing
operations and at any other points within a paving lane when concrete placement is
interrupted for 30 minutes or longer.
b. Transverse construction joints at the end of each day's placing operation shall be
installed in the location of a planned transverse contraction or expansion joint.
c. Transverse construction joints located at planned transverse contraction joints shall be of
the same type as the dowelled transverse joints.
d. When concrete placement is interrupted for 30 minutes or longer, or cannot be continued
due to equipment failure or adverse weather conditions, a transverse construction joint

Concrete Pavement
Final November 2004
Page 501-18
may be installed within the slab unit, but only within the middle third of the length of the
slab between planned joints. Excess concrete shall be removed.
e. When a construction joint is installed within a concrete slab unit the joint shall, unless
otherwise detailed, be a keyed and tied construction joint.
f. A transverse construction joint within a concrete slab unit shall not be provided with a
groove at the surface of the concrete.
g. If sufficient concrete has not been mixed to form a slab at least 3 m long when an
interruption occurs, the excess concrete back to the last preceding joint shall be removed
and disposed of.
h. Dowel bars shall be installed in all transverse construction joints whose location does not
coincide with the location of a transverse expansion or contraction joint.
(h) Expansion Joints.

Expansion Joints shall consist of joint filler board, dowel bars and sealing groove.
(i) Filler board for expansion joints shall be the thickness described in the Contract within a
tolerance of + or – 1.5 mm and of a firm compressible material of sufficient rigidity to
resist deformation during the passage of the concrete paving plant.
(ii) The expansion joint filler board shall have a ridged top as described in the Contract,
except where a sealing groove former is permitted by the Engineer.
(iii) Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the
sheathed dowel bar.
(iv) If the filler board is provided in more than one piece the abutting ends shall be fastened
securely and held accurately in position by stapling or other means approved by the
Engineer.
(v) The expansion joint filler board shall be positioned vertically within the prefabricated joint
assembly along the lines of the joint within the tolerances given in this Clause, and at
such depth below the surface as will not impede the passage of the finishing beams on
the paving machines.
(vi) The expansion joint filler board, together with the sealing groove, shall provide a complete
separation of adjacent slabs and any spaces around dowel bars and between the sub-
base and the filler board shall be packed with a suitable compressible material after fixing
the joint assembly.
(vii) Form expansion joints around structures and features, which project through, into or
against the pavement and at other locations as detailed.
(viii) Joint filler shall be of the type and thickness indicated and shall be installed so as to form
a complete uniform separation of materials on either side of the joint.
(ix) Where other joints in the paving are sealed with preformed, self-expanding cork, the
expansion joint filler shall be a full depth strip of the same material.
(x) Where other joints in the paving are sealed with preformed elastomeric strips, expansion
joints shall be formed by fixing an inset form strip such as "Fibre-board" or polystyrene
foam to the edge of the hardened slab. The strip shall extend for the full depth of the slab
and be of thickness equal to the nominal width of the joint. It shall be in two parts with the
top part equal in depth to the seal groove shown on the drawing. The strip shall be fixed
with a suitable waterproof adhesive. Do not place concrete until the adhesive has set.
When concrete has hardened sufficiently, remove top section of former strip and insert
sealer.
(g) Transverse Expansion Joints
Transverse expansion joints shall be formed according to Sub-Clause 501.11.11 above.
Concrete Pavement
Final November 2004
Page 501-19
(i) Dowel bars shall be placed through transverse joints and hold parallel to the surface and
centreline of the slab by a metal device that remains in the pavement.
(ii) Dowel placement implanters may be used while the concrete is plastic provided they
conform to the dowel tolerance specified.
(iii) All concrete that leaks into the joint expansion space shall be removed.
(iv) The preformed joint filler shall be installed full-depth, perpendicular to the sub grade, and
continuous across the full pavement width.
(v) Damaged or repaired joint filler shall not be used.
(vi) Joints in the slab and sub-base shall be staggered so that they are not coincident
vertically and are at least 1 m apart.
(vii) Transverse joints shall be straight within the following tolerances along the intended line
of the joint, which is the straight line transverse to the longitudinal axis of the carriageway
at the positions shown in the Contract.
(viii) Deviations of filler board from the intended line of the joint shall be not greater than + or –
10 mm.
(ix) The best-fit straight line through joint grooves as constructed shall be not more than
25 mm from the intended line of the joint.
(x) Deviations of the joint groove from the best-fit straight line through the joint shall be not
greater than 10 mm.
(xi) Transverse joints on each side of a longitudinal joint shall be in line with each other and of
the same type and width.
(xii) Transverse joint grooves and cracks in the edge of the slab shall be covered with
masking tape prior to the construction of any adjacent pavement layer.
Table 501.7
Sampling and Testing

Material or Property or Category Test Methods or Frequency Sampling point
Product Characteristic Spec.
Concrete Slump — AACRA Test C-10 1 per load (2) Discharge
stream at point
of placement (1)
Air content — AACRA Test C-12 1 per load (2) Discharge
stream at point
of placement (1)
Unit weight — AACRA Test C-11 1 per load (2) Discharge
stream at point
of placement (1)
Temperature — AACRA Test C-9 First load Discharge
stream at point
of placement (1)
Making test — AACRA Test C-14 1 set per 1680 m2 Discharge
specimens. but not less than stream at point
1 per day (3) of placement (1)
Compressive — AACRA Test C-12
strength (4)
Concrete Pavement II AACRA Test C-16 1 core per 185 m2 In place after
Pavement thickness (5) sufficient
hardening
Smoothness I AASHTO T286-96 See Clause See Clause
(6) or 501.15 501.15
ASTM E1082-90

Concrete Pavement
Final November 2004
Page 501-20
(1) Sample according to AACRA Test C-9 (ref: Division 802 and AACRA Soils and Materials Manual;
Section 8.9) except composite samples are not required.
(2) See Clause 501.11.6
(3) Cast at least 4 compressive strength test cylinders and carefully transport the cylinders to the job site curing
facility.
(4) A single compressive strength test result is the average result from 2 cylinders cast from the same load and
tested at 28 days.
(5) Thickness is not a statistically evaluated parameter unless concrete pavement payment is by the square metre.
(6) Applies only to an item used as a final surface course constructed under the contract.
(h) Contraction Joints

(i) Transverse contraction joints
Transverse contraction joints in paving cast between fixed forms shall be sawn, induced
and/or formed as detailed.
Transverse contraction joints in slip-formed paving shall be sawn.
(ii) Sawn Contraction Joints
Sawn contraction joints shall be constructed by cutting a groove in the hardened
concrete. Sawing operations shall be carried out as required during the day or night
regardless of weather conditions.
If uncontrolled cracking of concrete occurs, concrete placing shall be suspended.
Provide one standby-sawing machine for every machine planned for use.
Saw cuts shall be at least 45 mm deep or such greater depth as is detailed on the
drawings and of uniform width in the range 3-5 mm for the full depth of the cut.
The line of the transverse contraction joint shall be without any discontinuities. No edge
shall deviate from a 3 m straight edge by more than 10 mm.
The surface of the transverse contraction joint shall not exhibit more than 5 mm of vertical
or horizontal edge ravelling. The length of edge ravelling shall not be more than 300 mm
in any 1 m length of joint on each edge. Saw debris shall be washed from the joint and
pavement immediately after sawing.
The time of sawing shall be varied between 6 and 24 hours after initial paving, depending
on existing and anticipated weather conditions, and shall be such as to prevent
uncontrolled cracking of the pavement. Sawing of the joints shall commence as early as
possible, commensurate with the concrete having hardened sufficiently to permit cutting
the concrete without excessive chipping, spalling or tearing.
The sawn faces or joints will be inspected for undercutting or washing of the concrete due
to early sawing. If this action is sufficiently deep to cause structural weakness or
excessive cleaning difficulty, the sawing operation shall be delayed, and resumed as
soon as sawing can be continued without damaging the concrete slab. Nevertheless, all
sawing shall be completed not later than 24 hours after placement of the concrete. The
joints shall be sawn, if the concrete is sufficiently hard, in the sequence of the concrete
placement, initially at every fourth joint, then at the intermediate intervals.
Before sawing a joint, the concrete shall be examined closely for cracks, and the joint
shall not be sawn if a crack has occurred near the location chosen for a joint. Discontinue
sawing if a crack develops ahead of the saw cut.
Immediately after each joint is sawn, the saw cut and adjacent concrete surface shall be
thoroughly flushed with water until all waste from sawing is removed from the joint and the
joint caulked with plastic or rubber tubing or suitable "Tee" shaped extrusion which will
remain in place and prevent the entry of foreign material into the joint.
(iii) Cleaning and Temporary Sealing
Immediately after any sawing, the saw cut shall be cleaned of all debris. The cleaning
method used shall not damage the saw cut nor leave any substance deleterious to the

Concrete Pavement
Final November 2004
Page 501-21
concrete or to the adhesion of the joint sealants to be used. The method shall incorporate
a pressurised liquid or liquid/air jet. Cleaning liquid shall not be gravity fed from tanks.
Immediately after cleaning the joint shall be temporarily sealed by a continuous
closed-cell polyethylene backer rod of diameter shown on the drawings or as required by
the Engineer. The top of the sealant shall be neither higher than nor more than 10 mm
below the concrete surface. The backer rod shall pass over any longitudinal joint seal
already in place.
The temporary sealant shall be maintained by the Contractor until the joint is sealed
permanently. Damaged or disturbed temporary sealants shall be removed, the transverse
contraction joint re-cleaned to the satisfaction of the Engineer and a new temporary
sealant inserted.
(iv) Formed Contraction Joints:
Formed transverse contraction joints shall be constructed by formation of a weakened
plane in the plastic concrete. This may be achieved by the insertion of a preformed cork
sealer during placing and finishing or by the insertion of a crack inducer during placing
and the subsequent insertion of a preformed elastomeric sealer.
- Crack Induction
Crack inducers shall be of suitable material and of dimensions shown on the
drawings. Details shall be submitted for approval before use. They shall
comprise a permanent section that remains in the completed joint and a
removable top section. Insert the crack inducer so that the top of the removable
section finishes flush with the surface of the concrete.
- Cork Sealed Joints
The Contractor shall submit details of contraction joint forming equipment for
approval before commencing placing operations. Unless otherwise approved,
equipment for installing sealers shall be a machine equipped with a vibratory
cutting and installing bar for cutting a vertical groove in the plastic concrete at
the prescribed joint location and, preferably simultaneously, installing the sealer
to the required depth throughout the full width of the paving lane. The vibration
units of the cutting and installing bar or bars shall be so arranged that the
vibration will be uniformly distributed throughout the bar. The intensity of
vibration shall be adjustable as required to form a groove of correct size for the
sealer, and for compacting the concrete around the in-place sealer. The cutting
and installing bar shall be either hydraulically assisted or of sufficient mass to
form the groove in conjunction with the vibration units.
The depth of preformed cork sealer shall be at least equal to the depth of joint
shown on the drawings. Protect cork from exposure to moisture at all times until
it is incorporated into joints. Do not soak before installation. Insert the joint
sealer in the plastic concrete immediately following final finishing. Adjacent
sections of joint sealer within each slab unit shall be securely joined by suitable
adhesives or fasteners so that the sealer is continuous from edge to edge of the
pavement lane. The concrete adjacent to the sealer shall be compacted using a
vibrating plate float.
On completion, the top of the sealer shall be between 0 and 5 mm below the
finished surface of the adjacent concrete. Remove tape from top of sealer when
concrete has attained final set.
(i) Joint Grooves
(i) Joint grooves shall be either sawn or wet formed in the surface of the slab to promote
cracks at the required positions. They may be of any convenient width up to a maximum
of 15mm but their depth shall be as given in this Clause.
(ii) The sealing groove may be constructed at the same time as the joint groove or be sawn
to the required dimensions later.
Concrete Pavement
Final November 2004
Page 501-22
(iii) Transverse joint grooves shall be either sawn in the hardened concrete or wet formed in
the plastic concrete. Longitudinal joint grooves shall be wet-formed except at construction
joints. Unless otherwise approved by the Engineer, expansion joint sealing grooves shall
be sawn.
(iv) Transverse joint grooves which are initially constructed to less than the full width of the
slab shall be completed by sawing through to the edge of the slab and across longitudinal
joints before an induced crack develops at the joint.
(v) Before the slab is used by construction traffic, transverse joint grooves shall be
temporarily sealed with an approved compressible caulking strip.
(vi) Sawing shall be undertaken as soon as possible after the concrete has hardened
sufficiently to enable a sharp edged groove to be produced without disrupting the
concrete and before random cracks develop in the slab. The grooves shall be between ¼
and ½ of the specified depth of the slab and of any convenient width up to a maximum of
15 mm.
(vii) When slabs are constructed more than one bay wide, a longitudinal joint groove shall be
formed by inserting a groove former ahead of the longitudinal finishing beam from an
approved dispenser. The displaced concrete shall be re-compacted by a vibrating
compactor or similar device, at least 300 mm wide operating symmetrically along the line
of the joint.
(viii) After finishing the concrete, the groove-forming strip shall be in the correct position and
alignment, within 100 of the vertical and at a depth below the surface which is just
sufficient to allow for the passage of the finishing beam without displacing the strip.
Longitudinal groove forming strips in wet-formed longitudinal joint grooves shall be left in
place.
501.12 Final Strike-off, Consolidation and Finishing

501.12.1 Consolidation and Strike-off
The Contractor may be required to construct main line pavement and interchange ramp pavement using one
or more finishing machines.
The freshly placed concrete shall be vibrated, struck off accurately and screeded with approved equipment
so that, when compacted and finished, the surface of the pavement will have the required elevation and
cross section.
A sufficient and uniform amount of concrete to ensure filling all voids and depressions shall be carried in
front of screed at all times.
501.12.2 Floating
After the concrete has been struck off and consolidated, it shall be further smoothed and trued by means of
an approved longitudinal float or an approved transverse smoothing float. Floating shall be in an
approximately longitudinal direction from one edge to the other. The float shall be worked along the surface with
a sawing motion to edge and with the forward operator slightly ahead.
501.12.3 Checking and Surface Correction

(a) As soon as the longitudinal or final floating is complete, all laitance, surplus water, and inert material
shall be worked off the surface and the surface made smooth by a scraping or dragging motion with
a long -handled 3 m straightedge.
(b) The straightedge shall be placed at the centre of the pavement with the blade parallel to the
centreline and then pulled slowly and uniformly to the edge. The blade shall then be moved forward
one-half its length and the operations repeated until the surface is free from irregularities and makes
contact with the blades at all points.
Concrete Pavement
Final November 2004
Page 501-23
(c) During this checking operation, any remaining depressions shall be filled with fresh concrete and
struck off. In general, addition of superficial water to the surface of the concrete to assist in finishing
operations will not be permitted.
501.12.4 Final Finishing

(a) After the surface has been prepared as described above and the water sheen has practically
disappeared and, unless otherwise specified or directed, the pavement shall be textured with a drug
strip of burlap.
(b) The drag shall consist of a seamless strip of dump burlap or cotton fabric that shall produce a
uniform surface of gritty texture after dragging it longitudinally with a slight back and forth transverse
motion along the full width of the pavement.
(c) In order to obtain the desired surface qualities or texture, the Engineer may require the use of an
approved belt and belting procedure or an approved brooming operation. The belting operation or
brooming operation may be required separately, jointly, or along with and in addition to the burlap
drag.
501.12.5 Edging at Forms and Joints.

(a) Before the concrete has taken its initial set, the edge of the pavement along each side of each slab
and on each side of formed joints shall be worked with an approved tool and rounded to the radius
required by the plans.
(b) A well defined and continues radius shall be produced and a smooth dense mortar finish obtained.
The surface of the slab shall not be unduly disturbed by tilting of the tool during use.
(c) All joints shall be tested with a straightedge before the concrete has set and correction made if one
side of the joint is higher than the other or if they are higher or lower than the adjacent slabs.
501.13 Curing
Immediately after finishing and when marring will not occur, the concrete shall be cured for a minimum of 72
hours. The concrete shall not be left exposed for more than one half hour during the curing period.
Concrete shall be cured using one of the following methods:
(a) Initial Curing.
Immediately after finishing operations have been completed and until the impermeable curing
blankets have been applied, the surface of the concrete shall be kept continuously damp by means
of a water fog or mist applied with suitable spraying equipment.
(b) Water method (Moist Curing).
As soon as possible after the finishing operations have been completed and the concrete has set
sufficiently to prevent marring of the surface, the forms and entire surface of the newly laid concrete
shall be covered with wet hessian or cotton mats.
(i) After shrinkage, cotton mats and hessian strips shall have a width at least 300 mm
greater than necessary to cover the entire width of the faces of the concrete slab.
Provision shall be made to anchor the mats securely to ensure that they remain in place
in windy conditions. The mats shall overlap by at least 150 mm. The mats shall be
saturated before placing and shall be kept continuously saturated and in close contact
with the pavement edges and surface for the duration of the required curing period.
(ii) The moist curing shall be continued for a period of not less than 12 hours and until the
impermeable blankets are applied.
(iii) When weather and other conditions are suitable, the Engineer may waive the requirement
for moist curing and allow the immediate application of impermeable blankets on
completion of initial curing.
(c) Impermeable Blanket Curing.
Concrete Pavement
Final November 2004
Page 501-24
On completion of moist curing and for the remainder of the curing period, the concrete shall be covered with
impermeable curing blankets complying with the following requirements:
(i) Impermeable blankets shall be cotton or hessian backed white opaque polyethylene
sheet, or white opaque polyethylene sheeting, or other suitable waterproof sheeting which
shall be stitched or cemented together to make blankets of width at least 1 m greater than
the lane being placed and not less than 9 m long. The blankets shall be free from visible
defects, tears and holes and shall comply with the requirements of ASTM C171.
(ii) The blankets shall have sufficient strength to meet the required conditions of service and
shall be approved before use. Hessian or cotton polyethylene-coated blankets shall be
saturated thoroughly with water before placing.
(iii) The curing blankets shall be in pieces large enough to cover the entire width and edges
of the slab. The blankets shall be placed with the light-coloured side up. Adjacent
blankets shall overlap not less than 300 mm with the lapped edges securely tied or
weighted down along their full length to prevent displacement by billowing from winds.
Blankets shall be folded down over the side of the pavement edges, continuously
weighted, and secured.
(iv) Tears and holes appearing in blankets during the curing period shall be repaired
immediately. The blankets shall remain in place during the remainder of the specified
curing period.
(v) If contraction joints are sawn, the curing blankets shall be removed for the minimum
distance and time necessary to carry out the joint sawing operations and, following
caulking of the joint, the blanket shall be replaced immediately.
(d) Liquid membrane curing compound method.
The concrete curing in this method shall comply with the following requirements:
(i) The liquid membrane method shall not be used on surfaces to receive a rubbed finish.
Use on construction joint surfaces is permitted only if the compound is removed by
sandblasting before placement of concrete against the joint.
(ii) Use type 2 white pigmented, liquid membrane only on the top surfaces of bridge decks or
on surfaces not exposed to view in the completed work. Use type 1 or 1-D clear curing
compounds on other surfaces.
(iii) Mix membrane-curing solutions containing pigments before use. Continue to agitate
during application. Use equipment capable of producing a fine spray.
(iv) Apply the curing compound at a minimum rate of 0.3 L/m2 or 1L per 45 m2 in one or two
uniform applications. If the solution is applied in 2 applications, follow the first application
with the second application within 30 minutes and apply at right angles to the first
application.
(v) If the membrane is damaged by rain or other means during the curing period, immediately apply
a new coat over the damaged areas.
Sawn joints shall be protected from intrusion of foreign material into the joint before sealing and
damaged areas shall be repaired immediately with additional compound.
(e) Waterproof cover method.
(i) The surface shall be wetted thoroughly using a fog mist applicator.
(ii) The surface shall be entirely covered with a waterproof cover with a lap cover of at least
450 mm. The cover shall be extended beyond the edges of the slab at least twice the thickness
of the pavement and the cover shall be placed in complete contact with the surface.
(iii) Masses or other approved methods shall be used to maintain contact and lap joints shall be
sealed, sewn, or cemented to prevent opening or separating while curing.

Concrete Pavement
Final November 2004
Page 501-25
(iv) When the air temperature is expected to drop below 20C, the Contractor shall furnish a sufficient
supply of insulating material and the pavement surface and sides shall be insulated to a depth to
maintain a temperature above 50C for 3 days. Thermometers shall be furnished and placed so
as to record continuously.
(v) Forms shall be removed when the concrete has hardened sufficiently to resist damage, but not
earlier than 12 hours after placing concrete. The sides of the exposed slabs shall be protected
immediately with a curing method equal to that provided for the surface.
(vi) Erosion of the base course beneath the exposed pavement edges shall be prevented until
shoulders are constructed.
Hold Point 501.4
Process Held: Placement of concrete paving.

Submission Details: At least 10 working days prior to commencement of concrete paving,
the Contractor shall submit details on the type and methods of
proposed curing for the Engineer's approval.
501.14 Sealing Joints

(a) After curing is completed all joints, both longitudinal and transverse, shall be filled with the specified
sealant. The required joint configuration to receive the seal shall be formed by sawing.
(b) Cut and seal joints before the pavement is opened to construction or public traffic. Sealant reservoirs
shall not be sawn within 72 hours after placing concrete. No joint sealer shall be applied in wet
joints.
(c) All joints shall be cleaned of all foreign material, including membrane curing compound and concrete
slurry, immediately after joint sawing. Dry joints shall be blown with compressed air. Sealing material
shall not be applied unless the joint faces are clean and surface dry.
(d) Preformed joint seals, silicone sealant, or hot-poured sealant shall be used for expansion joints and
shall be applied as per the manufacturer's instructions and approval by the Engineer.
(e) Silicone or hot-poured sealant shall be used for longitudinal and transverse contraction joints and
shall be applied as per the manufacturer's instructions and approval by the Engineer.
Hold Point 501.6
Process Held: Sealing of Joints.

Submission Details: At least 5 working days prior to proposed commencement of sealing of
joints the Contractor shall submit a certificate of compliance and the
manufacturer's instructions on the use of sealant from a certified
laboratory or recognized institution.

Concrete Pavement
Final November 2004
Page 501-26
501.15 RIDING QUALITY

The finished surface must have a smooth longitudinal profile and, on roads with a designated or
proposed speed limit in excess of 60 km/hour, except within roundabouts, the riding quality of the
finished surface must be measured in terms of International Roughness Index with a Profilometer, or
a calibrated roughness meter vehicle in accordance with AASHTO PP 37-02 and ASDTM E-950..
A section of road will be deemed to have achieved conformance for ride quality if the IRI for each
section does not exceed 2.5:
For sections having riding quality outside that specified value, deductions in accordance with Table
501.8 shall apply.
Table 501.8
International Roughness Index (IRI) Value Deduction per cent for the value of the
section
Greater than 2.5 to 3.0 2
Greater than 4.0 Top 30 mm to be removed and replaced

provided remaining thickness of layer is at least
twice the nominal mix size otherwise remove
and replace whole depth of layer.
501.16 Opening to Traffic.

Traffic shall not be allowed on new concrete pavement earlier than 14 days after concrete placement, unless
concrete tests indicate one of the following conditions is obtained.
(a) Flexural strength of 35 MPa according to AACRA Test C-25 (ref: Division 802 and AACRA Soils and
Materials Manual; Section 8.25).
(b) Compressive strength of 36 MPa according to AACRA Test C-18 (ref: Division 802 and AACRA
Soils and Materials Manual; Section 8.18).
Specimens shall be cured according to AACRA Test C-14 (ref: Division 802 and AACRA Soils and Materials
Manual; Section 8.14), for determining form removal time or when a structure may be put into service.
Traffic shall not be allowed on the pavement when joint sealant is tacky and traffic debris would embed into
the sealant.
501.17 Conformance Criteria

501.17.1 Compressive Strength of Concrete
(a) Test specimens for determining the compressive strength of concrete shall be standard cylinders
complying with AACRA Test C-18 (ref: Division 802 and AACRA Soils and Materials Manual;
Section 8.18) requirements.
(i) A production certification for the Portland cement shall be furnished by the Contractor.
(ii) The Contractor shall supply a sufficient number of cylinder moulds to meet the
requirements for the frequency of testing shown in Table 501-7 and copies of test results

Concrete Pavement
Final November 2004
Page 501-27
shall be forwarded to the Engineer. The Contractor shall mark all specimens for
identification purposes.
(iii) The cost of all work and material required in the making, curing, delivery and testing of
specimens shall be borne by the Contractor.
(iv) The lower specification limit is the minimum required compressive strength at 28 days
specified in Table 501-3.
(v) A single compressive strength test result is the average result from 2 specimens cast
from different samples from the same load and tested at 28 days. See Table 501-7 for the
acceptance quality characteristic category.
(vi) The compressive strength of the concrete represented by a pair of specimens moulded
from one sample shall be the average compressive strength of the two specimens unless
the two results differ by more than 3 MPa, in which case the higher result shall be taken
to represent the compressive strength of the lot of concrete.
(vii) If the 28 day compressive strength of test cylinders for any lot is less than 33 MPa or
greater than 45 MPa, the lot represented by the test cylinders shall be removed and
replaced in accordance with Sub-clause 501.17.3 of this specification.
(b) In case of non-conformance, the Contractor may propose through disposition of a non-conformance
report to core the in-situ concrete base for testing of the actual compressive strength as being
representative of the particular lot. The locations for testing shall be nominated by the Engineer.
Such locations may be determined by the use of a nuclear density meter, or any alternative method.
Testing shall be carried out at the request of the Contractor.
After testing for compressive strength of cores, where required, the Engineer shall consider the test
results and shall at his absolute discretion determine the compressive strength of the concrete to be
either:
(i) The average of the 28 day compressive strength of the pair of specimens moulded at the
time of placing; or
(ii) The equivalent 28 day compressive strength of the core.
501.17.2 Compaction and Tolerances

(a) Concrete Pavement
The finished surface of concrete pavement shall be uniform in appearance and shall comply with
the tolerances itemised in Table 501-9. Surface shape shall be such that water cannot
accumulate at any point.
Table 501.9
Tolerances
Item Tolerance
Level ± 10 mm
Thickness + Unspecified – 5 mm
Straightness 5 mm maximum departure from 3 m straightedge both
ways
(ii) Thickness measurements shall be determined by survey measurements or coring. If

concrete paving thickness is outside the specified limits, the work shall be removed and
replaced in accordance with Sub-clause 501.17.3 of this specification.
(iii) The lower specification pavement thickness limit is the required thickness minus
6.25 mm. See Table 501-7 for the acceptance quality characteristic category.
Concrete Pavement
Final November 2004
Page 501-28
(b) Dowels
The deformation from true shape of the ends of a dowel shall not exceed 1 mm on the diameter
of the dowel and shall not extend more than 1 mm from the end of the dowel.
Dowel bars shall be placed subject to the following tolerances:
(i) Two-thirds of the number of bars in the joint shall be within 2 mm in 300 mm.
(ii) The remaining third, less one per 3 m length of joint, shall be within 4 mm in 300 mm.
(iii) No bar shall differ in alignment from an adjoining bar by more than 2 mm in 300 mm in
either plane.
(c) Joints
The alignment of joints shall not vary by more than 15 mm from that shown on the drawings. Pavement
surfaces in the vicinity of joints shall comply with the parameters itemised in Table 501-9.
(d) Joint Sealers
Dimensional tolerances for preformed self-expanding cork joint sealer in the unexpanded state shall
be ± 1.5 mm in width and ± 3.0 mm in depth.
(e) Repair of Core Holes
The Contractor shall clean and restore all core holes taken in the base with non-shrink cementitious
concrete having a compressive strength of not less than that in the base and a maximum nominal
aggregate size of 10 mm. The surface of the restored hole shall be similar to the surrounding
surface in texture and colour. The cost of restoring core holes shall be borne by the Contractor.
(f) Sampling and Testing
(i) All sampling and testing of materials supplied and work carried out under this section of the
Specification shall be performed in accordance with the relevant AACRA Standards or as
otherwise specified.
(ii) Work under this Specification shall be subdivided into lots or discrete work areas. The
Engineer shall have the right to reject a lot which is visually non-homogeneous and/or
non-representative.
(iii) The specified testing shall be taken at the random test locations established in each lot in
accordance with the specified minimum testing frequency as specified elsewhere in this
specification and as shown in Table 501-7. The test/s taken shall be considered to
represent the total volume of material placed within the lot.
(iv) Frequency of Testing
The frequency of testing shall be appropriate to verify conformity and shall not be less than
that stated in Table 501-7. Where no minimum frequency of inspection or testing is stated,
the Contractor shall nominate appropriate frequencies in their Inspection and Test Plan(s).
The Contractor shall include in the management review of the Quality System, a review of
the appropriateness of the frequency of testing nominated in the Inspection and Test
Plan(s). Such review shall take into account the frequency of non-conformance detected,
including non-conformance remedied by simple reworking.
501.17.3 Non-conforming Work - Removal of Non-conforming Concrete

(a) Where directed by the Engineer, rejected Concrete pavement shall be removed and replaced in
accordance with this Clause.
(i) Rejected Concrete pavement which extends more than 25 m longitudinally shall be
replaced by mechanical means unless the slabs are odd-shaped or mismatched.
Replacement shall be in full slab widths between longitudinal joints and/or external edges.
(ii) At least 7 days before the commencement of pavement removal, the Contractor shall
submit, for the approval of the Engineer, details of the proposed methods of carrying out

Concrete Pavement
Final November 2004
Page 501-29
the work which shall be such as to prevent damage to the adjoining base and the
underlying sub-base.
(iii) Any slab adjoining the removed concrete slab that is damaged by the Contractor's
operations also shall be removed and replaced in accordance with this Clause. The cost
of all work and materials under this Clause shall be borne by the Contractor.
Hold Point 501.6
Process Held: Removal and disposal on non-conforming concrete

Submission Details: At least 5 working days prior to proposed commencement of the work
the Contractor shall submit details of the equipment and methods
proposed for removal and disposal of concrete paving
501.17.4 Replacement of Concrete Slab Pavement

(c) Before commencement of the replacement concrete pavement, the sub-base shall be prepared and
de-bonded in accordance with this Specification.
All work involved in the replacement of base shall comply with the Specification, including the
following additional requirements:
(i) The joint faces on the adjoining slab at the transverse saw cuts shall be deeply scabbled
below the top 25 mm which shall be left smooth. Tie bars shall be provided to form a
transverse construction joint in accordance with this specification.
(ii) Transverse contraction joints shall be continuous across the full width of the base
containing the replaced section. The length of the joint across the full width of the base
shall be sealed with the same sealant as in adjacent work and in accordance with this
specification.
(iii) The lower two thirds of the depth of the longitudinal joint faces shall be deeply scabbled
and any concrete considered to be unsound by the Engineer shall be removed. A crack
inducer ribbon shall be attached to the surface of any formed longitudinal joint in the
replacement base and tie bars provided to form a longitudinal tied joint in accordance with
this specification.
(iv) Tie bars placed into hardened concrete shall be set by the use of a hydrophilic epoxy
resin. The setting system used shall develop anchorage strength at least 85 per cent of
the yield strength of the bar.
(v) No traffic will be permitted on the pavement until curing is complete. Traffic shall be
excluded from the finished concrete until it is at least 14 days old, except that paving
equipment other than concrete trucks will be permitted after curing is completed, provided
that adequate means are furnished to prevent damage to slab edges, and that all spilled
materials are removed immediately.
501.18 Measurement and Payments

The rates tendered for the payment items shall include full compensation for work in restricted areas or for
work requiring hand placing.
Pay Item 501 P1: Concrete trial pavement:
Pay Item 501 P1.1 Mechanical construction in square metres (m2)
Pay Item 501 P1.2 Manual construction in square metres (m2)

Concrete Pavement
Final November 2004
Page 501-30
The unit of measurement for the trial pavement shall be square metres of completed trial section. Not more
than a total length of 300 m of mechanically constructed trial pavement and not more than 60 m of manually
constructed trial pavement will be measured for payment as described in Clause Pay Item 501P17.
The tendered rate shall include full compensation for constructing the trial pavement complete as specified.
Pay Item 501 P2: Concrete pavement
The unit of measurement shall be (thickness indicated) square metres (m2) of concrete pavement placed
and finished in accordance with the Specifications and the Project Specifications.
The quantity shall be calculated from the authorised dimensions of the completed surface except when the
Engineer requires or the Drawings show local deviations from the specified thickness, such as at bridge
approach slabs. The volume of concrete in such cases shall be converted into an equivalent area in square
metres based on the specified thickness of the slab.
The tendered rate shall include full compensation for procuring and furnishing all the materials, storing the
materials, providing all plant and equipment, determining the mix proportions, mixing, transporting, placing
and finishing the concrete, texturing and curing, including formwork, repairs done to defective work,
protecting the pavement against damage, construction joints and process control.
The tendered rate shall also include full compensation for the provision of any additional width required by
the Contractor to the earthworks and/or pavement layers to suit the particular requirements of the paving
equipment. It shall also include full compensation for the removal of the additional widening which extends
beyond the limits of the specified cross-section.
In the case of rehabilitation work, the tendered rate shall also include full compensation for cleaning existing
joints where new concrete has to join up with existing work, for straightening existing dowels and tie bars,
and for cutting off existing bars as specified.
The tendered rate for concrete pavement also shall include full compensation for constructing joints,
furnishing and placing all appurtenant materials, all in accordance with the Specifications.
The tendered rate for concrete pavement also shall include full compensation for furnishing and placing all
steel reinforcement, tie bars and dowels, and for drilling and testing cores, conducting tests and process
control, all in accordance with the Specifications.
Pay Item 501 P3: Extra over item Pay Item 501 P2 for concrete pavement
The tendered rate for hand-placed concrete shall be extra over the rate tendered for Pay Item 501P2 and
shall be measured in square metres (m2) and include full compensation for the more difficult work, and
incidentals required for placing the concrete by hand where placing cannot be done by normal slip-form or
side-form equipment. It also shall include compensation for all the required formwork. Pay Item 501P3 does
not apply to rehabilitation work.
Pay Item 501 P4: Texturing and curing the concrete pavement
Pay Item 501 P4.1: Burlap-dragged and grooved texture in square metres (m2)
Pay Item 501 P4.2: Curing in square metres (m2)
The unit of measurement for texturing and curing shall be the square metres of completed pavement which
has received the specified surface texturing and which was cured as specified. The quantity shall be
calculated from the specified horizontal dimensions of the completed concrete surface in the case of
texturing and from the specified horizontal dimensions of the completed concrete surface, plus the surface
area of the slab sides, in the case of curing.
The tendered rate for texturing shall include full compensation for providing the plant and equipment required
and for applying the specified surface texture.
The tendered rate for curing shall include full compensation for providing the curing compound and its
application as specified at the specified nominal rates of application by means of an approved pressure
distributor. The tendered rate also shall include compensation for spraying the curing compound in unsealed
joints after the sawing has been completed.
Pay Item 501 P5: Variation in the rate of application of the curing compound
The unit of measurement in respect of increases or decreases in the rate of application of the curing
compound shall be the litre (l).
Concrete Pavement
Final November 2004
Page 501-31
Payment for variations shall be made as specified in Sub-Clause 102.13 of these specifications.
Pay Item 501 P6: Joints:
Pay Item 501 P6.1: Expansion joints complete (excluding dowels) in metre (m)
Pay Item 501 P6.2: Longitudinal hinge joints:
(i) Sealed hinge joints (type indicated with reference to drawings)in metre (m)
(ii) Unsealed hinge joints (type indicated with reference to drawings)in metre (m)
(iii) Hinge joints between existing and new concrete in rehabilitation work in metre (m)
Pay Item 501 P6.3 Sealed transverse contraction joints sawn in two separate
operations(widths as shown on the drawings) in metre (m)
Pay Item 501 P6.4 Dowel bars (mild steel) (diameter and length indicated)
(i) Installed in new concrete each number (No)
(ii) Installed in existing concrete in rehabilitation work. each number (No)
Pay Item 501 P6.5 Tie-bars (diameter and length indicated)

(i) Installed in new concrete each number (No)
(ii) Installed in existing concrete in rehabilitation work each number (No)
Pay Item 501 P6.6 End caps for dowels at expansion joints each number (No)
Pay Item 501 P6.7 Forming and sealing the joints between asphalt and concrete
pavements in metre (m)
Pay Item 501 P6.8 Cleaning of tie-bars and dowels in existing concrete pavement and
straightening tie-bars in existing concrete pavement in rehabilitation
work each number (No)
The unit of measurement for joints in the pavement shall be the metre of completed joint, except that dowel
bars and tie-bars across joints shall be measured separately by the numbers of each type installed.
Construction joints as such shall not be measured for payment and their cost shall be deemed to be included
in the rate tendered for the concrete pavement. However, if the position of a longitudinal construction joint
coincides with that of a hinge joint, the Contractor will be paid at the rate tendered for the type of hinge joint
replaced by the construction joint, provided that the requisite number and sizes of tie bars for the hinge joints
are installed. Where the hinge joint replaced by the construction joint is a sealed hinged joint, the
construction joint shall be sawn and sealed, in which case the Contractor will be paid at the tendered rate for
sawn and sealed hinge joints.
The tendered rates for expansion joints shall include full compensation for forming the joint complete with
joint filler, rounding or chamfering the corners (if required) and installing a compression seal.
The tendered rates for longitudinal hinge joints shall include full compensation for sawing the joint (if
required) and supplying and inserting the seal (if required).
The tendered rate for transverse contraction joints shall include full compensation for sawing the joint and
installing the specified type of seal, including appurtenant materials, and for temporarily sealing the joint with
paper rope.
The tendered rates for dowel bars and tie-bars shall include full compensation for supplying, cutting, placing,
holding the bars in position, including a supporting framework or cradles where required, and fixing the end
caps and bond breaking materials to dowels.
The tendered rate for forming and sealing the joints between asphalt and concrete pavements shall include
full compensation for supplying all the necessary plant and materials, for forming a joint to the required
dimensions in the asphalt seal, cleaning the joint and sealing it as specified in Pay Item 501P16.
Pay Item 501 P7: Drilling and testing of cores:
Pay Item 501 P7.1: 100 mm cores drilled from the pavement each number (No)
Concrete Pavement
Final November 2004
Page 501-32
Pay Item 501 P7.2: 150 mm cores drilled from the pavement and tested for compressive
strength each number (No)
The unit of measurement shall be the number of cores drilled or drilled and tested on the instruction of the
Engineer. Cores drilled by the Contractor at his own initiative as part of his process control or for testing
cracks sealed at the Contractor's own cost, will not be measured for payment.
The tendered rates shall include full compensation for drilling the test cores and, where applicable, having
them tested by an approved laboratory, and for all labour, transport, testing charges and other incidentals,
save only the cost of providing a core-drilling machine on the site, which is paid for separately. It shall also
include compensation for restoring the concrete pavement where holes were drilled.
Pay Item 501 P8: Steel reinforcement in concrete pavement:

Pay Item 501 P8.1: Mild steel bars in tonnes (t)
Pay Item 501 P8.2: High tensile steel bars in tonnes (t)
Pay Item 501 P8.3: Welded steel fabric in kilograms (kg)
The unit of measurement for steel bars shall be the tonne of reinforcing steel in place in accordance with the
drawings or as authorised.
The unit of measurement for welded steel fabric shall be the kilogram of welded steel fabric in place in the
special panels of concrete paving which require reinforcement, the quantity of which shall be calculated from
the area of the mesh used in accordance with the drawings or as authorised.
The tendered rates shall include full compensation for supplying, delivering, cutting, bending, welding,
placing and fixing the steel reinforcement, including all tying wires, spacers and waste.
Pay Item 501 P9: Removing existing concrete in rehabilitation work:
Pay Item 501 P9.1 Concrete without reinforcement in cubic metres (m3)
Pay Item 501 P9.2 Reinforced concrete in cubic metres (m3)
The unit of measurement shall be a cubic metre of concrete broken up and removed to approved spoil
dumps as specified. The quantity shall be determined in accordance with the authorized horizontal
dimensions and the average depth of the part removed.
The tendered rate shall include full compensation for breaking up the concrete, loading, transporting over a
free haul distance of 1.0 km, and placing it in approved spoil dumps. The tendered rate shall also include full
compensation for the protection of adjacent concrete and its repair should it be damaged.
Dowels and tie bars in existing concrete and stays used to keep the bars in position will not be regarded as
reinforcing.
Pay Item 501.P10: Sawing existing concrete in rehabilitation work
The unit of measurement shall be a square metre (m2) of saw-cut in the existing concrete as approved by
the Engineer and sawn to the required depth, measured once only irrespective of the number of times the
sawing has to be repeated to obtain such depth. The quantity shall be the product of the authorized length
and depth of the saw-cut.
The tendered rate shall include full compensation for demarking the saw line, providing and applying water
and other material, and for sawing the concrete to the satisfaction of the Engineer.
This item shall not apply to the sawing of joints.
Pay Item 501.P11: Removing existing pavement layers in rehabilitation work
Pay Item 501.P11.1: Uncemented material in cubic metres (m3)
Pay Item 501.P11.2: Cemented material in cubic metres (m3)
Pay Item 501.P11.3: Cemented crushed stone in cubic metres (m3)
The unit of measurement shall be a cubic metre of material excavated and removed. The quantity shall be
computed in accordance with the authorized dimensions for the excavation. The classification of the material
shall be made in accordance with the provisions of Division 203.
Concrete Pavement
Final November 2004
Page 501-33
The tendered rate shall include full compensation for excavating the material and disposing thereof to
approved spoil dumps.
Pay Item 501.P12: Recompaction of underlying pavement layers of gravel
The unit of measurement shall be a cubic metre (m3) of material reprocessed and compacted to required
density stated. The quantity shall be calculated in accordance with the authorised dimensions of the layer.
The tendered rate shall include full compensation for breaking up the layer, watering, mixing, compacting
and finishing, and preparing the layer for placing the concrete.
Pay Item 501.P13: Rehabilitation work-reconstructing underlying pavement layers with
Pay Item 501.P13.1 Gravel material in cubic metres (m3)
Pay Item 501.P13.2 Crushed stone in cubic metres (m3)
Pay Item 501.P13.3 Asphalt in cubic metres (m3)
The unit of measurement shall be a cubic metre of underlying pavement layer reconstructed. The quantity
shall be computed in accordance with the authorised dimensions.
The tendered rate shall include full compensation for procuring transporting and placing the material, and
preparing the layer for placing the concrete.
Pay Item 501P 14: Extra over item Pay Item 501P13 for stabilisation of underlying pavement layers
under reconstruction:
Pay Item 501.P14.1: Chemical stabilisation of gravel layers in cubic metre (m3)
Pay Item 501.P14.2: Chemical stabilisation of crushed-stone layers in cubic metre (m3)
Pay Item 501.P14.3: Bituminous stabilisation of crushed-stone layers in cubic metre (m3)
The tendered rate shall include full compensation for the additional costs for stabilising the material,
including mixing the material and the stabilising agent in the plant, curing the layer, and providing the water
and the curing agent. The provision of the stabilising agent will be paid for separately under Pay Item
501P15.
Pay Item 501P15: Stabilising agents applied in rehabilitation work:
Pay Item 501P15.1: Ordinary Portland cement in tonnes (t)
Pay Item 501P15.2: Anionic stable grade bitumen emulsion (60% net bitumen) in litres (L)
Pay Item 501P15.3: Other chemical stabilising agents (type indicated) in tonnes (t)
Pay Item 501P15.4: Other bituminous stabilising agents (type and grade stated) in litres
(L)
Pay Item 501P16: Preparing the underlying layers after the concrete has been removed in
rehabilitation work:
Pay Item 501 P16.1: Cemented gravel or crushed-stone layer in square metres (m2)
Pay Item 501 P16.2: Uncemented crushed-stone layer in square metres (m2)
Pay Item 501 P16 2: Asphalt sub-base in square metres (m2)
The unit of measurement shall be a square metre of existing underlying layer prepared in accordance with
the requirements of Division 302. The quantity will be computed in accordance with the authorized
dimensions of the prepared layer.
The tendered rate shall include full compensation for preparing the layer in accordance with the specified
requirements, testing for level, cleaning the edge of the existing concrete, providing and applying water, and
for removing any remaining loose material and waste.
Separate payment will be made for providing and placing asphalt and slurry.
This item shall not apply to reconstructed or reprocessed layers.
Pay Item 501 P17: Retexturing existing concrete pavement in rehabilitation work
Concrete Pavement
Final November 2004
Page 501-34
The unit of measurement shall be a square metre (m2) of existing concrete pavement, which has been
retextured.
The tendered rate shall include full compensation for all equipment, labour and material required for
executing the work, complete as specified.
Pay Item 501 P18: Repairing joints and cracks in existing concrete pavement in rehabilitation work:
Pay Item 501 P18 1: Joints in metres (m)
Pay Item 501 P18.2: Cracks in metres (m)
The unit of measurement shall be a metre of joint or crack actually repaired on the instruction of the
Engineer and in accordance with the requirements of the project specifications.
The tendered rate shall include full compensation for procuring, providing and applying all material, and for
repairing, complete as specified. Payment shall distinguish between various types and sizes of joints and
cracks.
Pay Item 501 P19: Drilling and placing dowels and tie bars in existing concrete in rehabilitation
work:
Pay Item 501 P19 1: Dowels each number (No)
Pay Item 501 P19.2: Tie bars each number (No)
The unit of measurement shall be the number of bars placed in existing concrete at the joints with new
concrete.
The tendered rate shall include full compensation for providing all materials, cutting the bars, drilling the
holes in the existing concrete, placing and fixing the bars with epoxy, and treating the sliding ends of the
dowels, complete as specified.
Pay Item 501 P20: Re-treating existing dowels:
Pay Item 501 P20 1 Sliding end in existing concrete each number (No)
Pay Item 501 P 20 2 Sliding end in new concrete each number (No)
The unit of measurement shall be the number of bars re- treated.
The tendered rate shall include full compensation for cleaning and re-treating the bars as specified and to
the satisfaction of the Engineer.

Concrete Pavement
Final November 2004
Page 501-35

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Section 500

501 CONCRETE PAVEMENTS ............................................................................................................ 501-1

501.17.3 Non-conforming Work - Removal of Non-conforming Concrete................................... 501-29

Standard Specification for AACRA Road & Bridge Works

501 CONCRETE PAVEMENTS

Gradation of Fine Aggregate AACRA Test A-5

Gradation of Fine Aggregate AACRA Test A-5

501.5.2 Trial Batches

Test results for soluble salt content.

501.6 Reinforcement, Tie Bars and Dowels

Standard Specification for AACRA Road & Bridge Works

501.7 Joint Fillers

(a) Preformed Elastomeric Joint Sealer:

Additional deflection Requirement for preformed elastomeric joint sealer

501.8 Curing Materials

501.9 Field Material Tests

Standard Specification for AACRA Road & Bridge Works

501.10.2 Sub-Base Planer

501.10.3 Batching Plant & Equipment

501.10.5 Transporting Vehicles

501.10.6 Slip-Form Paver

501.10.7 Concrete Spreaders

(a) Forms shall be free of warps, bends or kinks;

501.10.9 Finishing Equipment

501.10.10 Transverse Groover

501.10.11 Curing Membrane Spray Equipment

501.10.12 Rain Protection

Standard Specification for AACRA Road & Bridge Works

501.10.13 Concrete Saws

501.10.14 Miscellaneous Equipment

501.11 Construction Requirements

501.11.2 Conditioning of Sub-Base or Base Course

501.11.3 Slip-Form Paving

Standard Specification for AACRA Road & Bridge Works

501.11.4 Fixed Form Paving

501.11.5 Construction of Irregular Areas

501.11.6 Handling, Measuring and Batching Materials for Concrete

Standard Specification for AACRA Road & Bridge Works

Hold Point 501.1

Process Held: Production of concrete for concrete paving.

501.11.7 Weather and Lighting Conditions

501.11.8 Mixing Concrete

(a) Central mix plant.

Standard Specification for AACRA Road & Bridge Works

501.11.9 Placing Steel

Standard Specification for AACRA Road & Bridge Works

(ii) For all bars, after construction of the slab:

Standard Specification for AACRA Road & Bridge Works

Hold Point 501.3

Process Held: Placement of Reinforcement

501.11.10 Placing Concrete

(a) Procedures for Placing:

Time Between Mixing and Completion of Concrete Pavement Slabs

Hold Point 501-3

Process Held: Placement of concrete paving.

Standard Specification for AACRA Road & Bridge Works

(c) Longitudinal Joints

Standard Specification for AACRA Road & Bridge Works

Standard Specification for AACRA Road & Bridge Works

(h) Expansion Joints.

Sampling and Testing

Standard Specification for AACRA Road & Bridge Works