2544.01 DESCRIPTION.
This work is for cleaning and filling cracks in an existing pavement or paved shoulder. It involves filling large cracks and spalled areas with HMA and filling smaller cracks with filler material. This type of work is intended primarily for existing pavements that are not to be resurfaced. If additional work is to be required, it will be defined elsewhere in the contract documents.

2544.02 MATERIALS.
HMA mixture shall be a hot mixture meeting requirements of Section 2203 for a 3/4 inch, 1/2 inch or 3/8 inch (19 mm, 12.5 mm or 9.5 mm) mixture size, or a similar mixture from a commercial source subject to approval of the Engineer. A high performance bituminous cold premix mixture may be used with approval of the Engineer. The Engineer's approval of the use of a premix will be based on the availability of the specified hot mixture when this work is being done and the length of haul.

Tack-coat material shall be SS-1, SS-1H, CSS-1, CSS-1H, and MC-70 meeting requirements of Section 4138 or 4140. Mixing of CSS and SS grades will not be permitted. Emulsion shall be used as the tack-coat bitumen prior to October 1. For Fall work after that date, a cutback asphalt may be used.

Filler material shall be emulsified asphalt meeting the following requirements for CRS-2P or CRS-2 and be of the quality to also be used for seal coat construction.

A. Polymer-Modified Cationic Rapid Set Asphalt Emulsion, CRS-2P.
This bituminous material shall be a rapid set emulsion that has elastic properties.

B. Cationic Rapid Set Asphalt Emulsion, CRS-2.
This bituminous material shall have the properties of rapid set emulsion.

C. Requirements.
The CRS-2P and CRS-2 emulsions shall comply with Section 4140.

Blotting material shall be a sand meeting requirements of Section 4124 or Section 4125, or a similar sand approved by the Engineer.

2544.03 EQUIPMENT.
Equipment shall include the following:

A. Water cleaning equipment capable of delivering water with a pressure of 2,000 psi (13.8 MPa) from a nozzle to the crack being cleaned.

B. Compressed air capable of providing moisture free and oil free air to blow sand and other foreign material from a crack.

C. Air chisel or hand tools to remove loose and spalled material adjacent to cracks.

D. Heating kettle or pressure distributor for applying filler material through a hand-operated wand or nozzle.

2544.04 CLEANING AND FILLING.
Cleaning shall be done with either a high-pressure air or with water equipment, except water blasting equipment will not be allowed when the temperature is below 32°F (0°C). In all cases, cleaning shall include removal of vegetation from the cracks. Cleaning methods other than those specified in this specification may be necessary to remove vegetation. Other methods shall be subject to approval of the Engineer.

When specifically required by the plans, a soil sterilant, such as Spike or an approved equal, shall be placed in the crack prior to placing the filler material.

For filling cracks, a hand-operated wand or pouring pot shall be used, which is capable of placing the filler material into the crack and filling to the adjacent surface. The nozzle or spout shall be small enough to place the filler material into the crack without soiling the adjacent surface.

All cracks filled with emulsion shall be tightly squeegeed with a narrow, 2 inch (50 mm) or less, V-shaped, rubber-edged squeegee, immediately after placement of the filler. Measures shall be taken to hold the filler in place, preventing run-out at pavement or shoulder edges and low areas; this may be done by use of a sand dam or an application of blotter material, in conjunction with the squeegee operation.

A. For cracks wider than 1 inch (25 mm), the Contractor shall remove all loose and spalled material from 1 inch (25 mm) within the opening and adjacent to the opening of cracks. The Contractor shall clean these cracks with high-pressure water, blow free of water, tack, and then fill with hot mix. Loose and spalled material shall be removed with an air chisel, picks, or other hand tools.

The cracks shall be cleaned of loose and spalled material, old crack filler when deemed necessary by the Engineer, sand, and other foreign debris by the use of high-pressure water. Cleaning shall continue until essentially all debris and loose materials have been removed to a depth of 3 inches (75 mm) within the crack opening.

The cleaned cracks shall be blown free of water.

The crack surfaces shall be lightly tacked with tack-coat material as a hand operation.

The cracks shall be filled with the hot mix specified, rodded and tamped into place and leveled with the adjacent surface. The mixture shall be warm and pliable when placed. This mixture shall be placed prior to filling cracks with emulsion. A thin application of emulsion shall be placed over the hot mix and tightly squeegeed.

B. Cracks 1/4 inch to 1 inch (5 mm to 25 mm) in width shall be cleaned with air pressure or high-pressure water sufficient to remove old crack filler, sand, and other foreign debris when required by the Engineer. The depth of cleaning shall be at least 1 inch (25 mm). The depth shall be to sound material, but a depth greater than 3 inches (75 mm) will not be required.

Cracks shall be filled with emulsion filler material. A hand-operated wand shall be used which is capable of placing the filler material into the crack and filling it to the adjacent surface. The nozzle attached to the wand shall be small enough to place filler material into the crack without soiling the adjacent surface.

C. Cracks less than 1/4 inch (5 mm) shall be cleaned sufficiently to remove old crack filler when deemed necessary by the Engineer, sand, and other foreign debris.

Cracks shall be filled with emulsion filler material.

D. Map-cracked areas shall be covered with emulsion filler material with a suitable hand-operated squeegee.

The filler material shall be a thin, smooth application.

The filler material shall be promptly blotted with a light application of blotter material.

2544.05 LIMITATIONS.
On projects where a fog seal or other surface treatment is to be done in conjunction with this work, the crack filling shall be done first. Except when this work is in preparation for a seal coat or slurry seal, crack filling will not be allowed on pavements from May 15 to September 30. Crack filling on paved shoulders will be allowed during this time.

When filling cracks with emulsion, sufficient time shall be allowed for the emulsion to flow to the bottom of the crack and to fill it completely full. In filling, a second pass may be necessary before leaving the work zone.

One additional filling, or refilling, will be necessary where the filler has settled into the crack opening. These areas will be identified by the Engineer.

The cleaned cracks need not be filled the same day they are cleaned. However, at the time of filling, cracks shall be free of standing water as determined by visual examination. Recleaning may be necessary if the openings become contaminated before being filled. The work may be done as a single, coordinated operation.

The work shall be conducted on only one lane of the pavement at a time, and in accordance with the traffic control plan and Article 1107.09. Use of a pilot car may be required.

Traffic shall be permitted to use the pavement during this construction, and all operations shall be so conducted as to provide a minimum of inconvenience to traffic.

Articles 1107.08, 1107.09, and 1108.03 shall apply.

2544.06 METHOD OF MEASUREMENT.
The Engineer will measure the work of maintenance cleaning and filling cracks, satisfactorily completed as follows:

A. Cleaning and Filling Cracks.

1. Pavement Maintenance.
The Engineer will calculate the number of miles (kilometers) of main line pavement on which cracks were cleaned and filled to the nearest 0.1 mile (0.1 km). The calculations will be based on the center line distance of main line, two-lane pavement, corrected for main line pavement of more than two lanes, including climbing lanes. At intersections, rest areas, and interchanges designated for cleaning and filling, the additional areas of widened pavement, ramps, storage lanes, turning lanes, paved medians, and parking in rest areas will not be separately measured for pavement.

2. Shoulder Maintenance.
The Engineer will calculate the number of miles (kilometers) of paved shoulders on which cracks were cleaned and filled to the nearest 0.1 mile (0.1 km). The calculations will be based on the center line distance of the adjacent main line pavement, a single measurement for shoulders on both sides of the pavement. At intersections, rest areas, and interchanges designated to be cleaned and filled, the additional areas of paved shoulders on ramps, gores, and turning lanes will not be measured separately for payment.

Between limits for which cleaning and filling is intended for either pavement or shoulders, no deductions will be made for bridges, intersections, or other interruptions where cracks are not to be cleaned and filled.

B. Hot Mix Asphalt for Crack Filling.
The Engineer will determine the weight (mass) of hot mixture used for filling cracks larger than 1 inch (25 mm), based on actual weight (mass). Mixture not used in the work will be deducted, based on actual scaled weights (mass) or estimates.

C. Filler Material (Maintenance).
The Engineer will compute the volume of filler material placed, using the method described in Article 2307.06, B. The total quantity will include the material placed in cracks and used to cover map-cracked areas.

Blotting material and tack-coat material will not be measured separately for payment.

2544.07 BASIS OF PAYMENT.
For the work of cleaning and filling cracks, the Contractor will be paid as follows:

A. Cleaning and Filling Cracks (Pavement Maintenance) or (Shoulder Maintenance).
For the number of miles (kilometers) of pavement or shoulders on which the cracks were cleaned and filled, the Contractor will be paid the contract unit price per mile (kilometer).

B. Hot Mix Asphalt for Crack Filling.
For the number of tons (megagrams) of HMA used in filling cracks over 1 inch (25 mm), the Contractor will be paid the contract unit price per ton (megagram).

C. Filler Material (Maintenance).
For the number of gallons (liters) of filler material placed in cracks and joints, the Contractor will be paid the contract unit price per gallon (liter).

These payments shall be considered full compensation for cleaning the cracks, furnishing and placing the HMA, filler material, all blotting material, and tack-coat material that is necessary, and for furnishing all equipment and labor therefor, in accordance with the contract documents.