2542.01 DESCRIPTION.
This work shall consist of routing or sawing and cleaning of random cracks and existing transverse and longitudinal joints in PCC pavement and sealing the prepared cracks and joints with an approved sealing material.

Crack and joint cleaning and sealing is intended to address longitudinal cracking, transverse cracking, and corner breaks. Crack and Joint cleaning and sealing is not intended to clean or seal durability (“D”) cracking or map cracking. Definitions for these pavement distress types can be found in the ‘Distress Identification Manual for the Long-Term Pavement Performance Program’ (Publication No. FHWA-RD-03-031, dated June 2003, web address: http://www.tfhrc.gov/pavement/ltpp/reports/03031/03031.pdf).

2542.02 MATERIALS.
Hot poured joint sealer and backer rod shall meet requirements of Article 4136.02. Installation of preformed elastomeric joint seals meeting the requirements of Article 4136.02 may be required in the contract documents. Substitution of elastomeric joint seal material for poured joint sealer material will not be allowed unless otherwise specified in the contract documents.

2542.03 EQUIPMENT.

A. Routing or Sawing Equipment.
Routing or sawing equipment, where required, shall be power driven, capable of cutting the cracks to the required dimensions without excessive spalling of the adjacent surface.

Sawing equipment, where required, shall be power driven (wet or dry) capable of sawing the sealant reservoir to the dimensions shown in the contract documents.

B. Water and Abrasive Blasting Cleaning Equipment.
Water cleaning equipment shall be capable of delivering water with a pressure of 2,000 psi (13.8 MPa) from a nozzle to the crack or joint being cleaned, to remove existing joint sealer, debris, and loose material from the crack or joint.

Abrasive blast equipment shall be capable of removing the existing sealant, saw slurry, silt, or other foreign material from the vertical face of the crack or joint to the specified depth, leaving a clean, dry, newly exposed concrete surface.

C. Air Compressors.
Air compressors shall provide moisture and oil free air and shall be of sufficient size to blow sand and other foreign material from the crack or joint prior to placing the sealant material.

D. Equipment for Heating and Placing Sealant Material.
Equipment used for heating and placing hot pour sealant material shall be an oil jacketed, double boiler type, heating kettle or other thermostatically controlled equipment of a type approved by the Engineer, capable of heating the material to 400°F (205°C) and pumping the material into the prepared crack or joint.

E. Auxiliary Equipment.
Auxiliary equipment, such as brooms, scrapers, etc., shall be provided as necessary to perform the work.

2542.04 CONSTRUCTION.
A partial depth finish patch may be required when joints or cracks have edge spalls or other distress greater than 3 inches (75 mm) in width. If not otherwise included as part of the contract work, these areas will be designated by the Engineer as extra work. Partial depth finish patches shall be constructed in accordance with Section 2530. Joints or cracks less than or equal to 3 inches (75 mm) in width shall be sealed without patching.

Cracks and joints shall be cleaned of existing joint sealer, vegetation, dirt, and all other foreign material to the depth of the bottom of the backer rod. The edges shall be sand blasted throughout the proposed depth of the joint sealer, leaving a clean, dry, newly exposed concrete surface on the vertical edges. The angle of approach of the sand blast nozzle to each vertical face of the reservoir shall be approximately 30 degrees and the sand blast nozzle must have a guide which inserts in the joint and assures positive location and directional control of the nozzle. This will require two passes of the sand blasting operation for each joint and crack; one pass for each joint or crack edge. Sand blasting shall be done just prior to the application of the joint sealer. When cleaned joints or cracks are contaminated before being sealed, they shall be recleaned by sand blast before sealing. Rain will be considered contamination.

The bond breaker at the bottom of the joint or crack shall be a backer rod. It shall be dry when installed. If the width of opening exceeds the maximum size available, approved alternates of bond breakers at the bottom of the crack or joint may be used.

Cracks and joints in partial depth HMA finish patches shall be widened to 1/2 inch (13 mm), if widening is necessary, and the cleaning and sealing operation shall be extended across the joint or crack.

Joints and cracks shall be dry and blown clean with compressed air prior to placing the backer rod and joint sealer. Joints and cracks shall be filled to the level shown in the contract documents.

Sealer material shall be heated, handled, and applied according to the manufacturer's recommendations.

Cracks and joints which have an average opening of 3/8 inch (10 mm) or less shall be routed or sawed to provide a minimum sealant reservoir of 3/8 inch (10 mm) with by a nominal 1/2 inch (13 mm) depth. Backer rod shall be used for cracks and joints greater than 3/8 inch (10 mm) width. The backer rod, when required, shall be placed in the cracks and joints to a depth that will provide at least 5/8 inch (16 mm) clearance above the backer rod for the sealer. Cracks shall be cleaned of all foreign material to a depth necessary to accommodate the sealer material and the backer rod to be used. The backer rod shall be dry when placed.

2542.05 TRAFFIC CONTROL.
When there is a separate item for traffic control, all signs and traffic control devices, such as flaggers, barricades, traffic cones, warning lights, and pilot car signs (when required) shall be furnished by the Contractor in accordance with Section 2528. All traffic control devices are to be erected, maintained, and removed by the Contractor.

The work shall be conducted on only one lane of the pavement width at a time. When work encroaches on an adjacent lane, a flagger will be required at that location.

Articles 1107.08, 1107.09, and 1108.03 shall apply.

2542.06 LIMITATIONS.
When other work is included in the contract, the operations shall be sequenced so that undersealing, longitudinal subdrains, patching, grinding or milling, installation of retrofit load transfer, grinding or milling, and crack and joint sealing are done in the area in that order.

Joint and crack sealing shall be performed only when the ambient air and pavement surface temperatures are above 40°F (4°C). When near this minimum temperature, additional air blasting or drying time or both may be necessary to assure a satisfactory bond to the joint surfaces.

Lanes may be opened to traffic only after the sealer has set sufficiently so it will not pick up under traffic. Blotting material may be applied to the sealer, but only after the sealer surface has set so as to avoid penetration of the blotting material into the sealer. Old sealant, other debris, and saw slurry shall be removed from the pavement surface before the pavement is opened to traffic. Dry sawed or routed joints or cracks shall be cleaned with a stream of air sufficient to remove all dirt, dust, and deleterious material that can adhere to the joint face before the pavement is opened to traffic. This work shall be done within 3 hours after the joint or crack has been dry sawed or routed. Wet sawed joints shall be cleaned with high pressure water immediately after sawing to remove residue produced by the sawing operation.

Joints and cracks shall be sealed within 5 working days after completion of any sawing or routing or removing old joint sealant material or debris from the crack or joint.

Crack and joint sealing after September 30 will not be allowed. When joint sealer cannot be placed in an otherwise completed joint or crack prior to this date due to temperature or other conditions, the Contractor shall temporarily seal these joints or cracks with a joint sealer over the winter shutdown period. This shall be removed, and the joint or crack shall be recleaned and resealed according to this specification at the Contractor's expense during the next construction season.

Overfilling with sealant will not be allowed. Sealant placed on the pavement surface shall be removed immediately.

2542.07 METHOD OF MEASUREMENT.

A. Crack and Joint Cleaning and Sealing (PCC Pavement)
The Engineer will calculate the number of miles (kilometers) of main line pavement and shoulders on which cracks and joints were cleaned and sealed 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 sealing, the additional areas of widened pavement, ramps, storage lanes, turning lanes, paved medians, and parking in rest areas will not be separately measured for payment. Between limits for which cleaning and sealing is intended for either pavement or shoulders, no deductions will be made for bridges, intersections, or other interruptions where cracks or joints are not to be cleaned and sealed.

Shoulders 4 feet (1.2 meters) or less in width will not be measured separately for payment.

B. Sealer Material (PCC Pavement)
The Engineer will measure in pounds (kilograms) the amount of sealer material used in cracks and joints.

2542.08 BASIS OF PAYMENT.

A. Crack and Joint Cleaning and Sealing (PCC Pavement)
For the number of miles (kilometers) of pavement or shoulders on which the cracks and joints were cleaned and sealed, the Contractor will be paid the contract unit price per mile (kilometer). This payment shall be considered full compensation for all labor, equipment, and materials (except for sealer, but including backer rod) for cleaning and sealing cracks and joints. Shoulders 4 feet (1.2 meters) or less in width shall be considered incidental to the price bid for Crack and Joint Cleaning and Sealing (PCC Pavement).

B. Sealer Material (PCC Pavement).
For the number of pounds (kilograms) measured, the Contractor will be paid the predetermined contract unit price per pound (kilogram). This payment shall be full compensation for furnishing the sealer material only.

If not otherwise included as part of the contract work, partial depth finish patches designated by the Engineer will be paid for as extra work in accordance with Article 1109.03, B.