2004 Specifications CSJ 0196-02-120 SPECIAL SPECIFICATION 2042 Decorative Colored Pattern Concrete Paving 1. Description. This Item shall govern for the furnishing and placing of colored concrete wave pattern pavement in accordance with the details shown on the plans and the requirements of these specifications. An Integral color admixture will be used to color the large wave pattern colors. An integral color admixture will be incorporated into concrete with Dry Shake Color Hardener to create additional colors in the small wave pavement pattern as indicated on drawings. The colored paving shall be broom finished as approved by Engineer from mockup review. Concrete tooled jointing will be used to separate adjacent colors. 2. Quality Assurance. Installer of the Colored Pattern Concrete Pavement shall have the minimum following qualifications: (1) Provide Experienced On-Site Supervision. The installer shall provide a qualified foreman or supervisor who has a minimum of three years experience with stamped or imprint textured colored concrete and who has successfully completed at least five stamped or imprint textured colored concrete installations of high quality and similar in scope to this project, using the stamp and color system proposed for this project. (2) Provide Certified Licensed Contractor. The installer shall provide cast-in-place concrete on the job site by trained and experienced workmen who have a minimum of three years experience with stamped or imprint textured colored concrete and who have successfully completed at least five colored concrete installations of high quality and similar in scope to this project, using the color system proposed for this project (3) Perform Work According to ACI. Perform work in accordance with ACI 301, 302, 303. (4) Provide Same Source Materials. Obtain materials from same source throughout colored concrete installation. (5) Follow Applicable Department Regulations. Conform to applicable codes and regulation for paving work performed within the public right-of-way. 3. Materials. All materials shall conform to the respective requirements of Items 420, Concrete Structures ; 421, Hydraulic Cement Concrete and DMS-4640, Chemical Admixtures for Concrete with the following exceptions: (1) Cement. Portland cement shall be Type 1. The same brand and source shall be used throughout the structure. (2) Coarse Aggregate. The coarse aggregate shall consist of durable particles of natural or crushed gravel and shall conform to Item 421, Hydraulic Cement Concrete. 1-5 2042
If utilizing integral color admixture, aggregate must be non-reactive. Gradation for coarse aggregate shall be as shown on the plans. (3) Fine Aggregate. Fine aggregate shall consist of clean, hard, durable and non-coated particles of natural or manufactured sand or a combination thereof, with or without mineral filler and shall conform to Item 421, Hydraulic Cement Concrete. If utilizing integral color admixture, aggregate must be non-reactive. Gradation for fine aggregate shall be approved by the Engineer. (4) Concrete. The concrete shall be Class A. An air entraining agent and/or a Type A water-reducing or a Type D water-reducing retarding admixture complying with DMS- 4640, Chemical Admixtures for Concrete may be used. Add integral color admixture in quantities recommended by coloring admixture manufacturer to achieve selected color. The concrete shall not contain any admixture or additive that contains calcium chloride. Provide a 3 minimum to 5 maximum slump mix. Add polypropylene fiber reinforcement at point of concrete batching and at manufacturer recommended quantity. Strength specimens shall be made, cured and tested in accordance with Test Method Tex-448-A. (5) Fiber Reinforcement. ASTM C948, collated, fibrillated 3/4 inch (19mm) long virgin polypropylene fibers. (6) Integral Color Admixture. Color admixture shall be a single-component, colored, water-reducing, set-controlling admixture, factory formulated and packaged in cubic yard dosage increments, not multiple additives and pigments added separately into the mix. Color admixture shall conform to ASTM 979. One (1) color as shown on the drawings. (7) Color Hardener. Commercially manufactured pigmented dry-shake color hardeners, or equal are to be used. Three (3) colors as shown on the drawings. (8) Curing Agent. As recommended by color manufacturer. Water based emulsion color cure complying with ASTM 309 as a curing membrane and with all applicable air pollution regulations is to be used. (9) Sealing Agent. Water based concrete and masonry sealer, single component, epoxymodified, penetrating type. VOC, EPA, OSHA and FDA compliant. VOC shall be less than 130 grams/liter. Skid resistance shall conform to ASTM C 1028-89 requirements. Product is to dry clear with a satin sheen to a semi-gloss. (10) Wave Jointing Tools. 1/8 x 4 minimum height flexible plastic strips for creating variable, smooth radius S -curve wave joint lines for tooling. (11) Joint Filler. Asphalt impregnated fiberboard, ASTM D1751, 1/2 inch (12mm) thick. (12) Joint Backer Rod. Extruded, molded closed cell neoprene foam rod. (13) Joint Sealant. Two part polyurethane sealant, urethane, SL grade. Color: from manufacturer s full range. One sealant color for each concrete color. 2-5 2042
(14) Bonding Agent. ASTM C1059, Type II, non-redispersible, acrylic emulsion or styrene butadiene rubber. (15) Epoxy-Bonding Adhesive. ASTM C881, two component epoxy resin, capable of humid curing and bonding to damp surface, of class and grade to suit requirements. Types I and II, non-load bearing, for bonding hardened freshly poured concrete to hardened concrete. 4. Contractor-Provided Pre-Construction Test Specimen and Mock-Ups. The Contractor shall supply a 1 yard square minimum (approximately 3 in. thick) test specimen of each color, showing each color, joint type, pattern, and texture to be duplicated in the field for approval by the Engineer prior to beginning work on the mock-ups. After approval of the test specimen, provide two full wave pattern pavement mock-ups with surface colors, textures and patterns specified, for architect approval prior to beginning the work. Provide one mock-up in the pavement grid north of FM407 adjacent to the u-turn lane loop and one mock-up in the pavement grid south of FM407 adjacent to the u-turn lane loop. Remove test specimen from the project site after acceptance of the Mock-Ups. (1) Mock-Up Size. Provide one full 11 wide x 12-6 long section within the 4 wide concrete band grid shown on the drawings. (2) Mock-Up Revisions. The mock-ups are to be constructed as part of the finished work, to dimensions, textures, colors, joints and appearance as indicated on drawings. Refinish or remove and replace the mock-ups as required by the Engineer to produce acceptable work that will become the approved standard for workmanship, quality and appearance. (3) Purpose. The purpose of the contractor-provided mock-up wave pavement is to demonstrate the Contractor s ability to meet requirements for design dimensions, concrete form wave pattern jointing appearance and stamped colored finish uniformity, technique and coverage, and other work as described herein and shown in the plans. Approved contractor-provided pre-construction mock-up paving will become the Engineer s standard by which acceptability of the aesthetics of the general installation will be judged. All constructed work, including the variation of appearance between separate batches/pours of cast-in-place stamped colored concrete and between adjacent pavement waves, shall be within the color range specified. (4) Protect the Mock-Up. The Contractor shall be responsible for protection and maintenance of approved mock-up wave pavement examples throughout the duration of the Project, including repairing damages and refinishing to match condition of adjacent work. All mock-up paving shall meet the requirements, be constructed at the sole expense of the Contractor, and will remain the Contractor s property at the conclusion of the Project, unless accepted as finished work in place as designed. (5) Replace Damaged Mock-Ups. Immediately remove and replace all mock-up pavement that are damaged beyond the point of acceptable repair, in the opinion of the Engineer, until project completion and final project acceptance. 3-5 2042
(6) Inspection Conditions. The mock-ups and patches will be evaluated and inspected by the Engineer during dry daylight conditions at a distance of 10 feet following cleaning by the Contractor as necessary to remove dirt, debris and other contamination interfering with the ability to judge the acceptability of the aesthetics of the completed work. 5. Appearance and Finish. The constructed work will be compared with the approved mockup samples for conformance with the color and finish requirements of this specification. The Engineer will review for acceptance (in accordance with the requirements stated herein) of the uniformity in color, quality of surface finishes, and other appearance characteristics of the completed concrete work. (1) Work that fails to meet the Contract requirements and is inadequate to serve the design purpose, including appearance qualities specified in this Special Specification, will be considered defective and a default by the Contractor under the Contract, and the Engineer may require the correction of removal and replacement at the Contractor s expense. Decisions regarding defective work will be made by the Engineer. (2) Finish all exposed surfaces with a mild detergent, light broom scrub and light power wash cleaning or other method as shown on the plans or approved by the Engineer prior to their evaluations. Multiple cleanings may be required to achieve acceptable results. 6. Construction Methods. Any required excavation and backfill shall be done in accordance with Item 400 Excavation and Backfill for Structures, except for measurement and payment, and/or in accordance with Items 110 Excavation, and 132 Embankment. The Contractor shall supply a 1 yard square minimum (approximately 3 in. thick) test specimen showing each color, pattern, and texture to be duplicated in the field for approval by the Engineer prior to beginning work on the mock-ups. (1) When utilizing integral color admixture, good batch to batch uniformity shall be maintained. The same brand of cement, source of sand, and water/cement ratio should be maintained for each load of concrete of the same color. After adding color, mixer should operate at mixing speed for at least 10 min. Concrete should be placed when weather conditions can remain constant throughout pour and finishing operations. (2) Stop concrete pours intentionally at plan locations of expansion joints or construction joints only. Provide sealed expansion joints with joint filler along walls, along curbs, around columns, and where shown on plans. When stopping concrete pour at construction joints, install sheet metal joint assembly of sufficient section to prevent deflection. Provide tooled construction joints, scored to a minimum depth of ¼ of slab thickness and at intervals indicated. Seal all expansion and joints. (3) The concrete mix shall be placed and screeded to the proper grade and wood floated to a uniform surface in the normal manner. (4) The colored hardener, where utilized, shall be applied evenly to the plastic surface by the dry-shake method using a minimum of 65 lb. per 12 sq. yd. It shall be applied in 2 separate applications, wood floated after each application, and troweled only after the final floating. 4-5 2042
(5) While the concrete is still in the plastic stage of set, using special forming tools approved by the Engineer, the concrete shall be tooled and finished to create the surface as shown on the plans and as approved by the Engineer. (6) The colored curing and finishing compound used shall be thinned and applied in accordance with manufacturer's directions. The coverage shall be approximately 600-650 sq. ft. per gal. Plastic sheeting shall not be used. 7. Measurement. This Item will be measured by the square yard of the thickness specified using the dimensions shown on the plans. This is a plans quantity measurement Item and the quantity to be paid for will be that quantity shown in the proposal and on the Estimate and Quantity sheet of the contract plans, except as may be modified by Article 9.8. If no adjustment of quantities is required, additional measurements or calculations will not be required. 8. Payment. The work performed and materials furnished in accordance with this Item and measured as provided under Measurement will be paid for at the unit price bid for Colored Textured Concrete of the type and thickness specified. This price shall be full compensation for furnishing, placing, jointing, finishing, curing, cleaning and sealing of the colored pattern concrete. The preparation of the test specimen and mock-ups described in this specification will not be paid for directly and shall be considered subsidiary to the appropriate bid item. The above payment shall be full compensation for all materials, tools, labor, equipment and incidentals necessary to complete the work. Compacted Subgrade and base required for the stamped colored concrete will not be paid directly but will be subsidiary to this item. The Engineer reserves the right to require complete removal and replacement of concrete that does not conform to the approved contractor-provider mock-up panels. Removal and replacement of work rejected will be at the Contractor s sole expense. 5-5 2042