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> **The following is an optional specification that can be used for long
> performance joint seals in concrete pavements:**

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### **ITEM P-604 COMPRESSION JOINT SEALS FOR CONCRETE PAVEMENTS**

DESCRIPTION

**604-1.1** This item shall consist of preformed polychloroprene
compression seals used for sealing joints of rigid pavements.

MATERIALS

**604-2.1 PREFORMED SEALS.** Preformed joint seal materials shall be a
vulcanized elastomeric compound using polychloroprene as the only base
polymer. The material and the manufactured seal itself shall conform to
ASTM D 2628 and CRD C 548. The joint seal shall be a labyrinth type seal
with the uncompressed depth of the seal greater than the uncompressed
width of the seal, \[except that for seals 1 inch or greater in width,
the depth need be only 1 inch or greater\]. The actual width of the
uncompressed seal shall be 13/16 inch or 1 inch \[or \_\_\_\_\_ \]
within a tolerance of plus 1/8 inch and minus 1/16 inch.

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> **In paragraph 604-2.1, the actual width of the joint seal should be
> 13/16 inch or 1 inch at the option of the Contractor. However, for
> unusual circumstances or for resealing joints in existing pavement
> that have to be sawed out to an extra width a wider seal should be
> specified. 1 inch should be used for slab greater that 20 feet and
> less that 25 foot.**

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**604-2.2 LUBRICANT/ADHESIVE.** Lubricant/adhesive used for the
preformed elastomeric joint seal shall be a one-component compound
conforming to ASTM D 2835.

**604-2.3 DELIVERY AND STORAGE.** Materials delivered to the job site
shall be inspected for defects, unloaded, and stored with a minimum of
handling to avoid damage. Storage facilities shall be provided at the
job site to protect materials from weather and to maintain them at
temperatures as recommended by the manufacturer.

**604-2.4 submittals.** Certified copies of test results shall be
provided \[\_\_\_\_\_\] days prior to use of material on the project.

**a. Construction Equipment List.** List of proposed equipment to be
used in the performance of construction work, including descriptive data
shall be provided to the engineer \[\_\_\_\_\_\_\] days prior to use on
the project.

**b. Manufacturer\'s Instructions.** Where installation procedures, or
any part thereof, are required to be in accordance with the
manufacturer\'s recommendations, printed copies of theses
recommendations shall be furnished to the engineer \[\_\_\_\_\_\] days
prior to use on the project. Installation of the material will not be
allowed until the recommendations are received. Failure to furnish these
recommendations can be a cause for rejection of the material.

**c. Samples.** Regardless of testing responsibility, samples of the
materials shall be submitted by the contractor to the engineer for
written approval \[\_\_\_\_\_\_\] days prior to use on the project.
Written or printed directions from the manufacturer giving recommended
criteria for installation shall be furnished to the engineer at the same
time, plus certification from the manufacturer that the seal selected is
recommend for the installation involved on this project. No material
will be allowed to be used until it has been approved.

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> **The blank spaces for testing the materials will be filled in to
> allow ample time for sampling, testing, and shipping to the project.
> Normally, this will require a minimum of 60 days.**
>
> **For the following paragraph optional wording is in brackets:
> Designer should select the applicable statement for testing and
> determining specification compliance and delete the inapplicable
> statement. The first statement will be selected for all projects
> except where the project is less than 4,000 linear feet of preformed
> joint seal material. When the project requires less than 4,000 linear
> feet of preformed joint seal material, the first statement can be
> deleted and the second statement used.**

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**604-2.5 TEST REQUIREMENTS.** Each lot of preformed joint seal and
lubricant/adhesive produced for this project shall be sampled,
adequately identified, and tested for conformance with the referenced
applicable material specification. A lot of preformed seal shall consist
of one day\'s production or 20,000 linear feet for each cross section,
whichever is less. A lot of lubricant/adhesive shall consist of one
day\'s production. \[Samples of the preformed joint seal and
lubricant/adhesive material shall be submitted and will be tested by the
Engineer. No material shall be used at the project prior to receipt of
written notice that the materials meet the laboratory requirements. The
cost of testing the samples from each original lot supplied will be
borne by the Engineer. If the sample fails to meet specification
requirements, the materials represented by the sample shall be replaced
and the new materials tested. A cost of \[\_\_\_\_\_\_\] for Engineer
testing of each lot of replacement material will be charged to the
Contractor.\] \[Testing of the preformed joint and lubricant/adhesive
material shall be the responsibility of the Contractor and shall be
performed in an approved independent laboratory and certified copies of
the test reports shall be submitted for approval \[\_\_\_\_\_\] days
prior to the use of the materials at the job site. Samples of each lot
of material shall also be submitted and will be retained by the Engineer
for possible future testing should the materials appear defective during
or after application.\] The Contractor shall furnish additional samples
of materials, in sufficient quantity to be tested, upon request.
Conformance with the requirements of the laboratory tests specified will
not constitute final acceptance of the materials. Final acceptance will
also be based on the performance of the in-place materials.

**604-3.1 EQUIPMENT.** Machines, tools, and equipment used in the
performance of the work required by this section shall be approved by
the engineer before the work is started and shall be maintained by the
contractor in satisfactory condition at all times.

**a. Joint Cleaning Equipment.**

(**1) Concrete Saw.** A self-propelled power saw with water-cooled
diamond or abrasive saw blades shall be provided for cutting joints to
the depths and widths specified and for removing filler **\[existing old
joint seal\]** or other material embedded in the joints or adhered to
the joint faces.

(**2) Sandblasting Equipment.** Sandblasting equipment shall include an
air compressor, hose, and a long-wearing venturi-type nozzle of proper
size, shape, and opening. The maximum nozzle opening should not exceed
1/4 inch. The air compressor shall be portable and shall be capable of
furnishing not less than 150 cubic feet per minute and maintaining a
line pressure of not less than 90 psi at the nozzle while in use. The
compressor shall be equipped with traps that will maintain the
compressed air free of oil and water. The nozzle shall have an
adjustable guide that will hold the nozzle aligned with the joint about
1 inch above the pavement surface and will direct the blast to clean the
joint walls. The height, angle of inclination, and the size of the
nozzle shall be adjusted as necessary to ensure satisfactory results.

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> **Sandblasting should be shown as an option to waterblasting for new
> pavement installations.**
>
> **Sandblasting equipment with a 1/4-inch nozzle requires at least 137
> cubic feet per minute of air to function efficiently. A larger nozzle
> would not serve any useful purpose in cleaning a joint.**

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(**3) Waterblasting Equipment.** Waterblasting equipment shall include a
trailer-mounted water tank, pumps, high-pressure hose, a wand with
safety release cutoff controls, nozzle, and auxiliary water resupply
equipment. The water tank and auxiliary water resupply equipment shall
be sufficient capacity to permit continuous operations. The pumps,
hoses, wand, and nozzle shall be of sufficient capacity to permit the
cleaning of both walls of the joint and the pavement surface for a width
of at least 1/2 inch on either side of the joint. The pump shall be
capable of supplying a pressure of at least 3,000 psi. A pressure gauge
mounted at the pump shall show at all times the pressure in pounds per
square inch at which the equipment is operating.

**b. Sealing Equipment.** Equipment used to install the preformed seal
shall place the preformed seal to the prescribed depths within the
specified tolerances without cutting, nicking, twisting, or otherwise
damaging the seal. The equipment shall not stretch or compress the seal
more than 3.0 percent longitudinally during installation. The machine
shall be an automatic self-propelled joint seal application equipment
and shall be engine powered. The machine shall include a reservoir for
the lubricant/adhesive, a device for conveying the lubricant/adhesive in
the proper quantities to the sides the preformed seal or the sidewalls
of the joint, a reel capable of holding one full spool of preformed
seal, and a power-driven apparatus for feeding the joint seal through a
compression device and inserting the seal into the joint. The equipment
shall also include a guide to maintain the proper course along the joint
being sealed. The machine shall at all times be operated by an
experienced operator.

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> **Single-axle type seal application equipment should not be permitted;
> this tool tends to cause excessive stretching and may cut or distort
> the seal. The following subparagraph may be added only for pavements
> less than 500 square yards:**
>
> **"The hand operated joint seal application equipment shall be a
> two-axle, four-wheel machine that shall include means for compressing
> and inserting the preformed seal into the joint and a reel capable of
> holding one full spool of preformed seal. Auxiliary equipment shall be
> provided to coat both sides the seal or the joint with
> lubricant/adhesive just prior to the installation of the preformed
> seal."**

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CONSTRUCTION METHODS

**604-4.1 ENVIRONMENTAL CONDITIONS**. The ambient temperature and the
pavement temperature within the joint wall shall be at least 35°F and
rising at the time of installation of the materials. Sealant application
will not be permitted if moisture or any foreign material is observed in
the joint.

**604-4.2 TRIAL JOINT SEAL AND LUBRICANT/ADHESIVE INSTALLATION.** Prior
to the cleaning and sealing of the joints for the entire project, a test
section at least 200 feet long shall be prepared at a location directed
in the project pavement using the specified materials and the approved
equipment, so as to demonstrate the proposed joint preparation and
sealing of all types of joints in the project. Following the completion
of the trial length and before any other joint is sealed, the trial
joints will be inspected by the Engineer to determine that the materials
and installation meet the requirements specified. If materials or
installation do not meet requirements the materials shall be removed,
and the joints shall be recleaned and resealed at no cost to the owner.
No other joints shall be sealed until the test installation has been
approved. If the trial section is approved, it may be incorporated into
the permanent work and paid for at the contract unit prices per linear
foot for sealing items scheduled. All other joints shall be sealed in
the manner approved for sealing the trial joints.

**604-4.3 PREPARATION OF JOINTS.** Immediately before installation of
the preformed joint seal, the joints shall be thoroughly cleaned to
remove all laitance, filler, \[old existing sealant,\] foreign material
and protrusions of hardened concrete from the sides and upper edges of
the joint space to be sealed. Any irregularity in the joint face that
would prevent uniform contact between the joint seal and the joint face
shall be corrected by \_\_\_\_\_\_\_\_ prior to the installation of the
joint seal.

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> **Joint openings of uniform cross section are essential to
> satisfactory installation of preformed polychloroprene joint seal.
> Openings must be sawed to provide smooth vertical faces of consistent
> width, within specified tolerances. Non-uniformity in width or
> roughness will cause variations in resistance of the joint seal to
> insertion and will result in irregular depth of insertion, stretching,
> and a tendency of the joint seal to twist so that the top of the seal
> is not at the surface.**
>
> **The proper preparation of joints with respect to the size of joint
> opening, required cleanliness of vertical and parallel joint faces,
> and uniform contact between the seal and the joint face can not be
> overemphasized. The neglect of any facet of these operations can
> result and has resulted in poor performance of joint seals.**

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**a. Sawing.** Joints shall be sawed to clean and to open them to the
full specified width and depth. Immediately following the sawing
operation, the joint faces and opening shall be thoroughly cleaned using
a water jet to remove all saw cuttings or debris remaining on the faces
or in the joint opening. Compression seal shall be installed within 3
calendar days of the time the individual joint cavity is sawed. Depth of
sawing the cavity shall be between 3/4 and 1 inch deeper than the
uncompressed depth of the seal (or otherwise recommended by the
manufacturer). The saw cut for the joint seal cavity shall at all
locations be centered over the joint line. The nominal width of the
sawed joint seal cavity shall be as follows; the actual width shall be
within a tolerance of plus or minus 1/16 inch:

(**1)** If a nominal 13/16 inch wide compression seal is furnished, the
nominal width of the saw cut shall be \[\_\_\_\_\_\]. However, this
shall apply only when the pavement temperature at the time of sawing is
between \[\_\_\_\_\_ and \_\_\_\_\_\] degrees F. If the pavement
temperature at the time of sawing is above this range, the nominal width
of the saw cut shall be decreased 1/16 inch. If the pavement temperature
at the time of sawing is below this range, the nominal width of the saw
cut shall be increased 1/16 inch.

(**2)** If a nominal 1 inch wide compression seal is furnished, the
nominal width of the saw cut shall be \[\_\_\_\_\_\]. However, this
shall apply only when the pavement temperature at the time of sawing is
between \[\_\_\_\_\_ and \_\_\_\_\_\] degrees F. If the pavement
temperature at the time of sawing is above this range, the nominal width
of the saw cut shall be decreased 1/16 inch. If the pavement temperature
at the time of sawing is below this range, the nominal width of the saw
cut shall be increased 1/16 inch.

The pavement temperature shall be measured and recorded in the presence
of the Engineer. Measurement shall be made each day before commencing
sawing and at any other time during the day when the temperature appears
to be moving out of the allowable sawing range.

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> **In Par 604-3.1.a, the requirements are based on giving the
> Contractor the option of using either nominal 13/16 inch or 1-inch
> wide compression seal. The designer will select the required valves to
> insert in the blanks for whatever geographical area in which the
> project is located based on the following table:**

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  -------------- ------------- ----------- -------------- --------- ----------------
                               **For                                
                               insertion                            
                               in blanks**                          

                 Expected                                           Allowable

                 Pavement                  Nominal                  Pavement
                                           Uncompressed             
                                           Sealant\                 
                                           Width-\                  
                                           Inches                   

                 Temperature                                        Temperature

                 Range in                                 Nominal   Range for

                 Service                                  Saw Cut-  Sawing-

  Area           Degrees F                                Inches    Degrees F

                                                                    

  Southwest      +10 to +160               13/16          8/16      +50 to +155

  Desert Area                              1\"            9/16      +55 to +180

                                                                    

  Southern U.S.  0 to +135                 13/16          8/16      +30 to +110

                                           1\"            9/16      +30 to +170

                                                                    

  Other          -30 to +135               13/16          8/16      +25 to +80
  Contiguous                                                        

  U.S. States                              1\"            9/16      +25 to +140

                                                                    

  Alaska and     -70 to +110               13/16          7/16      +50**\*** to
                                                                    +105

  Similar Areas                            1\"            8/16      +60 to +160
  -------------- ------------- ----------- -------------- --------- ----------------

**\* Put a note in the project specifications that this seal shall not
be installed in a saw cut less than 7/16 and thus cannot be used in this
area if sawing must be done at temperatures less than +50 degrees.**

**The above table is based on the following:**

**a. Tolerance from nominal specified width of uncompressed seal - plus
1/8 inch and minus 0 inch.**

**b. Tolerance from nominal saw cut width-plus or minus 1/16 inch.**

**c. Compression seal must be compressed at least 20 percent of its
uncompressed width at all times.**

**d. Compression seal must never be compressed more than 60 percent of
its uncompressed width at any time (narrowest opening in hot weather
must be at least 40 percent of uncompressed seal width).**

**e. Computations for slab (or joint) movement have been based on the
formula:**

**dW = 0.001056 x dT**

**dW = slab or joint movement in inches**

**dT = change in temperature in degrees F**

> **(The coefficient 0.0000528 was derived form the basic formula dL -
> 12 x c x l (a x dT x e).) To arrive at 0.001056; *a*, the thermal
> coefficient of concrete was assumed to be 5.5E-6 inch/inch/degree
> Fahrenheit: *e,* the drying shrinkage coefficient of concrete was
> neglected for these calculations. A value of 0.5 to 2.5 x 10-4 in./in.
> can be used for new concrete, and C, the adjustment factor due to slab
> friction was assumed to be 0.80. Slab length is assumed to be 20 ft.**

**f. The values for insertion in the blanks are based on the greatest
tolerance limit variation for both seal width and saw cut width.**

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> **For unusual conditions and for resealing joints in existing
> pavements where the prepared joint is extra wide, the designer will
> have to compute values to insert in the blanks. (Before the
> compression seal is used for resealing joints in existing pavements,
> it is common practice to resaw the joints - which will give a wider
> joint cavity. Width of sawing should be held to the same tolerance as
> specified for new pavements.)**

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**b. Sandblast Cleaning**. The concrete joint faces and pavement
surfaces extending at least 1/2 inch from the joint edges shall be
sandblasted clean. A multiple pass technique shall be used until the
surfaces are free of dust, direct curing compound, or any residue that
might prevent ready insertion or uniform contact of the seal and bonding
of the lubricant/adhesive to the concrete. After final cleaning and
immediately prior to sealing, the joints shall be blown out with
compressed air and left completely free of debris and water.

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> **Sandblasting of joints may not be permitted under certain
> conditions. Blowing sand and dust may either violate atmospheric
> pollution statutes, or may drift into areas where it would be
> objectionable. When sandblasting is prohibited, cleaning the joints
> with waterblasting equipment may be used and this paragraph deleted.**

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**c. Waterblast Cleaning.** The concrete joint faces and pavement
surfaces extending at least 1/2 inch from the joint edges shall be
waterblasted clean. A multiple pass technique shall be used until the
surfaces are free of dust, direct, curing compound, or any residue that
might prevent ready insertion or uniform contact of the seal and bonding
of the lubricant/adhesive to the concrete. After final cleaning and
immediately prior to sealing, the joints shall be blown out with
compressed air and left completely free of debris and water.

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> **Waterblasting equipment varies considerably with respect to design
> of wand, nozzle, water pressure, and water volume depending upon the
> manufacturer. Consequently, the effectiveness of a particular set of
> equipment cannot be predicted. The joints may be waterblasted the
> previous day and cleaned with compressed air immediately prior to
> sealing. The joints should be inspected to insure no foreign debris
> remains in the joint before sealing.**

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**d. Rate of Progress.** The stages of joint preparation which includes
sandblasting or waterblasting of the joint faces and air pressure
cleaning of the joints shall be limited to only the linear footage of
joint that can be sealed during the same workday.

**604-4.4 INSTALLATION OF THE PREFORMED SEAL.**

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> **Temperatures of the pavement and the atmosphere are not as critical
> for the installation of preformed polychloroprene joint seals as they
> are for poured sealants. Therefore, lower temperatures are acceptable
> and under some conditions sealing can proceed satisfactorily at
> temperatures lower than 35 degrees F. However, joints should be dry to
> obtain maximum cementing of the lubricant/adhesive to the concrete and
> manufacturers should be contacted for special instructions under cold
> conditions.**

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**a. Time of Installation.** Joints shall be sealed within 3 calendar
days of sawing the joint seal cavity and immediately following concrete
cure and the final cleaning of the joint walls. Open joints ready for
sealing that cannot be sealed under the conditions specified herein
shall be provided with an approved temporary seal to prevent
infiltration of foreign material. When rain interrupts the sealing
operations, the joints shall be washed, air pressure cleaned and allowed
to dry prior to installing the lubricant/adhesive and preformed seal.

**b. Sequence of Installation.** Longitudinal joints shall be sealed
first, followed by transverse joints and then all other joints. Seals in
longitudinal joints shall be cut so that all transverse joint seals will
be intact from edge to edge of the pavement. Intersections shall be made
monolithic by use of joint seal adhesive and care in fitting the
intersection parts together. Extender pieces of seal shall not be used
at intersections. Any seal falling short of the intersection shall be
removed and replaced with new seal at no additional cost to the owner.

**604-4.5 SEALING OF JOINTS.** The joint seal shall be installed using
the equipment specified in paragraph 604-3.1b EQUIPMENT. The sides of
the joint seal or the sides of the joint shall be covered with a coating
of lubricant/adhesive and the seal installed in such a manner as to
conform to all requirements specified. Butt joints and seal
intersections shall be coated with liberal applications of
lubricant/adhesive. Lubricant/adhesive spilled on the pavement shall be
removed immediately to prevent setting on the pavement. An in-place
joint seal shall be in an upright position and free form twisting,
distortion, cuts, and stretching or compression in excess of 3.0
percent. The joint seal shall be placed at a uniform depth within the
tolerances specified. In-place joint seal that fails to meet the
specified requirements shall be removed and replaced with new joint seal
in a satisfactory manner at no additional cost to the owner. The
preformed joint seal shall be placed to a depth of 3/16 inch, plus or
minus 1/8 inch, below the pavement surface except when the joint is
beveled or has a radius at the surface, or unless otherwise directed.
For beveled joints or joints with a radius at the surface, the preformed
joint seal shall be installed at a depth of 1/8 inch, plus or minus 1/8
inch, below the bottom of the edge of the bevel or radius. No part of
the seal shall be allowed to project above the surface of the pavement
or above the edge of the bevel or radius. The seal shall be installed in
the longest practicable lengths in longitudinal joints and shall be cut
at the joint intersections so as to provide continuous installation of
the seal in the transverse joints. The lubricant/adhesive in the
longitudinal shall be allowed to set for 1 hour prior to cutting at the
joint intersections to reduce the possibility of shrinkage. For all
transverse joints, the minimum length of the preformed joint seal shall
be the pavement width from edge to edge.

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> **Stretching of the preformed polychloroprene joint seal beyond the
> specified maximum must never be permitted, as breaks in the seal could
> occur later on. It is also possible that if the maximum is exceeded,
> when the longitudinal joints are cut to install the transverse joints
> that the joint seal material will return to its natural length leaving
> openings in the final product. Conversely, placing the seal so that
> the preformed seal is compressed longitudinally is also undesirable,
> as this practice tends to cause unsightly undulations and may exceed
> depth of installation tolerances. On airfield pavements a depth of
> 3/16 inch is desired to reduce the accumulation of dust and debris on
> top of the preformed seal, which could be ingested by aircraft
> engines. For other pavements 1/4 inch can be specified. It is
> recommended when the preformed seal in the longitudinal intersections
> are being cut that a knife blade be used to reduce the possibility of
> damage to the preformed seal on either side of the intersection.**

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**604-4.6 CLEAN-UP.** Upon completion of the project, all unused
materials shall be removed from the site, all lubricant/adhesive on the
pavement surface shall be removed, and the pavement shall be left in
clean condition.

**604-5.1 QUALITY CONTROL PROVISIONS.**

**a. Equipment.** The application equipment shall be inspected to assure
uniform application of lubricant/adhesive to the sides of the preformed
joint seal or the walls of the joint. If any equipment causes cutting,
twisting, nicking, excessive stretching or compressing of the preformed
seal, or improper application of the lubricant/adhesive, the operation
shall be suspended until causes of the deficiencies are determined and
corrected by the contractor.

**b. Procedures.**

**(1)** Quality control provisions shall be provided during the joint
cleaning process to prevent or correct improper equipment and cleaning
techniques that damage the concrete in any manner. Cleaned joints shall
be approved by the Engineer prior to installation of the
lubricant/adhesive and preformed joint seal.

(**2)** Conformance to stretching and compression limitations shall be
determined by the engineer. After installation, the distance between the
marks shall be measured on the pavement. If the stretching or
compression exceeds the specified limit, the seal shall be removed and
replaced with new joint seal at no additional cost to the owner. The
seal shall be removed up to the last correct measurement. The seal shall
be inspected a minimum of once per 100 feet of seal for compliance to
the shrinkage or compression requirements. Measurements shall also be
made as directed to determine conformance with depth and width
installation requirements. All preformed seal that is not in conformance
with specification requirements shall be removed and replaced with new
joint seal at no additional cost to the owner.

**c.** **Product.** The joint sealing system (preformed seal and
lubricant/adhesive) shall be inspected by the engineer for proper rate
of cure and bonding to the concrete, cuts, twists, nicks, and other
deficiencies. Seals exhibiting any defects, at any time prior to final
acceptance of the project, shall be removed from the joint, wasted, and
replaced in a satisfactory manner, as determined by the engineer.

METHOD OF MEASUREMENT

**604-6.1 MEASUREMENT.** The quantity of each sealing item to be paid
for will be determined by actual measurement of the number of linear
feet of in-place material that has been approved.

BASIS OF PAYMENT

**604-7.1 PAYMENT.** Payment will be made at the contract unit bid
prices per linear foot for the sealing items scheduled. The unit bid
prices shall include the cost of all labor, materials, the use of all
equipment, and tools required to complete the work.

TESTING REQUIREMENTS

The publications listed below form a part of this specification to the
extent referenced. The publications are referred to in this text by
basic designation only.

**U.S. ARMY CORPS OF ENGINEERS**

> CRD C 548 Standard Specification for Jet-Fuel and Heat Resistant
> Preformed Polychloroprene Elastomeric Joint Seals for Rigid Pavements

**AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)**

> ASTM D 2628 Preformed Polychloroprene Elastomeric Joint Seals for
> Concrete Pavements
>
> ASTM D 2835 Lubricant for Installation of Preformed Compression Seals
> in Concrete Pavements

**END ITEM P-604**

**Intentionally Left Blank**