May 15, 1998 CONCRETE MANUAL 5-694.697 (1)

5-694.697 PROGRESS CONTROL AND SURFACE SMOOTHNESS

Specification 2301.3P1 is hereby deleted and substituted by the following:

2301.3P1 Surface Requirements

After completion of the curing period and prior to the opening of the roadway to traffic, the Contractor shall test the pavement surface for surface smoothness and ride quality. See 2301.3P1c to determine if ride quality is required.

The Contractor shall furnish a properly calibrated, 7.62 m (25 ft.) wheel base, California type, computerized profilograph and competent operator certified by the industry in its' operation to measure pavement surface deviations in the longitudinal direction. The computer shall smooth the profile using a third-order Butterworth filter with a cutoff wavelength of 0.6096 m (2.0 ft.). The

computer shall generate a profile index using a 5.08 mm (0.2 in.) blanking band and shall use a 7.62 mm (0.3 in.) bump threshold to identify “must grind” locations. In lieu of a computerized profilograph, the Contractor may furnish a computerized analysis of the trace provided the above requirements are met.

Operate the profilograph in accordance with the manufacturer's instructions and at a speed no greater than a normal walk. To determine the profile index for mainline pavement, irregular pavement and ramps, make one pass at the midpoint between the wheel paths in each lane.

Make runs continuous and stop approximately 30 m (100 ft.) prior to a construction header. Evaluate construction headers for smoothness on the next subsequent pass. Evaluate for smoothness all terminal headers that tie into existing pavement and the existing portland cement concrete pavement existing approximately 15 m (50 ft.) adjacent to the terminal header. Bridge approach panels and bridge surfaces are exempt from these requirements, however, paving start-up areas are not exempt. Lift the test wheel and clearly label the profilogram to mark the beginning and end of each trace, each equation and each 152.4 m (500 ft.) marker. Completely label eachtrace to show the Project number, stationing, lane, wheel pass, date paved, date tested and the operator's name. Make runs within 48 hours of pavement placement.

Turn over the profile index (California Test Method 526 on file) test results and the trace to the Engineer within 48 hours of each run. This data is also used for ride quality determination when required.

The Engineer may test the entire Project length by an independent source. If the Engineer determines that the Contractor's certified test results are inaccurate, the Contractor is charged for this work at a rate of $500 per 1.6093 km per lane (1 lane-mile), with a minimum charge of $1000.

The Contractor shall remove all pavement areas represented by high points having deviations of 7.62 mm (0.3 in.) or more in 7.62 m (25 ft.) in the longitudinal direction, or 7.62 mm (0.3 in.) in 0.9144 m (3 ft.) transverse direction using an approved texture planing grinding device consisting

of multiple diamond blades. In the longitudinal direction, determine deviations according to California Test Method 526. In the transverse direction, determine deviations using a 0.9144 m (3 ft.) straight edge. After removing all individual deviations of 7.62 mm (0.3 in.) or more, surface test and provide necessary additional corrective work to achieve the required surface smoothness or riding quality.

NOTE: Deviations between 7.62 mm and 10.16 mm (0.3 in. and 0.4 in.) may remain in place if the ride is satisfactory in the judgement of the Engineer.

All costs relative to Contractor providing the profilograph and the appropriate profile index and traces are included in the unit bid price for 2301.502, Concrete Pavement, Standard Width and Item 2301.503, Concrete Pavement, Irregular Width.

P1c Riding Quality

The Engineer shall determine the final ride quality based on the results of the California profilograph based on the results of the California profilograph data provided under 2301.31b as modified herein. Paving Projects less than 0.8 km ( mile) in continuous length in a 7.2 m (24 ft.) wide standard roadway width and those portions of a paving project where the posted vehicle speed is anticipated to be less than 68 km/hr (42 mph), as determined by the Engineer are exempted from these riding quality requirements. The occurrence of bridges shall not interrupt the continuity determination, but the bridge surface and approach panels are not included in the ride quality determination. All pavements within 75 m (250 ft.) of a terminal header that is not adjacent to a

paved surface are exempt.

1. Each lane is divided into 0.1609 km (1/10 mile) sections and tested by the California profilograph.

2. Remaining subsections shorter than 0.1609 km (1/10 mile) is tested according to (1) above, but is prorated for equivalency in the riding quality.

3. Sections or subsections not excluded, which have riding quality greater than 63.13 mm/km (4.00 in/mile) but less than or equal to 94.70 mm/km (6.00 in/mile) as measured by the California profilograph are accepted at the unit bid price.

4. Sections or subsections not excluded, which have riding quality greater than 94.70 mm/km (6.00 in/mile) but less than or equal to 126.26 mm/km (8.00 in/mile) as measured by the California profilograph are accepted at the unit bid price less a payment deduction determined according to the following formula:

y = 0.006x² - 0.15156x + 8.372 PI calculated in mm/km

y = 2x² - 2x + 7 PI calculated in mm/km

16

Where:

y = price reduction in $/m² or $/yd²

x = profile index (PI)

Sections or subsections that have a profile index greater than 126.26 mm/km (8.00 in./mile) will require removal and replacement or texture planing to a profile index of 94.70 mm/km (6.00 in./mile) or less at the Contractor's option. Sections or subsections that have a profile index greater than 94.70 mm/km (6.00 in./mile) may be texture planed to eliminate payment reductions. Planing to provide a bonus is not acceptable.

5. Sections or subsections not excluded, which exhibit an exceptional riding quality less than 63.13 mm/km (4.00 in/mile), when tested by the California profilograph, are paid at the unit bid price plus a bonus according to the following formula:

y = ((63.1 – x) x $0.0212) For PI calculated in mm/km

y = ((4.0 – x) x $0.28) For PI calculated in in/mi

Where:

y = bonus in $/m² or $/yd²

x = profile index (PI)

The ride quality determination by the California profilograph method requires that the profilograph is computerized to assimilate and store pavement profile data or that the Contractor provides a computerized evaluation of the profilogram trace for a non-computerized profilograph. All mainline pavement except those sections exempt above, are subject to (1), (2) and (3) above except as modified below and the following:

For easy review by the Engineer, the Contractor shall provide a profile index test summary report including: stationing, length, square meter (yd 2 ) represented, and price adjustment for each 0.1609 km (0.1 mile) section. Adjacent lane results are reported in an adjacent column on the summary

report.

No section or subsection will receive a riding quality bonus if more than 5% of the section or subsection is corrected by surface texture planing. Texture planed areas of sections are not eligible for incentive bonuses.

NOTE: Metric measurements shall apply when the Project is let in the Metric system; English measurements shall apply when the Project is let in the English system.

On all concrete pavement construction, the Progress Control and Surface Smoothness are measured in the longitudinal direction by the California Profilograph. This machine consists of a frame 25 feet in length supported upon wheels at either end. The profile is recorded from the vertical

movement of a wheel attached to the frame at midpoint and is in reference to the mean elevation of the points of contact with the road surface established by the support wheels. The profilogram is recorded on a scale of 25 mm (1 in.) equal to 7.62 m (25 ft.) longitudinally and 25 mm (1 in.) equal to 25 mm (1 in.), or full scale, vertically.

The Contractor is responsible to have a trained operator on the job site to run the instrument. The machine is pushed down the pavement at no faster than a walk. A method of calibration in the vertical direction is placing a board of known thickness on the pavement and running the instrument over it. The profile should have a bump equal to thickness of the board. Check the

horizontal direction by moving the machine a known distance and checking the profile using the 25 mm (1 in.) to 7.62 m (25 ft.) conversion. The Contractor is responsible to “reduce” the profile while the Inspector's responsibility is to check the work and act upon the results.

Progress control is measured by the profile index as calculated and recorded by the profilogram reduction. This measurement is made the day after paving begins. The profile index value is then compared to the chart below to see if a change in the paving operation is needed.

PROFILE INDEX PAVING OPERATION

0-4 Good

4-6 Average

6-above Change is needed

After paving is complete, the Contractor must use the Profilograph results to locate any bump in excess of 8 mm (0.3 in.). The Contractor is required to grind any of these bumps out of the pavement.

Generally, before this is done, the areas are ridden by the Project Engineer to ensure the bump is severe enough to warrant grinding. A plastic template is available from the Concrete Engineering Unit.

REFERENCES

1. Section 5-694.640 through 5-694.671, FHWA HI-96-027, NHI Course 13133 --- Construction of Portland Cement Concrete Pavements, American Concrete Pavement Association, 1996.