RIGID PAVEMENT - Roads and Maritime Services

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CP

RELATED CONCRETE PAVEMENT DRAWINGS

CONSTRUCTION MAINTENANCE

DRAWING VOLUMEBASE TYPE

PCP MP

CRCP MC

JRCP MJ

© COPYRIGHT ROADS AND MARITIME SERVICES

SHEET No

No OF SHEETS

26

ISSUE

ED 2 REV 1 MJ

01

REGISTRATION No OF PLANS

VOLUME

PAVEMENT STANDARD DRAWINGS

RIGID PAVEMENT

Volume MJ - Jointed Reinforced Concrete Pavement

DATE

STANDARD DETAILS - MAINTENANCE MD.M10.MJ

DS2013/001890

ASSET MAINTENANCE DIVISION

ENGINEERING SERVICES BRANCH

PAVEMENTS UNIT

PREPARED BY:REGISTRATION No OF PLANS

SUPERSEDED

MD.M10.MJ

SIGNED DATE

APPROVED FOR USE

G. VOROBIEFF

PAVEMENTS AND GEOTECHNICAL

PRINCIPAL ENGINEER,

G. VOROBIEFF 28/05/2015 28/05/2015

02

REVISION REGISTER AND SHEET INDEX

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© COPYRIGHT ROADS AND MARITIME SERVICESTHIS SHEET MAY BE PREPARED USING COLOUR AND MAY BE INCOMPLETE IF COPIED

FOR AMENDMENTS REFER TO SHEET No 02

A3 ORIGINAL REGISTRATION No OF PLANS

26

ISSUE

ED 2 REV 1 MJ

VOLUME

SCALES: NOT TO SCALE, OR AS NOTED.

DATEJOINTED REINFORCED CONCRETE PAVEMENT (JRCP)


RIGID PAVEMENT


DS2013/001890ASSET MAINTENANCE DIVISION


PREPARED BY: PAVEMENTS UNIT

APPROVED FOR USE


PRINCIPAL ENGINEER,G. VOROBIEFF

28/05/2015

28/05/2015

REVISION REGISTER

ED/REV DATE SHEET AMENDMENT DESCRIPTION AUTHORISED

1/0 30/04/2001 ALL Initial issue

2/0 ALL

GM, RNIC

*PEPM&G

SHEET INDEX

SHEET No

COVER SHEET

DRAWING CONTENT

REVISION REGISTER AND SHEET INDEX

LEGEND

INDEX OF SHEETS

MJ01

MJ02

MJ03

MJ04

JOINT CATALOGUE

MJ11

JOINT RESEALING

MJ22-MJ23

JOINT SPALL REPAIRS MJ24-MJ25

MJ26

ROUTING AND SEALING OF CRACKS AND JOINTS

ANCHOR DEFECT REPAIRS

SLAB REPLACEMENT

MJ18

KERBS AND BARRIER

CROSS STITCHING OF CRACKS AND JOINTS - COMPROMISE PRACTICE

(See also MJ04)

MJ05-MJ10

MJ19-MJ21

MJ12-MJ17

Comprehensive revision14/03/2014

2/1 ALL Comprehensive revision PEP&G **

*** PRINCIPAL ENGINEER, PAVEMENTS AND GEOTECHNICAL

PRINCIPAL ENGINEER PAVEMENTS, MATERIALS AND GEOTECHNICAL

28/05/2015

03

LEGEND

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DESCRIPTIONTYPE

J18

J17

J16

J15

J14

J12

J10d

J10

J9

J7

J7d

J6

J5

J4

J3

J2d

J2

J1

J16d

Expansion: dowelled

Longitudinal: edge

Expansion: drill-dowelled

Isolation: without subgrade beam

Longitudinal: tied and sawn

Longitudinal: tied and formed

Longitudinal: drill-tied and formed

Longitudinal: tied and ribboned

Longitudinal: untied and formed

Longitudinal: untied and sawn

Transverse contraction: formed and dowelled

Transverse contraction: formed and drill-dowelled

Transverse contraction: knifed and dowelled

Hinge: tied and sawn

The suffix "d" relates to "drilled" tiebars or dowels.(b)

TABLE 3.2: JOINT TYPE NUMBERS AND DESCRIPTIONS

Table 3.2 Notes:

Transverse construction: tied and formed

Transverse construction: drill-tied and formed

Transverse contraction: sawn and dowelled

Longitudinal: edge and beamed

Isolation: with subgrade beam

Table 3.5 Notes:

LCS

1.0

1.5

TRAFFICKED (a) UN-TRAFFICKED (a) TRAFFICKED (a) UN-TRAFFICKED (a) TRAFFICKED (a) UN-TRAFFICKED (a)

SFCP SFCP - R

TABLE 3.5: GENERAL SLAB DIMENSIONAL LIMITS

3.5

84° 80° (75°)

3.5

4.3 (4.5)

1.0 0.6

0.80 (0.76)

6.0

2.5

4.3 (4.5)

1.0

NA

NA

75° (70°) 70° (65°)

6.0 (6.5)

2.5

4.3 (4.5)

0.3

NA

NA

75° (70°) 70° (65°)

2.5 2.5

4.3 (4.5) 4.5 (4.7)

0.6 0.3

NA

NA

NA

NA

W min

Shape Factor R = L / W

L max

W max

R max

L min

R min

Minimum Corner Angles (b)

(metres)

Slab Length L (c)

(metres)

Slab Width W (d)

JRCP

8.0 (10.0) 8.0 (10.0)

4.4 (4.6)

8.0 (10.0) 13.3 (16.7)

0.81 (0.78)

TABLE 3.1: PRACTICE NOTES

1. Scope

2. Dimensions

All dimensions are in millimetres (mm) unless noted otherwise.

3. Classification of maintenance practices

Definitions of terms is contained in the Specification.

reinforcing steel.

replacements, jointing, spall repairs, crack repairs, spacings of tiebars, and other

staff. Project-specific drawings must show precise details for items such as slab

reproduced in project-specific drawings for interpretation and/or application by site

spacings) they are intended solely as a guide to those designers and must not be

project designers. Where design tables are provided (for example, Table 9.1 for tiebar

These Drawings represent "Model" or "Standard" details which are intended for use by

must be adopted unless otherwise approved in writing by the Principal.

Best Practice repairs are the preferred option for repair of concrete pavements and

repairs are further classified according to Best Practice or Compromise Practice.

either fully or partially restores the load carrying capacity of the pavement. Structural

whether they are structural or non-structural repairs. A structural repair is one which

The maintenance practices shown in these drawings are classified according to

measure on curved slabs.

Width is the largest square measure between longitudinal edges or joints, or the largest radial(d)

on curved slabs.

Length is the largest edge measure between transverse contraction joints, or the longest chord(c)

Corner angles should be maximised wherever possible.(b)

See Note 1 in Table 3.1(a)

6.0 6.0 (6.5)

TABLE 3.6 REFERENCED DOCUMENTS

R83 Concrete Pavement Base

R15 Kerbs and Gutters

M258 Slab Replacement (Concrete Pavement)

3204 Preformed Joint Fillers for Concrete Road Pavements and Structures

T380 Field Adhesion of Joint Sealant to Concrete

T379 Cleanliness of Sawn Concrete Pavement Joints

T366 Dowel Pull-out Test

Australian/New Zealand Standards

AS/NZS 4671 Steel Reinforcing Materials

AS 3600 Concrete Structures

AS 1379 Specification and Supply of Concrete

Other Documents

D

TABLE 3.4: SYMBOLS

Joint type: 'D'

SYMBOL DESCRIPTION

Tiebars

TABLE 3.3: ABBREVIATIONS

Continuously Reinforced Concrete PavementCRCP

Lean-Mix Concrete SubbaseLCS

PCP-R

Dowelled Plain Concrete PavementPCP-D

Steel Fibre Reinforced Concrete PavementSFCP

SMZ

PCP Plain Concrete Pavement

Jointed Reinforced Concrete PavementJRCP

SFCP-R

TABLE A.B

Remove And ReplaceR & R

SYMBOL DESCRIPTION

ACRS

Selected Material Zone

Reinforced Plain Concrete Pavement (Discrete Slabs)

(Discrete Slabs)

Steel Fibre Reinforced Concrete Pavement with mesh added

Sheet A, Table A.B

MAX

MIN

NTS

NOM

TYP Typical

Nominal

Not To Scale

S A.B Sheet A, Schedule A.B

FIGURE A.B Sheet A, Figure A.B

Minimum

Maximum

Australian Certification Authority for Reinforcing Steels

or routing (MJ22 and MJ23).

sheets which show remedial activities such as joint resealing (MJ19-MJ21)

replacement work. They should not be confused with joint details on other

encountered in existing pavements and those which will be used in slab

Details shown on MJ05 and MJ06 are indicative of joints which will be(a)

for trafficked criteria.

Where an un-trafficked slab is likely to become trafficked within 20 years, it must be designed(f)

unavoidable. They must not be adopted by field staff without design review and approval.

Values in brackets show compromise limits for exclusive use by designers where their use is(e)

NA Not Applicable

70°

Roads and Maritime Services Specifications

Roads and Maritime Services Test Methods

Other Roads and Maritime Services Documents

Austroads Guide to Pavement Technology Part 2: Pavement Structural Design

Pavement Structural Design

RMS Austroads Guide Supplements - Austroads Guide to Pavement Technology Part 2:

Applications Single Sided Sections and Profiles

Standard Drawing MD.R132.D08.A.1 Type ‘F’ Concrete Safety Barrier Cast-in-situ

Standard Pavement Subsurface Drainage Details - Volume 5 - Rigid Pavement Details

Specification Guide NR83 Guide to QA Specification R83

Specification Guide NR82 Guide to QA Specification R82

Volume CP - Plain Concrete Pavement

Pavement Standard Drawings Rigid Pavement Standard Details - Construction

Volume CC - Continuously Reinforced Concrete Pavement

Pavement Standard Drawings Rigid Pavement Standard Details - Construction

04

INDEX OF SHEETS

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A

A

J10

J9

OR

J2

J1

J2

J10

OR

J6

J2

J1

J2

J6

J10

J9

OR

ANCHOR

Anchor rotation●

Anchor slab cracking●

ANCHOR DEFECT REPAIRSKERBS AND BARRIER

JOINT RESEALING

JOINT SPALL REPAIRS

ROUTING AND SEALING CROSS STITCHING

SHEET TITLE

MJ26 MJ11

Sheet Nos

KEY

MJ18MJ22, MJ23MJ24, MJ25MJ19 - MJ21

Kerb and barrier details●

Issues covered●

Compromise practice●

Longitudinal crack stitching●

Longitudinal joint stitching●

Treatment of arris faults●

Unplanned crack routing and sealing●

Joint routing and resealing●

Partial-depth repairs●Treatment of arris faults●

Joint resealing●

Joint resawing●

JOINT CATALOGUE

MJ05 - MJ10Edge details●

Dowel details●

Design of tiebars and drill-ties●

Sealant design●

Treatment of exposed joints (corrugated, keyed, and butt)●

Joint types and section details●

SLAB REPLACEMENT

Schedule of R & R activities●

Full and part-slab R & R●

MJ12 - MJ17

J9

J7d J9

J2d

J9 J7d

05

JOINT CATALOGUE

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DEVELOPMENT OF SAWCUT AND SILICONE SEAL JOINT

2 - TEMPORARY SEALING

DETAIL SECTIONS

1 - PRELIMINARY SEALING 3 - PERMANENT SEALING

SAWCUT

3 ± 1

SILICONE SEALANT

D/3

010

+ –

D/3

010

+ –

SILICONE SEALANT

WIDENING SAWCUT

SEE TABLE 8.1

JOINT DIMENSIONS;

BACKER ROD

FIRST SAWCUT

3 ± 1

35 ± 5

SAWCUT

WIDENING

SILICONE SEALANT

SEE NOTE 2 (S7.1)

SEAL FULL FACES;

A

-

DETAIL

B

-

DETAIL

5 ± 3

8 ± 2

D/4

010

+ –

3 ± 1

DS

RS

W S

MIN

15

FIRST SAWCUT

W S W S

SEE TABLE 8.1

JOINT DIMENSIONS;

(TYP)

BACKER ROD

POLYETHYLENE

CLOSED-CELL

(TYP)

BACKER ROD

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

C

-

DETAIL

DS

RS

D/3 MIN

D/3 MIND

EP

TH O

F B

AS

E

DE

PT

H O

F B

AS

E

D/3 MIN

D/3 MIN

SCABBLED/BUTT

KEYED

CORRUGATIONS

TIED AND SAWN

LONGITUDINAL:

JOINT TYPE

TIED AND FORMED

LONGITUDINAL:

JOINT TYPE

-

A

UNTIED AND FORMED

LONGITUDINAL:

JOINT TYPE

J1

: SEE FIGURE 17.1

: SEE FIGURE 16.3

: SEE TABLE 10.2

J2

J3

J4 J5

D

500 ± 35

D

500 ± 35

D/3 MIN

D/3 MIN

SEE NOTE 2 (S7.2)

TIEBAR FIXING :

SCABBLED/BUTT

KEYED

CORRUGATIONS

J2d

DRILL-TIED AND FORMED

LONGITUDINAL:

JOINT TYPE

DE

PT

H O

F B

AS

E

D

D

DE

PT

H O

F B

AS

E

D

DE

PT

H O

F B

AS

E

-

B

DE

PT

H O

F B

AS

E

D/3 MIN

D/3 MIN

D

J7

AT SPACING 500 C/C

E7-N12

D/3 MIN

D/3 MIN

SEE NOTE 2 (S7.2)

TIEBAR FIXING :

SCABBLED/BUTT

KEYED

CORRUGATIONS

AT SPACING 500 C/C

E8-N12

J7d

FORMED AND TIED

TRANSVERSE CONSTRUCTION:

JOINT TYPE

FORMED AND DRILL-TIED

TRANSVERSE CONSTRUCTION:

JOINT TYPE

UNTIED AND SAWN

LONGITUDINAL:

JOINT TYPE

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH

MIN

COVER 30

SHOWN IN TABLE 9.1

AT SPACING AS

E1-N12

AT SPACING AS SHOWN IN TABLE 9.1

E1-N12

AT SPACING AS SHOWN IN TABLE 9.1

E4-N12

250 MIN

RIBBON INDUCER

06

G

DE

PT

H O

F B

AS

E

LCS

JRCP

LONGITUDINAL: EDGE

JOINT TYPE

EXISTING WHERE GREATER

50 MINIMUM OR MATCH

J6

J

06

AS SHOWN IN TABLE 10.2

CORRUGATIONS

250 MIN

(CORRUGATIONS AS SHOWN IN TABLE 10.2)

BUTT EDGE OR CORRUGATED EDGE TO MATCH EXISTING

SCHEMATIC TIED AND RIBBONED

LONGITUDINAL:

JOINT TYPE

: SEE FIGURE 17.1

: SEE FIGURE 16.3

: SEE TABLE 10.2

: SEE FIGURE 17.1

: SEE FIGURE 16.3

: SEE TABLE 10.2

500 ± 35

D

CONSTRUCTION OR MAINTENANCE WORK

THIS JOINT TYPE IS NOT TO BE USED FOR NEWNOTE:

06

JOINT CATALOGUE

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D/4

010

+ –

SILICONE SEALANT

WIDENING SAWCUT

SILICONE SEALANT

DEBONDING STRIP

JOINT FILLER

SILICONE SEALANT

CONSTRUCTION OPTIONS

SEE NOTE 2 (S7.3) FOR

SILICONE SEALANT

CONSTRUCTION OPTIONS

SEE NOTE 2 (S7.3) FOR

SEE TABLE 8.1

JOINT DIMENSIONS;

SEE TABLE 8.1

JOINT DIMENSIONS;

DETAIL SECTIONS

SW

DS

RS

W S

DJ

DS

RS

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

G

-

DETAIL

F

-

DETAIL

E

-

DETAIL

D

-

DETAIL

D/4

010

+ –

INITIAL CRACK INDUCER

STAGE 1 STAGE 2

OF THE BASE

TOP SURFACE

THE FINISHED

SQUARE (± 6°) TO

INDUCER PLACED

INITIAL CRACK

SAWCUT

3 ± 1

010+–

SILICONE SEALANT

5 ± 3

8 ± 2

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

D/4

TRANSVERSE

DS

RS

SEE TABLE 8.1

JOINT DIMENSIONS;SW

DJ

SEE TABLE 8.1

JOINT DIMENSIONS;W S

DJ

DS

RS

H

-

DETAIL

AND

200

D/3 MIN

80 ± 20

SAWN AND DOWELLED

TRANSVERSE CONTRACTION:

JOINT TYPE

FORMED AND DOWELLED


JOINT TYPE

FORMED AND DRILL-DOWELLED


JOINT TYPE

KNIFED AND DOWELLED


JOINT TYPE

HINGE: TIED AND SAWN

JOINT TYPE

SUBGRADE BEAM

SUBBASE

SEE NOTE 6 (S7.2)

DOWEL CAP

GEOTEXTILE

SUBBASE

SUBBASE-

D/2 ± 25

MINIMUM 275

DEBONDING AGENT

MINIMUM 275

DEBONDING AGENT

MINIMUM 275

DEBONDING AGENT

MINIMUM 275

DEBONDING AGENT

MINIMUM 275

DEBONDING AGENT

JOINT TYPE

EXPANSION: DOWELLED / DRILL-DOWELLED

D/2 ± 25

D/2 ± 25

WITH SUBGRADE BEAM

ISOLATION:

JOINT TYPE WITHOUT SUBGRADE BEAM

ISOLATION:

JOINT TYPE

LONGITUDINAL: EDGE AND BEAMED

JOINT TYPE

J9 J10

BASE

EXISTING

J10dSEE TABLE S7.3 FOR DIAMETER

DRILLED AND FIXED

DOWELS 450 LONG @ 300 C/C

J12

J14

J15

J16 J16d

SEE NOTE 2 (S7.2)

(J16d ONLY)

FIXING

BASE

J17 J18

DE

PT

H O

F B

AS

E

D

BUTT JOINT

DE

PT

H O

F B

AS

E

D

SEE TABLE S7.3 FOR DIAMETER


600

D

DE

PT

H O

F B

AS

E

300 D

DE

PT

H O

F B

AS

E

BASE

D

DE

PT

H O

F B

AS

E

DE

PT

H O

F B

AS

E

D

SUBBASE

SEE TABLE 10.1

MESH

DE

PT

H O

F B

AS

E

D/2 ± 25

SEE TABLE 10.1

MESH

D/2 ± 25

DE

PT

H O

F B

AS

E SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESHSEE TABLE 10.1

MESH

80 ± 20

SEE TABLE 10.1

MESH

SEE TABLE 10.1

MESH CONTINUOUS ACROSS JOINT

L8TM

OR

SL92 MESH

LOW SIDE / EDGE DETAILS HIGH SIDE EDGE DETAILS/

D

D/4300+

–

CROSSFALL

EDGE OF CONCRETE EDGE OF CONCRETEBASE

VERGE OR APPROACH PAVEMENT

APPROACH PAVEMENT

VERGE OR

SUBBASE

60 ± 30

OF B

AS

E

DE

PT

H

J6 J18 J6 J18

J1

-

DETAIL

J2

-

DETAIL

J

-

DETAIL

EDGE DETAILS

05

C

-

F

-

F

-

D-

E

-

E

SEE TABLE S7.3 FOR DIAMETER


-

E

H

SEE NOTE 7 (S7.1)

COVER 80 ± 20

SEE NOTE 7 (S7.1)

30 MIN COVER -

J

SEE TABLE 10.1

MESH

MESH SEE TABLE 10.1

80 ± 20

SUBGRADE BEAM

L8TM

OR

SL92 MESH

EXISTING WHERE GREATER

50 MINIMUM OR MATCH

200

600

80 ± 20

D

D

DETAILS VOLUME 5

SUBSURFACE DRAINAGE

STANDARD PAVEMENT

AND MARITIME SERVICES

ACCORDANCE WITH ROADS

EDGE DRAIN IN

DRAINAGE DETAILS VOLUME 5

STANDARD PAVEMENT SUBSURFACE

ROADS AND MARITIME SERVICES

GEOTEXTILE IN ACCORDANCE WITH

SEE TABLE 7.3 FOR DIAMETER


SEE TABLE 7.3 FOR DIAMETER


07

JOINT CATALOGUE

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SCHEDULE 7.1 (S7.1)

NOTES

Scope

1.

Sealing of joint ends

2.

3.

Formed joint faces

4.

Joint debonding

5.

6.

Subgrade beams

7.

Mesh cover

8.

Anchors

9.

Kerbs

Edge drains

10.

SCHEDULE 7.3 (S7.3)

1.

PROCEDURES

2.

using dry oil-free compressed air through a probe inserted into the hole.

Drill holes (for tiebar and dowel fixing) must be thoroughly cleaned of dust

See MJ23

see Figure 17.1scabbled:(c)

see Figure 16.3keyed:(b)

see Table 10.2corrugated:(a)

Details of formed joints are shown as follows:

Reserved.

Positive debonding is therefore required, as follows:

must be prevented because it causes joint spalling, particularly at arrises.

Hence, whilst aggregate interlock is beneficial, intimate microtexture bond

All pavement joints are required to hinge to relieve curling stresses.

runs (in the case of formed joints).

material (in the case of outer edges) and mortar from subsequent paving

This is required to prevent the ingress of incompressibles such as verge

extend down the vertical faces of the joint and down any underlying crack.

Where joints "daylight" at outer edges and formed joints, the sealant must

SCHEDULE 7.2 (S7.2)

1.

2.

Fixing of tiebars and dowels

(a)

(b)

(c)

3.

Tiebars and drill-ties

and be placed:

In longitudinal joints, tiebars must be designed in accordance with Table 9.1

4.

5.The following practices apply to drill-ties:

6.

Dowels

Dowels must be installed ahead of paving and must:

7.The alignment tolerance of individual dowels is:

MATERIALS AND NOTES

(d)

delivery system.

or polyester setting system (resin) which is thoroughly mixed within the injection

Drilled tiebars and dowels must be fixed using a suitable two-component epoxy

completely fills the hole when the tiebar is inserted.

A nozzle must be used which reaches the end of the hole to ensure the resin

Steel grade and supply and fabrication of reinforcement

to facilitate fixing.

strength of the bar. Tiebars may be drilled at an inclination of up to 10°

For tiebars, it must provide an anchorage strength of at least 85% of the yield

'N' according to the diameter, for example, N12, N16, N20.

steel of grade 500 MPa (that is, D500N) which is notated in these drawings as

Bar reinforcement (including tiebars) must be deformed ribbed, normal ductility(a)

Steel must comply with AS/NZS 4671, as follows:

'SL' (square mesh).

500 MPa, which is notated in these drawings as 'RL' (rectangular mesh) or

Mesh reinforcement must be round or deformed, low ductility steel of grade(b)

R32.

notated in these drawings as 'R' according to the diameter, for example, R24,

Dowels must be round (plain) normal ductility steel of grade 250 MPa, which is(c)

reinforcement material.

The reinforcement fabricator must be certified by ACRS for fabrication of(e)

reinforcement material.

The reinforcement material suppler must be certified by ACRS for the supply of(d)

fills the hole once the tiebar is inserted.

the volume of the chemical anchor should be determined so that the resin just(a)

be 450 mm long and of diameter in accordance with Table 7.3.(a)

burrs and protrusions).

be straight and free of irregularities which could hinder their movement (such as(b)

be fully galvanised.(c)

which lies within the second-placed slab.

0.75 ± 0.25 mm. At formed joints, the debonding must be on the section

be coated at one end with a tough, durable debonding agent of thickness(d)

be supported so that no part of the assembly, except the dowel, crosses the joint.(f)

of ± 25 mm.

be equally positioned about the line of the intended joint within a tolerance(g)

both the tiebar and the concrete.

the tiebar must be rotated in the hole to maximise bond between the resin and(b)

movement equal to the width of the joint plus 15 ± 5 mm.

at expansion joints, have the debonded end capped to provide a clearance for(j)

with tolerances as given below.

parallel to the pavement surface and parallel with the local relevant control line,

unless otherwise shown on the Drawings, be placed at mid-depth (± 25 mm),(e)

be placed not closer than 150 mm to a longitudinal joint.(h)

in the finished slab: ± 2 mm.(b)

or isolation joint).

not closer than 300 mm to a transverse untied joint (for example, a contraction(a)

integrally with the adjoining concrete.

adjoining concrete is placed. The repair material must not be placed

honeycombing and re-entrant angles. Defects must be repaired before

The first-placed face must be dense and fully compacted and be free of(a)

the end of the hole to ensure that no dust remains in the hole.

oil-free compressed air. In both cases, a nozzle must be used which reaches

debris must be cleaned out of the holes using an industrial vacuum cleaner or

Cleanliness is critical to achieving good pull-out strength. Drilling dust and other

or sawcut.

to ensure a minimum vertical clearance of 30 mm to any proposed crack inducer(c)

before placing concrete: ± 2 mm.(a)

TABLE 7.3: DOWEL DIAMETER

THICKNESS (mm)

BASE SLAB

DIA (mm)

DOWEL

150 < D ≤ 175 24

175 < D ≤ 200 28

32

36

200 < D ≤ 260

D > 260

MARK DIA SHAPE LOCATION / DESCRIPTION LENGTH (m) SPACING (mm)

E1 N12 1 1.0 See jointing plan and Table 9.1

E2 N12 7 1.0 See jointing plan and Table 9.1

E4 N12 1 or 22 Drilled tiebars in longitudinal joints 0.75 See jointing plan and Table 9.1

E7 N12 1 1.0

E8 N12 0.75 5001 or 22

J1 N12 21 1.0 1 000 ± 50

J2 N12 1 1.0 1 000 ± 50

J3 N12 5 0.5

- - -

Table 7.1 Notes:

longitudinal joints

Kerb types SE and SL

Kerb types SF and SM

(a)

N12J4 9 0.325

drill-ties into an existing base slab.

Kerb types SF and SM when installed as

(b)

500 MAX; See MJ11

500 MAX; See MJ11

longitudinal joints. See Note (c).

Kerb types SA, SB, SO and SK

E2 is acceptable alternative in J1 joints

Tiebars in longitudinal joints

alternative to E1 for J1 joints

Tiebars in longitudinal joints

Tiebars in J7 joints

Drilled-ties in J7d joints

MESH -

or routing (MJ22 and MJ23).

sheets which show remedial activities such as joint resealing (MJ19-MJ21)

replacement work. They should not be confused with joint details on other

encountered in existing pavements, and those which will be used in slab

Details shown on MJ05 and MJ06 are indicative of joints which will be

Tiebars must not be sprayed with the debonding agent.(c)

Beams must be of Grade N32 concrete and have a steel-float surface finish.

Maximum of three layers of mesh at any one point.(c)

30 mm cover under sawcuts. Bottom cover must not be less than D/3.

Mesh top cover must be increased to the extent necessary to achieve(b)

80 ± 20 mm.- top and bottom cover:

80 ± 20 mm.- to joints and edges:

otherwise shown:

Mesh must be placed to provide the following cover unless(a)

on MJ06.

provided on the high side to minimise ingress of fines as shown in Detail J

Edge drains are normally only provided on the lower side. A geotextile is

sealing by sawing in accordance with MJ19-MJ21.

first-placed face. Where a filler is used, the joint must be prepared for

sawcutting or (in the case of formed joints) by fixing a temporary filler to the

In Details F and G on MJ06, the sealant reservoir may be created by

not closer than 150 mm to a transverse tied joint.(b)

Tiebars in kerbs (Shape 21) must be bent to satisfy cover requirements. They may be bent insitu.(c)

See Table 7.2.(b)

E2 tiebars must be securely fixed against rotation during paving.(a)

NOT TO SCALE

MESH

S2

S1

(a) S1 S2=

MESH

S2

S1

(b) S1 S2<

FIGURE 7.1: LAPPED SPLICE FOR WELDED MESH

(ADAPTED FROM FIGURE 13.2.3 AS 3600)

THE MINIMUM LENGTH OF OVERLAP = 100 mm

OVERLAP THE TWO OUTERMOST CROSS-BARS AS SHOWN IN FIGURE 7.1

adjoining base. See MJ11.

Fixtures such as kerbs and islands must be structurally compatible with the

for drill-ties) and be placed not closer than 150 mm to a longitudinal joint or slab edge.

In transverse tied construction joints, tiebars must be provided at 500 c/c (and 500 c/c

JRCP. See Figure 7.1. See Table 10.1.

500

TABLE 7.1: REINFORCEMENT SCHEDULE AND BAR SPACING

compound as the debonding agent in accordance with M258.

The first-placed face must be sprayed with wax emulsion curing(b)

not more than 0.15 MPa.

when tested in accordance with T366, have an average pull-out bond stress(i)

150

50

300300

50

150

500 ± 75500 ± 75

JOINTC

SEE NOTE (d)

30 MIN

L

L/2 L/2 L/3 2L/3

175

100 *( ) SEE NOTE (c)

2(b) S7.2SEE NOTE

10° MAX

175

SEE NOTE 2 S7.2

TABLE 7.2: BAR REINFORCEMENT SHAPES

Table 7.2 Notes:

*

Or as required to meet cover requirements under the sawcut.(d)

20 for SO and SK kerbs.

8 for SA and SB kerbs.( ) =(c)

All dimensions are to intersections of straight portions at outside of bends.(b)

Bending pin diameter to be 5 times bar diameter.(a)

1 2122

5 7

9

300

300

08

JOINT CATALOGUE

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TABLE 8.1: UNTIED JOINTS - SILICONE SEALANT DIMENSIONS

1 2 3 4 5 6 7

O (mm)

Opening

Design Joint

W (mm)

Width

expansions

Isolations and D (mm)

Joint depth

slabs

Bridge approach

longitudinal

> 18

4.6 < L ≤ 6.5

6.5 < L ≤ 8.0

8.0 < L ≤ 9.5

≤ 4.6 2.1

9.5 < L ≤ 11.5

11.5 < L ≤ 13.0

13.0 < L ≤ 15.0

2.9

3.5

4.0

4.4

4.8

6.0

7 (+3, -0)

9 (+3, -0)

10 (+3, -0)

11 (+3, -0)

12 (+4, -0)

14 (+4, -0)

17 (+5, -0)

See Note (h)

14 (+4, -0)

11 (+4, -0)

10 (+4, -0)

9 (+3, -0)

8 (+3, -0)

8 (+3, -0)

7 (+3, -0)

14 (+4, -0)

5 ± 3

5 ± 3

6 ± 3

6 ± 3

7 ± 3

8 ± 4

10 ± 4

8 ± 2

8 ± 2

8 ± 2

8 ± 2

10 ± 4

10 ± 4

12 ± 4

10 ± 4 12 ± 4 50 ± 5

50 ± 5

45 ± 5

45 ± 5

45 ± 5

40 ± 5

35 ± 5

35 ± 5

1

TABLE 8.2: TIED JOINTS - SILICONE SEALANT DIMENSIONS

2 3 4

D (mm)

Joint depth

3 < W ≤ 6 7 (+3, -0) 5 ± 3 30 ± 5

7 (+3, -0) 5 ± 3 35 ± 5

8 (+3, -0) 6 ± 3 40 ± 5

7 ± 3 50 ± 5

7 ± 3 60 ± 5

7 ± 3 65 ± 5transverse

6 < W ≤ 10

10 < W ≤ 15

15 < W ≤ 18

18 < W ≤ 22

> 22

transverse

longitudinal

longitudinal

10 (+4, -0)

12 (+4, -0)

14 (+4, -0)

Table 8.1 Notes:

(a)

Table 8.2 Notes:

(a)

(b)

(d)

(e)

(f) See Table 8.3 for calculation of effective slab length L and width W .

(g) The backer rod diameter should typically be about 25% larger than the joint width W .

(h)

(j)

The difference is as follows:

and the risk (in hot weather) of the sealant being ejected.

The recess varies according to joint type because of the relative potential for joint closure,

vary substantially between different sites.

There are many factors which will influence the magnitude of joint closure and so it may

will be damaged by traffic. The values listed in Column 6 are intended as guidelines only.

width. If the recess is inadequate, this will squeeze the sealant above the surface, where it

In isolation and expansion joints, the joint can close up to significantly less than its original

induced crack at the time of sealant installation.

regain contact. Hence, the risk of sealant ejection is low, being related to the width of the

In contraction and butt joints, the joint cannot close beyond the point at which the faces

(c)

It is important that the upward pressure on the sealant (in hot weather) is minimised.

such as the depth of the backer rod after lateral compression into the joint.

Values given for the depth of joint D are indicative only. Allowance must be made for factors

(b)

(c)

D is dominated by issues such as durability and penetration resistance (against stones etc).

Following from (b), sealant shape factor is less important than in untied joints. Hence, design of depth

(d)

(e)

(f)

(g) The backer rod diameter should typically be about 25% larger than the joint width W .

(h)

Allowance must be made for factors such as the depth of the backer rod after lateral compression into the joint.

However, tooling is still necessary to enhance the bond. Values given for the depth of joint D are indicative only.

input to Table 8.1 Column 1

length L or width W for

Calculation of effective slab

TABLE 8.3: SEALANT WIDTH CALCULATIONS

design

Sealant underComments

L =L + L

2W

L =L + L

2W

W =W + W

2W

W

W For tied joints, refer to Table 8.2.

W =W + W

2

Table 8.3 Notes:

(a)

(b) Refer to Figure 8.1 for key to dimensions L, W and W .

(e)

e

e

(f)

(b)

(d)

(b) (d) (e)

(f)

(f)

(f)

(f)

e e

e

e

e(a)

(a)

e e

e

(m)

Width W

or

Slab Length L

Refer to Figure 8.2 for key to dimensions W , D , R , and D .

Refer to Figure 8.2 for key to dimensions W , D , R , and D .

recess may need to be increased.

anchors. If experience at a particular location indicates a high degree of movement, the

Closure of bridge approach joints will normally be minimised by adjacent pavement terminal

hence expulsion of the sealant is unlikely.

The recess R can be reduced (relative to untied joints) because there is little chance of the joint closing,

(b(2)) (b(1))

(1)

(2)

Width O refers to the maximum winter opening, that is, maximum extension of the sealant.

(c)

A similar joint separating a ramp from the through-carriageway would be deemed to be "longitudinal".

parallel with the through-carriageway within a median crossing is still "transverse" relative to traffic movements.

The terms "transverse" and "longitudinal" relate to the direction of trafficking. Hence, an isolation joint which runs

and butt

Contractions

SILICONE SEALANT

D

W

D

R

AN

D M

IN

10 N

OM

SEE TABLE 8.2 FOR TIED JOINTS

SEE TABLE 8.1 FOR UNTIED JOINTS

S

S

J

S

FIGURE 8.2: SEALANT DIMENSIONS

joints and is independent of the J7 tied joint.

Note that the length L is measured between contraction

Untied joints and outer edges constitute "relief edges".

Tied kerbs must be included.

edge, independent of tied joints.

W , W , W and W are measured to the nearest relief

FIGURE 8.1: TYPICAL JOINT TYPES

KERB (TIED)

J2

J2

J9

W

W S3

J4

J10

J9

OR

J2

J2

J2

J2

J7

J1

J9

J14 J15OR

W S1

WS5

WS5

LLLL3 4 1 2

2

43

S S

S

JD

(c)

S S S J

S

S

S

S

S

J

D

S

S S S J

S

S

S

S

S

S S S J

1 2S1

1

3 4S2

1 2S3

S4

1 2 3 4

S5

3 4

S

S2

1

W S4

W (mm)

Width

D (mm)

Depth

R (mm)

Recess

D (mm)

Depth R (mm)

Recess

For larger widths, treat in accordance with MJ24 and MJ25.

in transverse joints: 24 mm (guide only)

in longitudinal joints: 18 mm

The width of silicone sealants is restricted as follows:

will open by the same amount.

two slabs each 4.2 m

two slabs 3.8 m and 4.6 m, and

length of adjacent slabs. Hence, joints between:

The magnitude of joint opening is proportional to the mean

25 ± 4

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

Use a polyurethane sealant


For details of tied joints, refer to Table 8.2.

for interpretation of "longitudinal".

The width of longitudinal silicone joints is limited to 18 mm maximum. See Table 8.2 Note (f)

For untied joints, refer to Table 8.1.

OR J10

which are largely free of spalling; see MJ19-MJ21 for further details.

installation. In the case of resawing (for sealing), the width is dominated by the need to provide clean faces

Width W is therefore not affected by slab dimensions but is dictated by other issues such as ease of sealant

In tied joints, hingeing is the only cause of sealant extension and hence its magnitude will typically be small.

KERB (TIED)

J2

WW

WW

09

JOINT CATALOGUE

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Table 9.1 Notes:

(mm)

Transverse Joint

Cover to

S ≥ 700 300 ≤ S/2 < 1 000

550 425

450 625

400 600

350 675

(a)

(b)

(c)

(d)

(e)

(f)

Tiebar spacing based on 12 mm deformed 500N steel and a value of interlayer friction µ = 1.5.

Base Thickness = Concrete base + asphalt surfacing.

EXAMPLES OF SUGGESTED LAYOUTS(mm)

Tiebar Spacing

ActualBASE THICKNESS 'D' (mm)

< 3.1

180 200 220 240

3.1 - 3.5

3.6 - 4.0

4.1 - 4.5

4.6 - 5.0

5.1 - 5.5

5.6 - 6.0

6.1 - 6.5

6.6 - 7.0

7.1 - 7.5

7.6 - 8.0

250

6

6

7

7

8

890 9

800 10

730 11

730 11

665 12

615 13

6

7

7

8

890 9

800 10

730 11

665 12

615 13

615 13

570 14

6

7

8

890 9

800 10

730 11

665 12

615 13

570 14

530 15

500 16

7

8

890 9

800 10

730 11

665 12

615 13

570 14

530 15

500 16

470 17

7

8

890 9

800 10

730 11

665 12

615 13

570 14

530 15

470 17

445 18

(a)

RED (m)

Distance

Relief-edge

13 14 16 17 18

14 16 17 19 20

15 17 18 20

16 18

8.1 - 8.5

8.6 - 9.0

9.1 - 9.5

9.6 - 10.0

615

570

530

500

570

500

470

445

500

470

445

420

470

420

400

445

400

19

TABLE 9.1: PROVISION OF TIEBARS

Average tiebar spacing (mm) and number of tiebars per 8.0 m slab

(b)

17 18470 445 400 20

17 19470 420

≥ 11.1

10.1 - 10.5

10.6 - 11.0

6.1 - 6.5

6.6 - 7.0

7.1 - 7.5

7.6 - 8.0

8.1 - 8.5

8.6 - 9.0

9.1 - 9.5

9.6 - 10.0

≥ 11.1

10.1 - 10.5

10.6 - 11.0

Bar size

890 9

1000 8

890 9

800 10

890 9

890 9

800 10

9 9 10 11

9 10 11 11

9 9 10 11 12

9 10 12 12

890

890

890

890

890

800

890

800

800

730

800

730

730

665

730

730

665

66511

9 10 12 13890 800 730 665 61511

10 11 13 14800 730 665 615 57012

6

7

8

1000 8

800 10

800 10

730 11

665 12

615 13

570 14

530 15

15

17

18

530

470

445

445 18

420 19

400 20

1000 8

9

9

10

890

890

800

800 10

730 11

730 11

210

6

7

1000 8

890 9

800 10

730 11

665 12

615 13

570 14

530 15

500 16

16

18

19

20

500

420

400

890 9

890 9

10

10

11

11

800

800

730

730

12665

12665

230 260

7

8

890 9

730 11

665 12

615 13

570 14

530 15

500 16

470 17

445 18

18

20

445

400

1000 8

890 9

800 10

800 10

11

12

12

13

730

665

665

615

14570

14570

270

7

9

800 10

730 11

665 12

615 13

570 14

530 15

470 17

445 18

420 19

19420

890 9

890 9

800 10

730 11

11

12

13

13

730

665

615

615

14570

14570

280

8

9

800 10

730 11

615 13

570 14

530 15

500 16

470 17

420 19

400 20

20400

890 9

800 10

800 10

730 11

12

12

13

14

665

665

615

570

14570

15530

N12

N16

Specialist advice is required

Specialist advice is required

Use N16 tiebars

Use N12 tiebars

1300

1300

1140

1140

1000

1300

1140

1140

1300

1140

1000

1000

1300

1140

1000

1300

1140

445

1140

1000

1140

1000

1140

1000

1140

890

1000

890

14

16

18

20

Example tiebar layout for 8.0 m slab

(g)

Tiebars must be placed at the spacing shown, with a tolerance of ± 20% on individual bars subject to the provision of the specified number of bars per slab.

contributors such as connected kerbs and for future widening.

Relief-edge distance (RED) is measured from the joint (or section) under design to the nearest relief edge. The value for RED must make allowances for stress

Space the remaining tiebars evenly in between.

Provide 300 mm to 1000 mm clearance from the end of the tiebar to transverse contraction joints.

Actual tiebar spacing determined as follows:

Maximum tiebar spacing is 1400 mm.

Tiebars

Number of

(h) It is necessary to check that the selected mesh provides adequate transverse steel to cater for the actual tied width, as shown in Table 10.1.

Round up number of tiebars to next whole number. Adjust offset to joints in accordance with Figure 9.1 and tiebar spacing similar to that shown.

Proportion number of tiebars for slabs that are not 8.0 m long. Average tiebar spacing is not to be less than the tabulated value for an 8.0 m slab.

675675

19 SPACES AT 350 C/C

20 TIEBARS 675675

600600


18 TIEBARS600600

625625


16 TIEBARS 625625

425425


14 TIEBARS 425425

S/2S/2SSSS/2S/2

TIEBARS

MIN

300

MIN

150

MIN

150

NTS

MINIMUM TIEBAR OFFSETS FROM JOINTS

J6

J7

J1

J2

J6

J9 OR J10

FIGURE 9.1

MIN

150

10

JOINT CATALOGUE

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(m)

Slab length

Mesh size (and Limiting RED )(a)

≤ 150 155 - 165 170 - 190 195 - 205 210 - 240 245 - 255

≤ 7.5

8

10

12

15

20

(c)(7.0)

(c)(6.5)

(c)(6.5)

(c)(6.5)

(c)(5.5)

(c)(5.0)

(c)(7.0)

(c)(7.0)

(c)(7.0)

(8.0)

(10.0)

(c)(6.5)

(c)(6.5)

(c)(6.5)

(8.0)

(8.0)SL718

(c)(6.5)

(c)(6.5)

(6.5)

(9.0)

(6.5)SL718

(c)(6.5)

(6.5)

(6.5)

(9.0)

(6.5)SL818

(5.5)

(5.5)

(6.5)

(5.5)SL718

(5.5)SL818

(5.0)

(6.5)

(6.5)

(5.0)SL718

(5.0)SL918

(b)

SL82

SL82

SL82

SL82

SL82

SL92

SL82

SL82

SL82

SL82

SL82

SL82

SL82

SL82

SL82

SL92

SL82

SL82

SL82

SL82

SL92

SL82

SL82

SL82

SL92

SL82

SL82

SL92

SL92

TABLE 10.1: MESH REINFORCEMENT

Table 10.1 Notes:

BASE THICKNESS 'D' (mm)

Roads and Maritime Services projects.

In the indicated cases, mesh SL72 is theoretically suitable (for base slab length, but not necessarily for large RED) but SL82 has been adopted for(c)

Tied kerbs must be included in the calculation of RED.

exceeding 10.0 m, the central lanes require increased transverse steel. (SL718 would be adequate in the outer lanes where the RED is lower.)

For a base slab 250 mm thick with SL718, the transverse steel (for example, 8 mm @ 200 c/c) is inadequate for RED > 5.0 m. Hence for tied widths(b)

transverse steel to contain unplanned longitudinal cracking, hence a design check is required. See example in Note (b).

The values in brackets indicates the upper limit for relief-edge distance (RED) for the indicated mesh size. At larger distances, there is inadequate(a)

FL

AT

g

BA

SE

D

THIC

KN

ES

S

FL

AT

g

HEIGHT

CORRUGATION

h

VERTICAL FACE

v

VERTICAL FACE

v

CORRUGATION DEPTH

d

DEPTH 'd'

CORRUGATION

HEIGHT 'h'

CORRUGATION

MINIMUM

FLAT 'g'

MINIMUM

20 10

12

< 200 3

CORRUGATIONS

NUMBER OF

'D'

THICKNESS

BASE

200 - 240

> 240

3 or 4

3 or 4

10 ± 3

12 ± 3

25

30 15

45

50

50

'v'

VERTICAL

MINIMUM

9 ± 3

It is not necessary to match the corrugation type of existing slabs during full or part slab replacement.(c)

Two alternative form profiles are shown, one suited to slipforming and the other suited to fixed-form work.(b)

The top and bottom corrugations must be concave in the first-placed face (ie convex on the form).(a)

TABLE 10.2: JOINT CORRUGATION DESIGN

Table 10.2 Notes:

CURVED PROFILE

REPLACED BY

FLATS MAY BE

TYPICAL FORM SECTION

11

KERBS AND BARRIER

At least one tie must be placed in any discrete section bounded by joints (for example, at kerb noses).

Notes:

they are also tied). Other kerb types (for example, SF) may be extruded.

Such kerbs are deemed to satisfy the "with shoulder" criteria for pavement thickness design purposes (as long as

in accordance with AS 1379 and must be either slipformed or fixed-formed (that is, they must not be extruded).

Unless otherwise allowed in the Specification, kerb types SA, SB, SC, SE, SK and SL must be strength grade N32

"with shoulder" criteria.

An integral slab widening may be required in order to comply with Austroads Guide to Pavement Technology Part 2

See Detail J on MJ06 and Schedule S7.1 for further details.

A geotextile fulfills an important function in keeping granular material from entering the base/subbase interface.

Edge drains fulfill an important function in draining the water which commonly runs along the base/subbase interface.

must be such as to prevent the occurrence of re-entrant angles in the base.

excluding mounted kerbs such as types SF, SG, SM) the angle of intersection must be 90° ± 6°, and the intersection

used as a control for the location of adjacent joints. Where a base joint intersects the nose of an adjoining kerb (that is,

The location of base joints relative to the extremities of islands and kerbs is critical. The dimensions so specified must be

Base joints must be extended into the adjoining kerb/median in like type.

(a)

(b)

(c)

(d)

(e)

(f)

(g)

Otherwise, kerb joints must be aligned at 90° ± 6° to the kerb line.

Where the kerb is placed on top of base pavement, the kerb joint must be aligned with the underlying joint.

Joints in kerbs (etc.) must be located to coincide with joints in the adjoining base, in accordance with R15.

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DETAIL

SCALE 1:20

K3

-

TYPE SB, SO AND SK

DETAIL

SCALE 1:20

K4

-

DETAIL

SCALE 1:20

K2

-

TYPE SE AND SL

DETAIL

SCALE 1:20

K1

-

TYPE SA

D/3 MIN

D/3 MIN

J1-N12-1000-1000

D

D/3 MIN

D/3 MIN

DMIN

50

D/3 MIN

D/3 MIN

D

SL SE

35 ± 1

0

D

SE & SL

80 ± 20

MIN

50

MIN

50

500 ± 50

500 ± 50

SF & SM

80 ± 20

SM

SF

MIN

50

BASE

SUBBASE

BASE

SUBBASE

MODIFIED TYPE SF AND SM

BASE

SUBBASE

J4-N12 @ 500 C/C IN ACCORDANCE WITH TABLE 7.1 WHEN INSTALLED AS DRILL-TIES INTO AN EXISTING BASE SLAB. ALSO SEE NOTE (d).

J3-N12 @ 500 C/C IN ACCORDANCE WITH TABLE 7.1 WHEN INSTALLED INTEGRALLY WITH BASE SLAB. ALSO SEE NOTE (d).

SEE NOTE (b)

500 MIN

DETAIL

SCALE 1:20

K6

-

BASE

SUBBASE

BASE

MAXIMUM 3 300

TIEBARS

TYPE F BARRIER

REFER TO ROADS AND MARITIME SERVICES STANDARD DRAWING MD.R132.D08.A.1

TYPE 'F' BARRIER (NOM 500 mm WIDE)

REFER TO ROADS AND MARITIME SERVICES STANDARD DRAWING MD.R132.D08.A.1

PROVIDE DOWEL

IN DETERMINING SLAB DIMENSIONS AND TIEBAR SPACINGS.

ALLOWANCE MUST BE MADE FOR THE KERB WEIGHT

REFER TO TABLE 3.5 GENERAL SLAB DIMENSIONAL LIMITS.

0.6 m MIN

DETAIL

SCALE 1:20

K5

-

INTEGRAL KERB/BASE

1.0 m MIN

J2

J7

J2

JOINT OMITTED IN THIS SLAB

J2

(WHERE SLAB WIDTH < 1.0m)

MESH (SEE TABLE 10.1)

J2-N12-1000-1000


J1-N12-1000-1000

MESH (SEE TABLE 10.1)MESH (SEE TABLE 10.1)


REINFORCEMENT NOT SHOWN FOR CLARITY

the desirable "design cracking".

are susceptible to transverse cracking which will be more closely spaced than

Longitudinal cracking in JRCP is undesirable because the resulting elongated slabs3.

as "design cracking".

and as long as the reinforcement is adequate. These cases have been labelled

not be injurious as long as they meet accepted guidelines for location and orientation,

Certain types of transverse cracking in JRCP are to be expected and will usually2.

Typical slab replacements and repairs

JRCP cracking

Existing transverse joints

NOTES

No

NOTESYMBOL

(where applicable)

DIMENSIONDESCRIPTION AND COMMENTS

1 A 1.5 m MIN

2 B

0.8W preferred MIN

1.5 m MIN

3 C

Untrafficked: 0.6 m MIN

Trafficked: 1.0 m MIN

See notes to Case Study.

Width of a longitudinal strip repair.C:

4 D

Untrafficked: 0.6 m MIN

Trafficked: 1.0 m MIN Width of residual slab.D:

5 J

J > 1.5 m

J = 0, or

refer to Figure 13.2 for details.

Offset between adjacent transverse tied joint;J:

6 L Length of slabL:

7 W Width of slabW:

8 84° MIN Slab corner angle

9 JRCP slab (or part-slab) replacement

CASE 7 : Termination of a longitudinal joint

premature longitudinal cracking.

A shorter residual length increases the risk of

yields an elongation ratio of 1.25 (maximum).

the width of that particular slab. A ratio of 0.8

is acceptable but 0.8W is preferred, where W is

Length of residual slab. A minimum value of 1.5 mB:

SLAB REPLACEMENT

Length of slab R & RA:

CASE 1 : Longitudinal central strip repair - Compromise Practice

CASE 2 : Longitudinal edge strip repair - Compromise Practice

CASE 3 : Transverse strip repair - Best Practice

CASE 4 : Full-slab replacement - Compromise Practice

CASE 6 : Multiple repair - Compromise Practice

CASE 8 : Part-length repair; slab end - Compromise Practice

CASE 5 : Part-length repair; mid-slab - Best Practice

Schedule 12.3 limits.

The transverse joints need not be parallel but all corner angles must comply with(b)

an expansion cavity of similar width.

Hence, if the existing longitudinal joint is untied, the joint in the strip repair must provide

The new sections of longitudinal joint must be consistent with the existing.

The repair must extend between existing longitudinal joints.(a)

Terminate at a Type J10 at the plan location of an existing Type J9 or Type J10.(b)

Terminate at a Type J7 as shown (that is, mid-slab).(a)

Two options are allowed:

10 #

that a filler be provided of nominal thickness 7 ± 3 mm.

withstand these compressive forces. However, where doubt exists, it is recommended

In full-width slab repairs, it is assumed that the full section will have the capacity to

(below any sawcut and/or sealant).

the width of the new expansion cavity should be not less than the width of existing joint

acts later to close all transverse joints. In these cases (for example, Cases 1, 2, and 6),

the repaired strip will bear the compressive forces of the full slab width when expansion

In longitudinal strip repairs, a full-depth expansion cavity must be provided otherwise5.

the missing slabs were infilled at a later date.)

the "chequerboard" method whereby alternate slabs were fully formed and paved, and

(Before the adoption of sawcutting, JRC pavements were typically constructed using

(expansion), depending on the original construction method.

contraction) whereas they may actually be Type J10 (formed contraction) or Type J16

The drawings in this Set typically show existing transverse joints as Type J9 (sawn4.

See Note 10 (S12.3)(a)

See Note 10 (S12.3)(b)

there is a risk that the Type J2d joint will reflect into the transverse repair.

The transverse repair should precede the longitudinal repair. If the reverse applies,(a)

See Note 10 (S12.3)(b)


the tolerance for alignment.

dowels and that the dowels will not be installed within

by the action of drilling large holes to install the

J10d or J16d joint, the existing slab will be damaged

There is a risk that in the process of constructing a

11

a corner of the concrete in the format dd-mm-yyyy.

Imprint the date of casting of the replacement slab in



CASE 9 : Transverse joint repair - Best Practice

CASE 10 : Full-slab replacement - Best Practice

12

SCHEDULE 12.1 (S12.1)

configurations, or a conforming combination.

describes each JRCP slab repair case. Repairs must comply with one of these

Figure 12.1 shows various allowable JRCP slab repair configurations. S12.21.

SCHEDULE 12.2 (S12.2) CONTINUED

SCHEDULE 12.3 (S12.3) KEY AND NOTES (REFER TO FIG 12.1)

SCHEDULE 12.2 (S12.2) CASE STUDIES (REFER TO FIG 12.1)

See Note 10 (S12.3)(c)

consistent with the cavity in the adjoining (existing) Type J9. See Note 5 (S12.1)

The new transverse joints are expansions (Type J16d) to provide an expansion cavity(b)

The repair must extend between existing transverse joints.(a)

See Note 10 (S12.3)(c)

consistent with the cavity in the adjoining (existing) Type J9. See Note 5 (S12.1)

The new transverse joints are expansions (Type J16d) to provide an expansion cavity(b)

The repair must extend between existing transverse joints.(a)

(Refer to Figure 13.2 and Figure 13.2 Notes)

Where 0 < J < 1.5 m is unavoidable, the initial pour must overlap the second pour.(c)

than the corner cracking shown in Figure 13.2 (which leads to secondary distress).

1.5 m so that cracking will be transverse (which resembles 'design cracking') rather

If the joint layout cannot be arranged such that J=0 then J should preferably exceed(b)

provide an expansion cavity of similar width.

Hence, if the existing longitudinal joint is untied, the joint in the strip repair must

The new sections of longitudinal joint must be consistent with the existing.


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TIED AND SAWN

J2 TIED AND FORMED

J6b J6c

J6

J7d

DRILL-TIED

LONGITUDINAL EDGE

DRILL-TIED

DRILL-DOWELLED

J1

J2d

J10d

J3 TIED AND RIBBONED

J9 SAWN AND DOWELLED

J10 FORMED AND DOWELLED

#

J16dDRILL-DOWELLED

EXPANSION:#

COMMON JOINT TYPES - JRCP

CASE 4

CASE 9CASE 8

CASE 10

CASE 6

CASE 5

CASE 5

CASE 2

CASE 1

FIGURE 12.1: TYPICAL SLAB REPLACEMENTS

J10d J10d

J2d

J2d

J2d

J2d

J2d

J2d

J16d J16d

J16d J16d

J9

J1

J2

OR

J7d

J7dJ7d

J7d J7d J7d

J7dJ9 J10

J9

J9 J9

J9

J9

J9

J2

J2

J2

J2

J2

J2

J2

J10 J10 J10

J2d

J2d

J2d

J2d

J2d J2d

J2d J2d

J2d

J7

J7

J7J16d

J10d

J10d

J1

J1

J1

J2

J3

J3

J6

J7d

OR OR

OR

OR

OR

OR OR

D

C

D

D

C

OR

D

C

B

A

J J

J

A

A

AABA

B

B

MIN

1 000MAX

4 300

OR

# #

# #

# #

J10OR J9 J10OR

J7d

J2dOR

J7d J7d

B

J7d

J1

OR

J2 J2dOR

CASE 7

J2d

J7d J7d

CASE 3

#

#

#

OR J2d

J9 J10OR

A

W

L

BABB

SEE FIGURE 13.2

SEE FIGURE 13.2

AB

B

No

NOTESYMBOL

(where applicable)

DIMENSIONDESCRIPTION AND COMMENTS

2 B

0.8W preferred MIN

1.5 m MIN

3 E

4 F

6 L Length of slabL:

7 W Width of slabW:

premature longitudinal cracking.

A shorter residual length increases the risk of

yields an elongation ratio of 1.25 (maximum).

the width of that particular slab. A ratio of 0.8

is acceptable but 0.8W is preferred, where W is

Length of residual slab. A minimum value of 1.5 mB:

CASE 1 : Kerb replacement

CASE 2: Single detector loop; slab-end

CASE 3: Single detector loop; mid-slab

CASE 4: Double detector loop

reconstructed as shown in details K5 to provide adequate shoulder support.

joints as shown, the side of the JRCP slab and abutting kerb should desirably be

Where trapezoidal shaped JRCP slabs develop corner cracks near intersecting J7(a)

SLAB REPLACEMENT - MISCELLANEOUS WORK

6.0 m MAX

4.8 m MIN

1.0 m MAX

0.15 m MIN

length of SFCP patch for a single detector loop.E:

edge distance to detector sawcuts in SFCP.F:

J9 J7d J7d J9

POUR B

J J

POUR A

BAB

Pour B follows Pour A.Scenario 1:

hinge deflections at the transverse joints of Pour A.

The risks are magnified by early trafficking because heavy vehicles will induce

There is a risk of reflection cracking in Pour B (as shown) within days of casting.

Scenario 2: Pour A follows Pour B.

Reflection cracking will not occur if the initial pour overlaps the second pour.

1 A 1.5 m MIN Length of slab R & RA:

5 J

J > 1.5 m

J = 0, or

refer to Figure 13.2 for details.

Offset between adjacent transverse tied joint;J:

CRACKING

REFLECTION

8 JRCP slab (or part-slab) replacement

FIGURE 13.2: MISMATCH OF TRANSVERSE JOINTS

omit tiebars from the longitudinal joint within the overlap length "J".

4-N12 1200 long 200 spacing trimmer bars across the potential crack path, and

Where 0 < J < 1.5 m is unavoidable, provide ancilliary reinforcement in the form of

9 #

10

a corner of the concrete in the format dd-mm-yyyy.

Imprint the date of casting of the replacement slab in

tolerance for alignment.

that the dowels will not be installed within the

action of drilling large holes to install the dowels and

J10d joint, the existing slab will be damaged by the

There is a risk that in the process of constructing a

than corner cracking (which leads to secondary distress).

1.5m so that cracking will be transverse (which resembles "design cracking") rather

If the joint layout cannot be arranged such that J=0 then J should preferably exceed

mesh or bar reinforcement in detector slabs.

Replace existing part-slab with SFCP. Seek specialist advice regarding the use of(a)





SCHEDULE 13.1 (S13.1) CASE STUDIES (REFER TO FIGURE 13.1)

(REFER TO FIGURES 13.1 AND 13.2)

SCHEDULE 13.2 (S13.2) KEY AND NOTES

Figure 13.2 Notes:

13

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J16dDRILL-DOWELLED

EXPANSION:

TIED AND SAWN

J2 TIED AND FORMED

J6b J6c

J6

J7d

DRILL-TIED

LONGITUDINAL EDGE

DRILL-TIED

J1

J2d

J3 TIED AND RIBBONED

J9 SAWN AND DOWELLED

J10 FORMED AND DOWELLED

HINGE: TIED AND SAWN

COMMON JOINT TYPES - JRCP

DRILL-DOWELLEDJ10d #

J17F

J9

J2

J2

J10

J7

J1 J3

J6

OR OR

OR

J7dCASE 1

CORNER CRACK

1 000 MIN

L

W

J10d J17F

J7d J10d

J2 J2

J9 J10d

DETECTORS

SIGNAL

TRAFFIC

F

FJ2

J2d J2J2

J7d J7d J10

J7d J10

RELIEF EDGE

BEB

F

F

4.5 ± 0.1 m 1.0 ± 0.1 m

CASE 2

CASE 3

CASE 4

KERB LIP LINE

J2d

#

#

#

B E

FIGURE 13.1: MISCELLANEOUS WORK

SEE FIG 13.2

SEE FIG 13.2

B 4.5 ± 0.1 m F

SLAB REPLACEMENT (UNACCEPTABLE PRACTICES)

14

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CASE 1: Skewed trench - crossing a transverse contraction joint

corrosion and possibly also to yield failure.

limited benefit. Large crack deflections (and openings) expose the reinforcement to rapid

Because of the high deflections within corner cracks, mesh and/or bar reinforcement provides(b)

Skewed cracking produces acute corners which are then prone to secondary cracking.

The slab cut-out is located in an area of high stress and so creates a risk of corner cracking.(a)

CASE 6: Service pit - slab end

CASE 8: Patch repair - corner or part-width or part-length

Comments under Case 7 also apply.(b)

the residual slab.

A Type J17 joint would increase the risk of block cracking because it would reduce the size of(a)

CASE 9: Service pit - mid slab, circular

case.

distance of the pit from the slab centroid. The design of the isolation joint must cater for the worst

The relative contraction movements between the pit and the slab will increase with increasing(c)

intersections at the pit.

A Type J17 joint is desirable to produce a controlled crack which would reduce the risk of acute(b)

CASE 10: Patch repair or utility- mid slab, rectangular

case.

distance of the pit from the slab centroid. The design of the isolation joint must cater for the worst

The relative contraction movements between the pit and the slab will increase with increasing(b)

risk that the cracking will be skewed.

joint there is an increased risk of longitudinal cracking (resulting in block cracking). There is a high

The cut-out is certain to generate cracking. If the crack runs square to the adjacent longitudinal(a)

CASE 11: Patch repair or utility - edge

CASE 12: Longitudinal trench

CASE 13: Mismatched transverse construction joint

CASE 14: Detector loop sawcutting

to detect the presence of vehicles.

The presence of reinforcing mesh within the slab can significantly reduce the sensitivity of the loop(c)

mechanism, and stress levels vary widely in different zones of the slab.

It is difficult to establish safe limits for sawcut depth because fatigue is a highly variable distress(b)

Sawcuts act as crack initiators, particularly under flexural fatigue loading.(a)

to the slab centroid. The design of the isolation joint must cater for the worst case.

There will be large contraction movements of the slab relative to the pit because of the distance(b)

failure.

deflections (and openings) expose the reinforcement to rapid corrosion and possibly also to yield

Consistent with Case 3, mesh and/or bar reinforcement provides limited benefit. Large crack(a)

CASE 2: Skewed trench - mid-slab

CASE 3: Drainage pit - slab corner

CASE 4: Drainage pit - mid-slab

CASE 5: Service pit - slab corner

with increasing distance of the pit from the slab centroid.

also to yield failure. The relative contraction movements between the pit and the slab will increase

Large crack deflections (and openings) expose the reinforcement to rapid corrosion and possibly

Consistent with Cases 3 and 5, mesh and/or bar reinforcement provides limited benefit.(a)

CASE 7: Patch repair - corner

This is similar to Cases 7 and 8.(a)

(resulting in block cracking). If the crack intersects at a skew then secondary distress is inevitable.

joint then further distress may occur because of the increased risk of longitudinal cracking

The cut-out is certain to generate cracking. If the crack runs square to the adjacent longitudinal(a)

Comments under Case 7 also apply.(b)

are observed.

Trenching will produce elongated slabs which will lead to reduced life unless dimensional limits(a)

"design cracking".

transverse crack which is unlikely to cause distress because it effectively constitutes

A circular pit located within the central third (length-wise) of the slab is likely to generate a single(a)

SCHEDULE 14.1 (S14.1) CONTINUEDSCHEDULE 14.1 (S14.1) CASE STUDIES UNACCEPTABLE PRACTICES

reinstated across the new trench slab, unplanned cracking will result (regardless of reinforcement).

All contraction joints must be continuous between free edges. If the contraction joint is not(b)

This applies both to the residual (original) slabs and to the new trench slab.

Corner angles more acute than 80°-85° are at risk of corner cracking and/or spalling.(a)

This applies to both the original slab and to the replacement slab.

Consistent with Case 1, corner angles more acute than 80°-85° are at risk of corner cracking.(a)

cracking (resulting in block cracking).

However, the existence of two close-spaced parallel cracks increases the risk of longitudinal(b)

distress unless they intersect joints (or cracks) at skew angles less than 80°-85°.

The transverse cracks induced by the pit resemble "design cracking" and so are unlikely to cause(a)

The comments for Case 10 apply.(a)

KERB AND G

UTTER

CASE 14

CASE 12

CASE 10

CASE 11

CASE 13

U

U

U

U

FIGURE 14.1: UNACCEPTABLE WORK PRACTICES

SLAB REPLACEMENT OR UTILITY

CONSEQUENTIAL UNPLANNED CRACKINGTRAFFIC SIGNAL DETECTORS

CRACKING

DESIGN

SCHEMATIC

CRACKING

DESIGN

SCHEMATIC CRACKING

DESIGN

SCHEMATIC

CRACKING

DESIGN

SCHEMATIC

CASE 1

CASE 2

CASE 3

CASE 4

CASE 6

CASE 7

CASE 8

CASE 9

SEE SCHEDULE 14.1 FOR EXPLANATORY NOTES

CASE 5

15

SLAB REPLACEMENT

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ACTIVITY METHOD

in the slabs which are to remain.

Every effort must be made to prevent sawcutting slurry from entering joints or cracks5.

removal

Concrete2.

spall the edges of the abutting slabs).

The perimeter strip is then removed manually using jack-picks (taking great care not to(b)

Internal sawcuts are used to break the slab into smaller pieces for removal.(a)

Excavator removal1.

There are two common methods of slab removal:

ACTIVITY METHOD

of tiebars

Reinstatement4.

All other tiebar details must be in accordance with Schedule 7.2.2.

Dowels5.

minimise early stress on the fresh concrete).

At formed joints the dowel length within the second-placed slab must be debonded (to2.

Dowels must be provided in accordance with Schedule 7.2.1.

repairs

Subbase6.

ACTIVITY METHOD

the repair

Cleaning out7.

debonding

Subbase8.

and sealing

debonding

Joint9. 1.

2.

Reinforcement

10.

design

11. Concrete mix

13. Jointing

traffic

14. Opening to

joint faces

of exposed

Preparation3.Sawcutting1.

line), in which case it may be a butt joint.

located 0.5 m or more outside a trafficked lane (for example ≥ 0.5 m outside an edge

All other longitudinal joints must be corrugated, keyed, or scabbled unless the joint is(b)

dowelled joints●

any untied joint●

The following joints may be butt joints:(a)

Longitudinal joints2.

removal with a minimum of damage to adjacent slabs / joints and to the subbase.

Internal cuts within the slab to break it in to manageable pieces to facilitate(b)

correct defects in the joints or adjacent slabs.●

reduce the risk of edge and arris damage on the slabs which are to remain.●

assist in slab removal.●

Perimeter cuts along existing joints (or with a minor offset) to:(a)

Two types of sawcuts are typically required:1.

Faces

Joints and cracks

strength development needed to suit trafficking requirements.(c)

construction logistics.(b)

structural and thickness design requirements.(a)

The concrete mix must be designed with consideration of:1.

not extend beyond the limits of removal.

longitudinal joint must not extend beyond the limits of removal. Transverse sawcuts must

250 mm beyond the limits of removal. Longitudinal sawcuts which are offset from an existing

Longitudinal sawcuts which precisely follow an existing longitudinal joint may extend up to4.

(S15.1): CONTINUED

arris rounding may require treatment in accordance with Figure 25.1.

In addition to those defects listed in Schedule 16.1 (and related Detail drawings) minor(e)

material.

and re-entrant angles. Minor defects may be corrected by plastering with an appropriate

The exposed face must be dense and fully compacted, and be free of honeycombing(d)

additional spalling).

itself may be best deferred until after the slab R & R (because the R & R may cause

be easier if carried out before removal of the failed slab. However, the defect repair

Where remedial sawing is required (to correct defects in adjoining joint faces), it may(c)

Spall repairs must be completed in accordance with MJ24 and MJ25.

be placed integrally with the adjoining concrete).

independently of the placement of adjoining concrete (that is, the repair material must not

Where remedial treatment (such as spall repair) is needed, it must be completed(b)

Exposed faces must be assessed and treated in accordance with Schedule 16.1.(a)

General1.

to the form to minimise edge damage during recovery.

first-placed slab for later straightening before the second pour. They need be placed close

single-lane R & R, tiebar drilling can be avoided by placing L-shaped tiebars into the

Where two adjoining slabs (joined by a common longitudinal joint) are to be replaced by3.

SCHEDULE 15.1 (S15.1): FULL AND PART-SLAB R & R (S15.1): CONTINUED

cleaned and then treated with a debonding agent in accordance with Schedule 7.1.

Before the replacement base is placed, the full face of all joints must be thoroughly

uneven bedding under the adjacent slab when the direction of curling reverses).

with a silicone sealant where it exceeds about 0.5 mm. (Ingress of grout will create

The exposed horizontal gap between the subbase and the base should also be sealed(b)

a silicone sealant to prevent ingress of mortar.

All corners, joints and any underlying cracks in the exposed slabs must be sealed with(a)

Mesh must be placed to provide cover as specified in Note 7 Schedule 7.1.2.

Replacement slabs must be reinforced with mesh as shown in Table 10.1.1.

new concrete

12. Placing of

New joints must be designed and constructed in accordance with MJ05-MJ09.

of these cylinders will provide the best guidance for timing of access to the repair area.

should be cast and cured alongside the slab and in a similar manner. Progressive testing

In order to monitor the rate of strength gain actually achieved on site, additional cylinders2.

materials and work processes may be used for guidance.

In cases where the requirements of Note 14.2 are not practicable, experience with particular3.

Note:

(a)

to trafficking strength.

Notes in this Schedule are referred to by both Activity and Method number. For example, Note 14.1 relates

8 m long, 4 m wide, 230 mm thick JRCP slabs typically have a mass of 18 t.●

Skewing of the slab often jams it in place and damages adjoining edges and arrisses.●

Subbase bond/suction can exceed 50 t per slab (for an 8 m long x 4 m wide slab);●

This method can be difficult because:(d)

The perimeter strip is then removed manually, in accordance with Note 2.1.(c)

using chemical anchors. They must be designed by a Chartered Professional Engineer.

The lifting hooks should be eye bolts which are resin-grouted into the top of the slab(b)

The slab (within the full-depth cuts) is lifted in a single piece.(a)

Crane lift2.

with Schedule 16.1.

the face will be smooth as a result of sawing and hence must be treated in accordance

All other transverse joints must be corrugated, keyed, or scabbled. In many cases,(b)

dowelled joints●

any untied joint●

The following joints may be butt joints:(a)

Transverse joints3.

design spacings in accordance with Table 9.1.longitudinal joints:●

at 500 c/ctransverse construction joints:●

must be as follows:

Drill-ties must be provided to replace or supplement existing tiebars. The final tiebar spacing1.

high interlayer bonding, which may initiate unplanned base cracking.(b)

reflection of subbase cracks into the new base.(a)

widths. The major risks associated with such defects are:

Cracks in the subbase should be examined for spalls, stepping, and for excessive crack2.

Seek specialist advice for assessment and repair of subbase.1.

200 mm from joints, but may be varied to suit individual conditions.

If existing tiebars are to be replaced by drill-ties, sawcuts would typically be about(b)

for welded splices.

and 400 mm for N16 bars. Shorter lengths are allowed (in accordance with AS3600)

To save tiebars, sawcuts must be located to provide lap lengths of 300 mm for N12 bars(a)

or cut.

a concrete subbase. Their location will depend on whether existing tiebars are to be saved

Internal cuts are typically just less than full-depth, but should not be deep enough to touch2.

minor corrections) rather than replacing them with a scabbled face.

Where existing corrugations are conforming, it is preferable to retain them (perhaps with

whether the existing corrugations or keyways are to be saved; see also Activity 3.(c)

rounding).

whether defects in the exposed face need to be corrected (for example spalling and/or(b)

whether tiebars are to be saved or cut.(a)

joint needs consideration. Factors include:

Perimeter cuts may be either full-depth or part-depth, and their precise location relative to the3.

All waste material resulting from the above operations must be removed.

compressive strength of 20 MPa.

The pavement should not be opened to traffic until the concrete has attained insitu1.

sheeting on the subbase in accordance with M258.

vehicles. An alternative method of debonding the subbase and base is to place polyethylene

A cover aggregate may be warranted to facilitate access by workers and construction

For granular subbases (including rolled concrete), a bitumen emulsion must be used.

The typical debonding treatment on LCS is wax emulsion applied at a rate of 0.5 litre/m².

Debonding must conform with M258.2.

very low friction can result in poor induction of joints.●

strong bonding may initiate unplanned base cracking.●

layers, for the following reasons:

It is important to achieve a suitable level of debonding between the subbase and base1.

● protection● curing● texturing● compaction● paving

cover issues such as:

Placing of concrete must also accord with the principles detailed in NR82 and NR83, which2.

Work must be in accordance with M258.1.

16

SLAB REPLACEMENT

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FIGURE 16.2: CORRUGATED JOINTS

which were common in NSW until the mid-1980s.

This shows typical dimensions for keyed joints,(a)

superseded in the mid-1980s by corrugated faces.)

successfully. (For these reasons, they were

(as shown) and were very difficult to slipform

They were susceptible to failure of the concave arris(b)

surface mortar.

be in the first-placed slab, which can be identified by

assume, following from (c), that the concave side will

in the absence of clear evidence), it is reasonable to

In trying to identify the orientation of the keyway (and(d)

with Figure 17.1.

otherwise), scabble the face in accordance

If the key is totally removed (by mistake, or(c)

with Figure 17.1.

otherwise), scabble the face in accordance

If the key is totally removed (by mistake, or(c)

material removed from the exposed faces.

the resulting face after treatment.

cracking in the new slab.

Scabble to remove any lip which might cause

1

MIN

3

attaching extra moulds to the form).

it is also easier to construct in this orientation (by

stress from the adjoining slab. In fixed-form paving,

so that it gains strength before being subjected to

typically require that the concave side be placed first,

concrete shear strength is low. Hence, specifications

can occur within days of construction while the

by load deflections and slab curling. Microcracking

side to the high arris stresses which are generated

The concave side is more sensitive than the convex(c)

25 60

30TIEBAR

15 ± 5NEW SLAB

15 ± 5NEW SLAB

NEW SLAB

D/3 TYP

CRACK

INDUCED

REMOVE LIP

NEW SLAB

VERTICAL FACE 45 MIN

NEW SLAB


POTENTIAL SPALL

SCABBLE

EXISTING JOINT RECESS

FIGURE 16.1:

16.1 AND 16.2

KEY TO FIGURES

(a)TYPE

JOINT

EXPOSED

DESCRIPTION NOTES

The joint effectively converts to a Type J2, scabbled.(b)

in the new slab.

Remove any lip to minimise the risk of crack initiation(a)

Refer to Figure 16.1.

corrugated

J2

J2, keyedRefer to Figure 16.3.

Refer to Figure 17.1.J2, butt

J3

J4

New tied joints

New untied joints

Design a sealant in accordance with Table 8.1.(f)

Carry out spall repairs in accordance with MJ24 and MJ25.(e)

and so do not need to be scabbled.

Untied joints are not expected to transfer shear loads(d)

sawn

J5,

ribboned

J5

J6

for remedial treatments on rounded/spalled edges.

according to the new joint type. See MJ24 and MJ25

Where widening is required at a Type J6, treat the edge

corrugated

J7

tied

construction:

Transverse

J7, keyed


tied

construction:

Transverse


tied

construction:

Transverse

J7, butt

where a spall repair has been carried out.

to minimise the stress on the abutting arrises, particularly

(sealed) joint cavity may be desirable in some situations

Formed tied joints normally do not require sealing, but a(b)

Treat in accordance with Cases 2-7.(a)


tied and sawn

Longitudinal:

tied and formed

Longitudinal:

tied and formed

Longitudinal:

tied and formed

Longitudinal:

The alternatives are as follows.

will depend on whether the new joint will be tied or untied.

Where an existing J4 face is exposed, the required treatment

ribboned

untied and

Longitudinal:

edge

Longitudinal:

OF JOINTS EXPOSED DURING R & R

SCHEDULE 16.1 (S16.1): TREATMENT

Design a sealant in accordance with MJ08.(b)

Treat in accordance with Cases 2-7.(a)


ribboned

tied and

Longitudinal:

sawn

untied and

Longitudinal:

FIGURE 16.3: KEYED JOINTS

Case 2: Exposed convex face

Case 2: Exposed convex face

J1

J8

sawn

construction:

Transverse Not valid.

J9

J10

J11

J12

J13

J14

Design a filler and sealant in accordance with MJ08.(c)

Carry out spall repairs in accordance with MJ24 and MJ25.(b)

Scabbling is not required.(a)

J15

J16

J17

The joint effectively converts to a Type J2, scabbled.(b)

initiation in the new slab.

Remove any lip (by scabbling) to minimise the risk of crack(a)


J18 according to the new joint type.

Where widening is required at a Type J18, treat the edge

gains its design strength.)

with the new concrete will cause distress before the patch

the embedded length is also debonded because any bond

Debond all exposed dowels. (This applies even where(d)

Design a sealant in accordance with MJ08.(c)


Untied joints do not need to be scabbled.(a)

gains its design strength.)

the new concrete will cause distress before the patch

embedded length is also debonded because any bond with

Debond all exposed dowels. (This applies even where the(d)

Design a sealant in accordance with MJ08.(c)


Untied joints do not need to be scabbled.(a)

dowelled

sawn and

contraction:

Transverse

dowelled

formed and

contraction:

Transverse

knifed

contraction:

Transverse

dowelled

knifed and

contraction:

Transverse

formed

contraction:

Transverse

beam

with subgrade

Isolation:

beam

subgrade

without

Isolation:

dowelled

Expansion:

tied and sawn

Hinge:

(S16.1): CONTINUED

DESCRIPTION

TYPE

JOINT

EXPOSED

(a)NOTES

joint type.

Treatments are based on the joint types encountered in the field, not the intended

Not valid.

Not valid.

of the convex side.

is warranted in conjunction with replacement

than about 45 mm) and so preventive work

(particularly if the top vertical face is less

side remains at risk of future failure

However, the top section on the concave

carry the same risk as with the concave slab.

Replacement of the convex slab does not(a)

(a)

SAWCUT

SAWCUT

SAWCUTSAWCUT

scabbling, after removal of the failed slab.(ii)

to assist with the slab removal), or

(as shown above, possibly arranged

sawcutting before slab removal(i)

This could be done by:

to 15 mm ± 5.

arris, the convex key should be reduced

To minimise stresses on the new concave(b)

minimum vertical face dimension.

Sawcut (if necessary) to provide the specified

spall repairs.

lengths. They are also beneficial to minimise stresses on

should be sealed to maintain consistency with adjacent joint

Formed tied joints normally do not require sealing, but they

Design a sealant in accordance with Table 8.2.(c)

MJ24 and MJ25.

Carry out any spall repairs in accordance with(b)

scabbling in accordance with Schedule 15.1 Activity 3.

If the exposed face is smooth, assess the warrant for(a)

Design a sealant in accordance with MJ08.(b)

MJ24 and MJ25.

Carry out any spall repairs in accordance with(a)

Shading indicates the following:

provided on MJ05-MJ09.

corrugations if they depart substantially from the advice

Further remedial treatment may be required on the underlying


formed

untied and

Longitudinal:

Treat in accordance with Type J10.

Treat in accordance with Type J14.

Design a filler and sealant in accordance with MJ08.(b)

Treat in accordance with Type J10.(a)

Note:

D/3+10 from the top (as shown in Figure 17.1).

Scabble the sawn section which is more than

Sawcut to the bottom of the top corrugation.

Option 2:

prevent future spalling on the concave side).

the specified minimum vertical face (to

Sawcut and scabble as shown to provide

Option 1:

FAILURE MODE

COMMON

Case 1: Typical keyed joint

Case 1: Exposed concave face

Case 3: Exposed concave face

replacing or repairing keyed slabs.

hence special care is warranted when

could also occur in replacement slabs,

The type of failure described under Case 1(a)

assist in slab removal.(ii)

and/or

remove arris spalling (or rounding),(i)

desirable in order to:

The sawcut (as shown) may also be(b)

provided in Table 10.2.

corrugations if they depart substantially from the advice

Further remedial treatment may be required on the underlying


beamed

edge and

Longitudinal:

17

SLAB REPLACEMENT

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Sawcut and scabble.

Option 1:

vertical face dimension.

Locate the sawcut to achieve the required

on the underlying face.

vertical face dimension, and the limiting slope

Locate the sawcut to achieve the required

Sawcut and scabble.

Option 1:

MJ24 and MJ25.

Carry out a spall repair as shown on

Option 2:

MIN

3

NEW SLAB


POTENTIAL SPALL

RIBBON

VERTICAL FACE

SCABBLE TO NEAR

NEW SLAB

RIBBON

FOR REMOVAL

SECTION

SCABBLE

NEW SLAB NEW SLAB NEW SLAB

VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN

OPTION 1 OPTION 2

CONCAVE ARRIS

REMOVE

RIBBON

CONCAVE ARRIS

REMOVE

MIN

3

1

RIBBONRIBBON

1

MIN

3

FOR REMOVAL

SECTIONREPAIR

SPALL

RIBBON

FACES

SCABBLED

INDUCED CRACK

RIBBON

sawing for joint resealing.

Frequent lateral deflections will complicate future

(which are likely to initiate unplanned cracking).

nonconforming because they create joint mismatches

plan alignment of the joint. Stepped offsets are

Consideration also needs to be given to the resulting(e)

length may be impractical over longer lengths.

A technique which is suitable for an isolated short

according to the length of nonconformity.

The selected method of repair is likely to vary(d)

accordance with Cases 2-7.

Where the ribbon is curled and/or inclined, treat in(c)

(apart from debonding) before concrete placement.

will leave a face which requires little or no treatment

Where the ribbon was well installed, joint exposure(b)

curled and/or inclined.

variable and they will often be found deeper and/or

shown here. However, their accuracy was highly

Specifications required that ribbons be placed as(a)

MJ24 and MJ25.

Carry out a spall repair as shown on

Option 2:

PERIMETER GROOVE 15

= 90° ± 5°

D/3

010

+ –

NEW SLAB

FIGURE 17.2: RIBBONED JOINTS

Case 1: Model ribboned joint Case 2: Curled and vertical Case 3: Curled and inclined

Case 5: Curled and vertical Case 6: Curled and inclined Case 7: Curled and inclined

SAWCUTSAWCUT

SAWCUTSAWCUT

SAWCUT

SAWCUT

D

D/3+10 MAX45 MINNEW SLAB

25 ± 15

SCABBLED FACE

FIGURE 17.1: BUTT AND SCABBLED FACES

than 1 in 3.

underlying face at a slope not greater

minimum) and the need to transition the

the vertical face dimension (of 45 mm

The location of the sawcut is dictated by(a)

material removed from the exposed faces.

the resulting face after treatment.

Shading indicates the following:3.

Where the new joint will be tied, a sealant will not be required in most cases. Where the new joint will be untied, a sealant must be designed in accordance with MJ08.2.

Ribboned joints are no longer used for new construction or maintenance work.1.

The face must be debonded in accordance with Activity 9 (S15.1).(d)

the new slab.

surface with indentations 4-6 mm deep that will provide a key for

over a large proportion of the scabbled face and to achieve a rough

Scabbling must be thorough enough to expose coarse aggregate(c)

damage from scabbling and to minimise arris spalling.

The top and bottom sections must be left smooth to prevent(b)

The warrant for scabbling is detailed under Activity 3 (S15.1).(a)

Figure 17.2 Notes:

from the top (as shown in Figure 17.1).

be scabbled below the line D/3+10 mm

Where deep sawing is used, the face must(b)

sawing and scabbling, or by deeper sawing.

Remove the ribbon by a combination of(a)

sawcut

1 ± 1

1


1

MIN

3

OPTION 1 OPTION 2

NEW SLAB


RIBBON

SCABBLE

NEW SLAB

RIBBON

REPAIR

SPALL

FACES

SCABBLED

PERIMETER GROOVE 15

Case 4: Curled and inclined

SAWCUT

SAWCUT

18

CROSS STITCHING OF CRACKS AND JOINTS - COMPROMISE PRACTICE

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TABLE 18.2: STITCHING LENGTHS

FIGURE 18.2: STITCH-BAR PROTECTION

CASE 12



Table 18.2 Notes:

TRANSVERSE AND CORNER CRACKS

STITCH-BAR SPACINGS FOR

TABLE 18.4:

A A

NOT TO SCALE

p

b/2

SUBBASE

L

==

L

t

D

t

L

L

FIXING COMPOUND

h

b

c

NOTES

L (mm)

hole to crack

Offset: drill

215

210

200

190

180

175

165

(mm)

D

Base thickness

c

250

240

230

220

210

200

190

250

300

Corner cracks 300

500Transverse cracks

L (mm)

protection

Length of

pL (mm)

stitch-bar

Length of

L (mm)

hole

Length of drill

bh

400450

380430

360410

340390

320370

300350

280330

CASE 10 : Longitudinal tied joint

CASE 9 : Late sawcut cracking

CASE 8 : Late sawcut cracking

CASE 7 : End-slab transverse cracking

CASE 6 : Multiple cracking

CASE 5 : Small corner cracks

CASE 4 : Large corner cracks

CASE 3 : Transverse mid-slab cracking

CASE 2 : Skewed longitudinal cracking

CASE 12 : Anchor Slabs

CASE 11 : Kerbs

CASE 1 : Longitudinal cracking

1

5

7

Not suitable for stitching. Similar to Case 8.(a)

success because secondary cracking is likely.

In unreinforced anchor slabs (that is, superseded design) stitching has had only moderate(b)

Stitching is not required or warranted in reinforced anchor slabs.(a)

See Fig 18.2 for protection details(b)

To suit drill angle = 30° and cover t = 25 mm(a)

Table 18.3 Notes:

(a,b)

7.1 - 7.5

(mm)

A

Joint offset

260240220200180

> 8

7.6 - 8.0

6.6 - 7.0

6.1 - 6.5

5.6 - 6.0

5.1 - 5.5

4.6 - 5.0

4.1 - 4.5

3.6 - 4.0

3.1 - 3.5

< 3.1

RED (m)

distance

edge

Relief-

(c) Base thickness D (mm)

MIN

300 mm

but

½C (± 200)

280

These dimensions apply for all slab sizes.1.

MAX

Spacing B (mm)

(TYP AND MIN)

Joint offset A (mm)

METHOD

L

CAPPING

FIGURE 18.1: TYPICAL CROSS-STITCHING APPLICATIONS

Spacing C (mm)

Check the total tied width.(i)

DENOTES RELIEF-EDGE DISTANCE*

BASE

*RED

KE

RB (

TIE

D)

J6

J1

J2

J3

OR

OR

J1

J2

J3

OR

OR

J6

J9

J2

J9 J10OR

BA

d1

CASE 1

CA

CASE 2C

A

*

d4

B

4

CASE 4

CASE 5

RED*

AC

d

d

5

5

CASE 3

CASE 6

dd

33

BBA A

d7

CA

CASE 7

CASE 10

CASE 8

RED*

CASE 11

CASE 9

LONGITUDINAL CRACKS AND JOINTS

STITCH-BAR SPACINGS FOR

TABLE 18.3:

ANCHOR

Cracking could be due to an inactive shoulder joint which may need sawing and/or deepening.(c)

Success is improved for d greater than 1 m.(b)

May be suitable for stitching.(a)

Secondary corner cracking is likely if β is less than 70°.(b)

a slab edge.

May be suitable for stitching if completed before the crack reaches another longitudinal joint or(a)

3

Do not stitch joints which are intended to be untied.(b)

May be suitable for stitching (to supplement tiebars).(a)

For convenience, insert all stitch-bars from the pavement side.(b)


400450450500600

400

450

450

500

500

600

700

700

900

400

450

500

500

600

600

700

700

900

450

500

500

600

600

700

700

900

1200

500

500

600

600

700

700

900

1200

500

600

600

700

700

900

1200

1200

400

400

450

450

450

500

600

600

700

900

900 900 900

900 900

900 900

900

Cross stitching may only be used with the written approval of the Principal.2.

weather (or during the middle of the day) when the crack is most tightly closed.

For the same reason, stitch-bars are best fixed (that is, epoxied) during warmer

avoid the need for routing and sealing.(d)

keep out incompressibles and water, hence:(c)

significantly reduce the chances of secondary slab cracking;(b)

maximise load transfer between slabs, hence:(a)

before they widen. Early stitching will:

formation of the crack, before it widens. Poorly tied joints should also be stitched

Crack stitching will be most successful if it is completed very soon after5.

RED

A

TABLE 18.1: STITCHING NOTES

are necessary.

service life of a slab before more extensive repairs such as slab replacement

Cross Stitching Compromise Practice is a technique which may extend the1.

routed. See Note 2 S12.1.

opening (that is, are stable) should not be stitched and may also not need to be

corroded mesh reinforcement or tiebars (as applicable). Cracks that are not

cracks/tied joints open up beyond 0.5 mm, due to causes such as inadequate or

Cross stitching of JRCP cracks or tied joints is only needed where the3.

previous success under similar conditions.(c)

intensity of heavy vehicle traffic.(b)

such as arris spalling, surface abrasion, condition of adjacent slabs).

the quality of the concrete (as indicated by distress additional to cracking,(a)

should take into consideration factors such as:

The decision to stitch (in preference to alternatives such as slab replacement)6.

thickness of 0.2 to 0.5 mm.

than 0.5 mm. Suitable protection is provided by bituminous paint with a

Protection must be provided in accordance with Figure 18.2 if the crack is wider7.

and joints only.

Use compressible self expanding polyurethane resin (foam) to seal wider cracks8.

It must include tied kerbs.

or crack being stitched to the nearest relief edge.

Relief-edge distance (RED) is measured from the joint(c)

Spacings may be varied by ±10% to suit site conditions.(b)

the underside of base and on the use of N12 stitch-bars.

This table is based on a coefficient of friction of 1.5 at(a)

N12 DEFORMED BAR

STITCH-BAR

SEE NOTE 7 (S18.1)

See Note 2 S12.1.(c)

Success is improved for d greater than 1.5 m.(b)


4

4For d less than 0.6 m (approximately), refer to Case 5.(c)

could indicate low strength concrete.

Success is reduced if other distress such as advanced arris spalling is present because this(b)

May be suitable for stitching where d is greater than 0.6 m and concrete is sound.(a)

Not suitable for stitching. Ongoing deterioration is likely.(a)

Treat According to Case 9 shown on MJ12 (or Case 8 if approved).(c)

This crack is effectively operating as the contraction joint and so stitching would lock up the joint.(b)

Not suitable for stitching.(a)

9 shown on MJ12 (or Case 8 if approved).

Not suitable for stitching where d is less than 0.6 m (approximately). Treat according to Case(a)

secondary cracking. Treat according to Case 9 shown on MJ12 (or Case 8 if approved).

Not suitable for stitching where d is less than 1.0 m (approximately) because of the risk of(a)

Table 18.4 Note:

After the capping material has set, open to traffic.11.

If the capping material is different from the resin, top off with the capping material after the resin has set.10.

to approximately 25 mm below the surface.b)

to the surface if the resin is the capping material, ora)

Inject further resin if required:9.

Insert the stitch-bar while gently oscillating the bar. Push the bar to the required depth.8.

Inject the resin/epoxy to the manufacturer's instructions to fill approximately 1/3 depth of the hole.7.

Thoroughly clean holes using a vacuum cleaner.6.

16 mm diameter drill bit and ensure that a clean concrete face results.

Where sealing has been undertaken, ream the hole after the self expanding resin (foam) has set using a5.

(foam) to prevent escape of the epoxy.

Where the crack width exceeds 1 to 2 mm, seal it (at the level of the stitch-bar) with self expanding resin4.

diameter must be less than the final hole diameter of 16 mm.

Drill holes (drill hole vertically for the first 10 mm to start). If crack sealing is required, the initial hole3.

Mark hole locations.2.

Investigate base thickness, determine the required length of stitch-bar, and offset of drill holes.1.

where base thickness is less than 180 mm.(c)

the concrete has low strength (less than 25 MPa), or(b)

the slab has two or more cracks, or(a)

Stitching is unlikely to be effective where:4.β

d

A

CA

19

JOINT RESEALING

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D

W

D

R

e

J

S

D

1

e

e(e)

JS

D

(g)

(c)S

(b)

6

6.0

4.8

4.4

4.0

3.5

2.9

74

2.1

32 5

slabs

Bridge approach25 ± 4 14 (+ 4,- 0) 10 ± 4 12 ± 4 50 ± 5

longitudinal

> 18

13.0 < L ≤ 15.0

11.5 < L ≤ 13.0

9.5 < L ≤ 11.5

8.0 < L ≤ 9.5

6.5 < L ≤ 8.0

4.6 < L ≤ 6.5

≤ 4.6 7 (+ 3,- 0)

9 (+ 3,- 0)

10 (+ 3,- 0)

11 (+ 3,- 0)

12 (+ 4,- 0)

14 (+ 4,- 0)

17 (+ 5,- 0)

7 (+ 3,- 0)

8 (+ 3,- 0)

8 (+ 3,- 0)

9 (+ 3,- 0)

10 (+ 4,- 0)

11 (+ 4,- 0)

14 (+ 4,- 0)

O (mm)

Opening

Design Joint

SW' (mm)

Width

D' (mm)

Depth

(etc)

Contractions

(f) (f)expansions

Isolations and

D' (mm)

depth

Joint

Width (W ) (m)

or

Slab Length (L )

Table 19.1 Notes:

e

METHOD

DESIGNNOTES

SCHEDULE 19.1 (S19.1) SCHEDULE 19.2 (S19.2)


S

e e

S

S

S

S

FIGURE 19.2: JOINT DIMENSIONS

W'

R'

D'

D'

ORIGINAL JOINT

RESAWN JOINT

S

SS

J

SS

J

S

AN

D M

IN

10 N

OM

AN

D M

IN

10 N

OM

Recess R' (mm)

silicone sealant width.

See Table 8.3 Note (a) regarding maximum desirable

SEALANT

SILICONE

SEALANT

SILICONE

J6

J6

J4

J5

J10

J10

J14

J10

J10

J12

J16

J9

J7

J9

J9

J1

J2

J3

OR

OR

J2

OR

J6

J2

J6J2

J2

KE

RB (

TIE

D)

SEE FIG 21.1

SEE FIG 21.2

SEE FIG 20.1

SEE FIG 20.4

SEE FIG 21.3

SEE FIG 21.2

SEE FIG 21.3

FIGURE 19.1: TYPICAL JOINT RESEALING APPLICATIONS

BACKER ROD

POLYETHYLENE

CLOSED-CELL

BACKER ROD

POLYETHYLENE

CLOSED-CELL

In Table 19.2, select the row corresponding to the nominated W' .(b)

or the width required to remove the desired amount of spalling.

Select a (re)sawing width W' which only just exceeds (by 1 or 2 mm) the existing width,(a)

For tied joints:3.

exceeds the current width. Adopt the values in that row for the (re)sawing.

If the existing joint width exceeds W' , move down Column 3 to the smallest value which(d)

If W' exceeds the existing joint width, adopt the values in that row for the (re)sawing.(c)

W or L .

From Table 19.1, read the design joint width W' which corresponds to the calculated(b)

Determine the effective slab length (or width) using the method shown on Figure 8.1.(a)

For untied joints:2.

might be one of the reasons for the sealant's failure.)

(It is also possible that the existing joint width was incorrectly designed and/or sawed, which

existing width to ensure the complete removal of sealant and to produce fresh concrete faces.

Measure typical existing joint widths. The selected (re)sawing width should just exceed the1.

Allow trafficking only after the sealant has become tack free.9.

required recess. Extend the sealant down all edges in accordance with Note 7 Schedule 19.1.

instructions (including a primer, where required). Tool it to enhance the bond and to provide the

Place the sealant in accordance with the specification and in accordance with manufacturer's8.

Depress the temporary seal to provide the required sealant thickness.7.

Trafficking may be necessary before sealing. Any damaged backer rod must be replaced.6.

Install closed-cell polyethylene backer rod or temporary seal as soon as possible after cleaning.5.

to remove all debris.

Immediately after sawing, clean joints and pavement surfaces with high pressure air or water4.

Install sedimentation controls around drainage pits for saw slurry and debris.3.

Refer to Figure 19.1 for typical joint resealing applications.2.

including "Wet Road" signs where water will flow across traffic lanes.

Establish traffic control and job safety in accordance with Safe Work Method Statements (SWMS),1.

TABLE 19.1: UNTIED JOINTS - SILICONE SEALANT DIMENSIONS

Refer to Figure 19.2 for key to joint dimensions.(h)

Width O refers to the maximum winter opening, that is, maximum extension of the sealant.(g)

The distinction between joint types is explained in Table 8.1.(f)

upward pressure on the sealant (in hot weather) is minimised.

such as the depth of the backer rod after lateral compression into the joint. It is important that the

Values given for the depth of joint D' are indicative only. Allowance must be made for factors(e)

The backer rod diameter should typically be about 25% larger than the joint width W' .(d)

Tooling is necessary to force the sealant against the faces, thereby enhancing its bond.(c)

See Table 8.3 for calculation of effective slab length L and width W .(b)

For tied joints, refer to Table 19.2.(a)

S

J

Table 19.2 Notes:

4321

18 < W' ≤ 22

> 22

S

transverse

longitudinal

(e)

(e)

transverse(e)

(e)longitudinal

(b)

SW' (mm)

Width

SD' (mm)

Depth (c)

SR' (mm)

Recess (d)

JD' (mm)

Joint depth

S

S

S

S3 < W' ≤ 6

6 < W' ≤ 10

10 < W' ≤ 15

15 < W' ≤ 18

5 (+ 4,- 0)

6 (+ 4,- 0)

8 (+ 4,- 0)

10 (+ 5,- 0)

12 (+ 5,- 0)

14 (+ 5,- 0)

5 ± 3

5 ± 3

6 ± 3

7 ± 3

7 ± 3

7 ± 3

30 ± 5

35 ± 5

40 ± 5

50 ± 5

60 ± 5

65 ± 5



TIED JOINTS - SILICONE SEALANT DIMENSIONS

TABLE 19.2:

the joint width W' .

The backer rod diameter should typically be about 25% larger than(f)

ramp from the through-carriageway would be deemed "longitudinal".

"transverse" relative to traffic movements. A similar joint separating a

with the through-carriageway within a median crossing is still

direction of trafficking. Hence, an isolation joint which runs parallel

In this context, the terms "transverse" and "longitudinal" relate to the(e)

lateral compression into the joint.

must be made for factors such as the depth of the backer rod after

Values given for the depth of joint D' are indicative only. Allowance(d)

enhancing its bond.

Tooling is necessary to force the sealant against the faces, thereby(c)

Refer to MJ08 for further details of the original joint design.(b)

For untied joints, refer to Table 19.1.(a)

EXISTING JOINT RESAWN JOINT

SEE FIG 20.2

SEE FIG 20.3

Specialist advice should be sought in this situation.

In untied joints, polyurethane (alone) is unlikely to have adequate extension capacity.(b)

In tied joints, polyurethane sealant can be used for greater widths.(a)

A limit of 18 mm has been imposed on longitudinal silicone seals (see Table 19.1, for example).9.

guidance on treatment of joint spalls.

R83 contains suitable criteria. If wider spalling is present, refer to Table 24.1 for

minor spalling (3-6 mm) is unavoidable and does not usually affect the performance of silicone sealants.

In selecting the width of (re)sawing, it is not necessary to remove all spalling. Even in new construction,8.

transverse joints during subsequent paving runs.

material into the joint. At longitudinal joints, the edge sealant must prevent the ingress of concrete into the

Sealants must extend down the full vertical face of joints at all edges to prevent the ingress of verge7.

the manufacturer's written instructions.

The permanent sealant must be an insitu cast silicone sealant, stored and installed in accordance with6.

longitudinal isolation joints should be continuous, with priority over contraction joints.(b)

transverse contraction joints must be continuous across longitudinal tied joints.(a)

priority must be given to the joint which will undergo the greatest movement. For example:

Sealants and their backer rods should be continuous between longitudinal joints. At joint junctions,5.

side of the pavement towards the low side.

In order to maximise the progressive flushing of sawcutting debris, cutting should proceed from the high

the reservoir should be thoroughly flushed out with high pressure air or water during the cleaning process.

old sawcut below the reservoir, it should not be disturbed. Where no spline is found, the sawcut below

Ingress of solids into existing joints (and underlying cracks) should be minimised. If there is a spline in the4.

dust, in which case the joint must be thoroughly recleaned before sealing.

Grit blasting should not be required if wet cleaning has been satisfactory. Grit blasting may create further3.

tested in accordance with T380.

is when Grade 1 (None) visual rating category is achieved. The adhesion of the sealant must be

The cleanliness of the joint faces must be tested in accordance with T379. An acceptable result(e)

loose debris (such as dust from sawn concrete) and any other material which may reduce the bond.

at the time of sealing, the reservoir must be thoroughly clean and dry, and must be free from all(d)

dries) to minimise adherence of fines to the joint faces.

cleaning (preferably by washing) should be undertaken immediately after sawing (before the slurry(c)

compressed air must be oil-free and should be at a pressure of about 610 kPa.(b)

the old sealant must be fully removed because it may be incompatible with the new one.(a)

Sealant performance is critically affected by the adhesion with the concrete, hence:2.

minimise arris spalling, to minimise water ingress and to protect tiebars against corrosion.)

joints; longitudinal formed tied joints; kerb joints. (Some of the reasons for sawing these joints are to

sealing of joints which were previously unsawn and/or unsealed. Examples are: transverse construction

for cracks; see MJ22 and MJ23 for routing and sealing of cracks.) It is also suitable for sawing and

This procedure is suitable for the resealing of transverse and longitudinal joints in JRCP. (It is not suitable1.

20

JOINT RESEALING

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Figure 20.3(a): Conforming ribbon Figure 20.3(b): Curled ribbon Figure 20.3(c): Inclined ribbon

Figure 20.1 Notes:

Figure 20.4 Note:

Figure 20.2(a) Notes: Figure 20.2(b) Notes:

concentrated stresses at the top of the sealant; see Figure 21.4 for explanation.

Also, the existing joint intersects the side of the new sealant which will impose

preferred option because Case 2 does not reduce the acute arris.

resawing should aim to minimise future arris spalling. Case 1 is the clearly

Where the existing joint is inclined beyond the range 90° ± 5° (to the surface),(b)

Select the resawing dimensions in accordance with Note 3 Schedule 19.2.(c)

stresses on the arris in order to minimise further failure.

Where there are early signs of joint spalling, resawing can be used to relieve(b)

potential loose wedges.

selected within this zone (Case 2) to maximise spall removal and to minimise

Failure is typically on the concave side, hence the resawing line should be

Spalling is often related to an inadequate vertical top face (which should be 50 ± 5).(c)

variations are warranted to address issues raised above.

Select the resawing dimensions in accordance with Note 3 Schedule 19.2 unless(d)

See Figure 20.3(b) Note (c) regarding wedge treatment.(e)

Figure 20.3(a) Notes:

curled, and/or inclined.

will often be found much deeper and/or

placed as shown above. By contrast, they

variable. Specifications required that they be

The accuracy of ribbon insertion was highly(a)

with Figure 20.2(a).

installed, resawing should be in accordance

Where the ribbon was reasonably well(b)

see Figure 20.3(b) and Figure 20.3(c).

Where the ribbon is curled and/or inclined,(c)

Figure 20.3(b) Notes:

Case 1

Case 2

Case 3

General

In all cases select the resawing dimensions in accordance with Note 3 Schedule 19.2.

Figure 20.3(c) Notes:

maximises the depth of ribbon to be removed.)

the one which intersects the surface crack and also

(As a general rule, it appears that the preferred line will be

Select the resawing dimensions in accordance with Note 2 Schedule 19.2.(a)

SILICONE SEALANT

W'S

S

ORIGINAL JOINT

= 90° ± 5°

D/3

010

+ –

INDUCED CRACK

SILICONE SEALANT

W'S

CASE 1

(PREFERRED)

W'S

CASE 2

(POOR)

W'S

CASE 1

(BEST)

CASE 2 CASE 3

(WORST)

W'S

CASE 1

(TO AVOID)

W'S

CASE 2

(PREFERRED)

(In this case, the preferred line also happens to maximise the depth of ribbon to be removed.)

Case 1 shows the preferred treatment. The selected sawing line minimises the risk of future joint or arris distress.(a)

ORIGINAL JOINT

SEE NOTE (b)

POTENTIAL SPALL

SEE NOTE (e)

CERTAIN SPALL

RIBBON

SPALLING

POTENTIAL

SEE NOTE (c)

WEDGE

POTENTIAL

SEE NOTE (d)

WEDGE

POTENTIAL

INDUCED CRACK

EXISTING JOINT OR

Figure 20.2(a): Butt face (Type J2b) Figure 20.2(b): Corrugated face (Type J2c)

FIGURE 20.3: LONGITUDINAL RIBBONED AND TIED JOINTS (Type J3)

LONGITUDINAL FORMED AND UNTIED JOINTS (Type J4)

FIGURE 20.4:

Also applicable to longitudinal induced and untied joints (Type J5)

NEW SAWCUT

NEW SAWCUT

NEW SAWCUT

the risk noted under (a).

Case 2 is the preferred option because it minimises(b)

the new sawcut; see Figure 21.4 for explanation.

be damaged if it bridges the ribbon's point of entry to

Case 1 should be avoided because the silicone could(a)

they must be removed, possibly by localised routing.

The residual piece is certain to spall under traffic. Where the optimal sawing line leaves residues like this,(e)

A potential wedge; see Figure 20.3(b) Note (c).(d)

This sawcut leaves the following potential problems:

NEW SAWCUTNEW SAWCUT


is unavoidable, a filler should be placed in the sawcut before sealing (to hold the wedge in place).

The sawcut produces a wedge which could dislodge and jam the joint's hinge action. If the formation of a wedge(c)

The acute arris may spall. However, sawing may also reduce spalling by relieving arris stress.(b)

This sawcut leaves the following potential problems:

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

Longitudinal sawn and tied joint (Type J1)

Select the resawing dimensions in accordance with Note 3 Schedule 19.2.(b)

Where warranted, cross-stitch in accordance with MJ18 before resealing.

inadequate tying (for example, by pull-out and/or yielding and/or corrosion).

Assess the integrity of existing tiebars. Variability in joint width could indicate(a)Where warranted, cross-stitch in accordance with MJ18 before resawing.

inadequate tying (for example, by pull-out and/or yielding, and/or corrosion).

Assess the integrity of existing tiebars. Variability in joint width could indicate(a)

Where warranted, cross-stitch in accordance with MJ18 before resawing.

Assess the integrity of existing tiebars, consistent with Figure 20.2(a).(a)

W'S

CASE 1

(TO AVOID)

J

W'S

CASE 2

(PREFERRED)

LOOSE WEDGE

POTENTIAL


SEE NOTE (c)

TARGET 50 ± 5

LESS THAN

VERTICAL FACE

NE

W D'J

N

EW D'

JD'

SR'

SD'

W'S

JD'

SR'

SD'

FIGURE 20.1: LONGITUDINAL SAWN AND TIED JOINTS (Type J1) FIGURE 20.2: LONGITUDINAL FORMED AND TIED JOINTS (Type J2)

W

1 ± 1

21

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TRANSVERSE SAWN CONTRACTION JOINTS (Type J9)

FIGURE 21.2:

ISOLATION JOINTS (Type J14)

FIGURE 21.3:

FIGURE 21.4: SEALANT RESERVOIR FAULTS FIGURE 21.5: SEALANT INSTALLATION - GENERAL

Figure 21.1(a): Butt face Figure 21.1(b): Corrugated face

Figure 21.5(a): Good practice Figure 21.5(b) : Poor practiceFigure 21.4(a): Ineffective reseal Figure 21.4(b): Short lived reseal

Figure 21.1(a) Notes: Figure 21.1(b) Notes:

Figure 21.2 Notes:

Select the resawing dimensions in accordance with Note 2 Schedule 19.2.(a)

W'S

JD'

ORIGINAL JOINT

NEW JOINT

W S

D

J

Figure 21.3 Notes:

See Figure 20.3(b) Note (c) regarding wedge treatment.(d)

unless variations are warranted to address issues raised in (a).

Select the resawing dimensions in accordance with Note 3 Schedule 19.2(c)

to minimise potential loose wedges.

should be selected within this zone (Case 2) to maximise spall removal and

50 ± 5). Failure is typically on the concave side, hence the resawing line

Spalling is often related to an inadequate vertical top face (which should be(b)

stresses on the arris to minimise further failure.

Where there are early signs of joint spalling, resawing can be used to relieve(a)


the sealant will be dormant and the joint remains unsealed.

The reseal shown here actually misses the joint, hence(b)

so selection of the resawing line is important.

The sealant must bridge the moving joint and(a)

(as shown), the sealant will either tear or debond.

If the moving joint intersects the side of the sealant(a)


compression movements are spread evenly throughout the sealant.

Good sealant design and installation ensures that expansion and(a)

concentrated strain at the joint will tear the sealant.

If the sealant is bonded along the bottom face, the

Hence, it is preferable that they be pushed towards the sawcut.

Care is required to prevent the fragments falling into the joint.(b)

as shown.

One possible remedy is to break off the wedge of concrete(a)

SLAB CONTRACTION SLAB CONTRACTIONINDUCER

RIBBON TYPICAL SEALANT DESIGN TYPICAL DESIGN FOR ROUTING UNSATISFACTORY DESIGN

BONDED FACES


will impose concentrated stresses on it; see Figure 21.4 for explanation.

acute arris. Also, the existing joint intersects the side of the new sealant which

Case 1 is the clearly preferred option because Case 2 does not reduce the

resawing should aim to minimise future arris spalling.

Where the existing joint is inclined beyond the range 90° ± 5° (to the surface),(a)

WEDGE

WEAK

WEDGE

WEAK

CASE 1 CASE 2

RESAWN AND RESEALED ROUTED AND RESEALED

Also applicable to Types J15 and J16

FIGURE 21.1: TRANSVERSE FORMED AND TIED JOINTS (Type J7)


SILICONE SEALANT

BACKER ROD (TYP)

POLYETHYLENE

CLOSED-CELL

JOINT FILLER

EXISTING JOINT

JD'

SD'

SR'

SW'

(TYP)

BACKER ROD

POLYETHYLENE

CLOSED-CELL

(TYP)

BACKER ROD

POLYETHYLENE

CLOSED-CELL

W'S

CASE 1

(PREFERRED)

W'S

CASE 2

(POOR)

ORIGINAL JOINT

NEW SAWCUT NEW SAWCUTW'S

CASE 1

(TO AVOID)

J

W'S

CASE 2

(PREFERRED)

LOOSE WEDGE

POTENTIAL

NEW SAWCUT

SEE NOTE (b)

TARGET 50 ± 5

LESS THAN

VERTICAL FACE

NE

W D'J

N

EW D'

NEW SAWCUT

Also applicable to Types J10, J12, and J17.

existing joint width (and hence will admit incompressible material).

it is permanently compressed to a width significantly less than the●

there are signs of deterioration, or●

Replace the joint filler if:(c)


This detail is applicable to longitudinal and transverse J14, J15, and J16.(a)

Figure 21.4(b) Note:

Figure 21.5(a) Note: Figure 21.5(b) Note:

SEE NOTE (a)

POTENTIAL SPALL

INDUCER

RIBBON

Figure 21.4(c): Effective reseal

22


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NOTES


METHOD


R 85

Table 22.2 Notes:

SYMBOL DESCRIPTION

W C

W

W

W

W

W

W

SP

R1

R2

85

S

U

Width of silicone sealant

Width of crack (without spalling)

Width of crack plus spalling

Width of rout - 1st pass

Width of rout - 2nd pass

85% spalled width. (b)

TABLE 22.2: NOMENCLATURE

TABLE 22.1: ROUT DIMENSIONS - TIED AND STITCHED CASES

Table 22.1 Notes:

R R B SW

(mm)

Rout width

(H = 5 mm)

15 mm cut to ½ round

B

(H )

and size

Backer rod shape

B

B

(H = 15 mm)

30 mm cut to ½ round

(H = 14 mm)

of height 14 mm

50 mm, slit segment

15 ± 3

30 ± 5

50 ± 7

(b)

type

Sealant

D

(mm)

Rout depth

15 (+ 5, - 0)

30 (+ 7, - 0)

30 (+ 7, - 0)

10 (+ 5, - 0)

11 (+ 5, - 0)

7 (+ 3, - 0)

R

(mm)

Sealant recess

D

(mm)

Sealant thickness

4 (+ 2, - 0)

3 (+ 2, - 0)

3 (+ 2, - 0)

RS

SD

BH

RD

W R

W or WU S

Polyurethane

Silicone or

Polyurethane

Polyurethane

Width of polyurethane sealant

Refer to Note (b) Schedule 23.1 for commentary.(b)

Refer to Details T-X, MJ23 for applicability.(a)

increase friction values.

Where a polyurethane is used in a longitudinal joint, its surface must be blinded with sand to11.

that joint so that the polyurethane is discontinuous.

Where a polyurethane sealant will cross an untied joint, a joint filler must be placed within10.

section, including any underlying cracks.

At slab edges and formed joints, sealants must extend down the vertical face of the routed9.

actions of wind or sealant installation.

held in place by a suitable flexible adhesive such that the rod will not be dislodged with the

of the reservoir so as to seal the exposed crack/joint. If necessary, the backer rod must be

accurately slit in a jig to the required shape. The backer rod is to be depressed to the bottom

The backer rod shown in Table 22.1 must be continuous closed-cell polyethylene. It must be8.

accordance with T380.

(None) visual rating category is achieved. The adhesion of the sealant must be tested in

joint faces must be tested in accordance with T379. An acceptable result is when Grade 1

concrete faces have been prepared in accordance with the guidelines. The cleanliness of the

deleterious to the adhesion of the sealant. Grit blasting is not required when the routed

free from all loose debris, pulverised concrete dust, and other material which may be

At the time of sealant installation, side walls of the reservoir must be thoroughly clean and7.

other times due to contraction and curling.

Crack widths should be assessed in the warmer part of the day because they will increase at6.

will be different to those in untied joints because of the differing magnitude of movement.

the required operating parameters of the sealant. The design of sealants in tied joints(b)

the width of spalling.(a)

The resawing/routing width is typically governed by two criteria:5.

will rarely be feasible for cracks.

For (re)sealing of joints, sawing should be considered in preference to routing, but sawing4.

before routing/sawing (to reduce the stress on sealants).

Wherever possible, cracks should be stitched; see MJ18. Stitching should be completed3.

to clean the faces to maximise sealant adhesion.(b)

to produce a reservoir shape with vertical sides and which is suitable for sealing.(a)

The purpose of routing and resawing is:2.

routing cut for the sawcut.

treatments detailed in MJ19-MJ21 are equally applicable to routing by substitution of a

where resawing is unsuitable. Where the joint to be routed is inclined and/or curled, the

This procedure is mainly applicable to treatment of cracks but may also be used for joints1.

Allow trafficking only after sealant has become tack free.9.

For polyurethanes, apply sand to the surface.

In sawcuts, install sealant in accordance with MJ19-MJ21.

In routings, install sealant in accordance with Table 22.1.8.

Install backer rod to provide the required sealant depth.7.

Inspect to ensure effective removal of all loose debris.6.

done immediately after sawing/routing and before the residue dries.

Clean out joints/cracks with high pressure water. This must be5.

Schedule 23.5 as applicable.

Repair joints and cracks in accordance with Schedule 23.1 to4.

Determine required rout width, W > W .3.

Mark areas to be treated.2.

Work Method Statements (SWMS).

Establish traffic control and work safety in accordance with Safe1.

S

of 50 ± 7 mm should only be varied after careful consideration and after suitable trialling.

suggested for logistical purposes only and may be varied if deemed desirable. However, the maximum width

Routing widths listed in Table 22.1 are limited to 3 categories. The values (and the number of 3) are(c)

In tied joints, polyurethane is preferable to silicone where distillate fuels are likely to be in concentration.(b)

than 18 mm and that all dimensions satisfy criteria in accordance with Table 19.1.

For untied/unstitched cases, this table may be used on the condition that the sealant is silicone of width less(a)

NOT TO SCALE

FIGURE 22.1: TYPICAL ROUTING APPLICATIONS

KE

RB (

TIE

D)

KE

RB (

TIE

D)

J1

J2

J3

OR

ORJ2

J9

J9

J2

J2J2J2

J7 J7

J14

UN

TIE

D J

OIN

T

(EG

J14

J15

J4

),

,

V

23OR

X

23

W

23

X

23

W

23

U

23

T

23

T

23

X

23

T

23OR

U

23

X

23

SEE MJ18

STITCHING

J9J10OR

J9 J10OR

OR

J10

J9 J10OR

23


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85

the economics of doing a single rout versus multiple passes.(ii)

of the capacity of the router to follow its path.

the curvature (or "crookedness") of the spalled crack, in terms(i)

depending on factors such as:

selection criteria for the rout width may differ between sites,

which is abbreviated to "85% spalled width" or W . However,

section. This is referred to as the "85th percentile spalled width",

about 85% of the total length of spalled crack within a selected

The width of rout should generally be such that it will impact on(b)


R

R

C

85


R

R


S

T

-

DETAIL

PLAN

U

-

DETAIL

PLAN

V

-

DETAIL

PLAN

W

-

DETAIL

PLAN

W1

-

SECTION

X1

-

SECTION

SP

C

R1

R2

S R

SP

R

S UW OR W

W

SP

W1

-

W1

-

R

ORIGINAL JOINT OR CRACK

W OR W WU S R

R

SP

X1

-

X1

-

FILLER

U US

R

W

ROUT WIDTH

W

W

W

WWW

18/22 # MAX

W

SILICONE OR POLYURETHANE AS APPLICABLE

POLYURETHANE

CLOSED-CELL POLYETHYLENE BACKER ROD (TYP)

CLOSED-CELL POLYETHYLENE BACKER ROD (TYP)

where structural spall repairs are not required.

cases. It is applicable only to tied and/or stitched applications

is not feasible. It is applicable to both longitudinal and transverse

This procedure is applicable to joints and cracks where sawcutting(a)

Typical Routing Procedure DETAIL T

the 85% spalled width W < 5 mm (NOM).(ii)

the crack width W < 0.5 mm.(i)

Routing will generally not be warranted where:(c)

Tied Longitudinal Joint Routing Procedure DETAIL U

W > 18 mm: Seal with polyurethane

W ≤ 18 mm: Seal with silicone(e)

For saw and seal dimensions: see MJ19-MJ21.

For rout and seal dimensions: see Table 22.1.(d)

economics of doing a single cut versus multiple passes.

may differ between sites depending on factors such as the

spalled joint within a selected section. However, the width

be such that it will impact on about 85% of the total length of

The cutting width (either sawn or routed) should generally(c)

Sawcutting should always be considered before routing.(b)

stitched, and have only minor spalling.

This procedure is applicable to longitudinal joints which are tied or(a)

Tied Transverse Joint Routing Procedure DETAIL V

W > 22 mm: Seal with polyurethane

W ≤ 22 mm: Seal with silicone(e)

For saw and seal dimensions: see MJ19-MJ21.

For rout and seal dimensions: see Table 22.1.(d)

doing a single cut versus multiple passes.

between sites depending on factors such as the economics of

joint within a selected section. However, the width may differ

such that it will impact on about 85% of the total length of spalled

The cutting width (either sawn or routed) should generally be(c)

Sawcutting should always be considered before routing.(b)

and/or stitched and which have only minor spalling.

This procedure is applicable to transverse joints which are tied(a)

ACCORDANCE WITH MJ24 AND MJ25

USE A STRUCTURAL REPAIR IN

LOCALISED WIDE SPALL

DETAIL T, U, OR V AS APPLICABLE

TREAT IN ACCORDANCE WITH

X

-

DETAIL

PLAN

S

IN ACCORDANCE WITH MJ19-MJ21

RESAW AND RESEAL

IN ACCORDANCE WITH MJ19-MJ21

SILICONE SEALANT


R

R

R

S

Untied Joint Routing Procedure DETAIL X

Detail T, U, or V as applicable.

Install the sealant over the full length of routed crack plus repair, in accordance with(iv)

Repair the wide spall in accordance with MJ24 and MJ25.(iii)

Insert a temporary filler to width W .(ii)

a later date may damage the repair).

Rout (or sawcut) the length of crack (or joint) adjoining the wide spall. (Routing or sawing at(i)

The suggested sequence of operations is as follows:(b)

structural repair is needed. It is applicable only to tied or stitched joints and cracks.

This procedure is applicable to multiple spalling types where a combination of routing and(a)

Combined Routing and Repairing Procedure DETAIL W

Install silicone sealant over the full length of joint in accordance with MJ19-MJ21.(iv)

Sawcut (or rout) the length of spalled joint (excluding the repair) in preparation for sealing.(iii)

Prepare and repair the wide spall in accordance with MJ24 and MJ25. Allow adequate curing time.(ii)

Insert a temporary filler to width W .(i)

The suggested sequence of operations (following routing) is as follows:(d)

22 mm in transverse joints

18 mm in longitudinal joints# adopt :

: treat in accordance with MJ24 and MJ25.For W > 57 mm

: treat in accordance with Detail XFor 18/22 # mm < W = 57

: resaw and seal in accordance with MJ19-MJ21For W = 18/22 # mm(c)

(of width designed in accordance with MJ19-MJ21).

Because of the magnitude of cyclic movement, at least part of the repair width must be a silicone(b)

expansion, untied butt) and which contain sections of substantial spalling.

This procedure is applicable to untied joints, either longitudinal or transverse (such as isolation,(a)

IN ACCORDANCE WITH MJ24 AND MJ25

USE A STRUCTURAL REPAIR

SPALLED WIDTH

W

CRACK WIDTH

W

ROUT No.1

W

ROUT No.2

W

W AND W

W

W = 18/22 # MAX

24

JOINT SPALL REPAIRS

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TABLE 24.1: CLASSIFICATION OF SPALLS AND SELECTION OF REPAIR METHOD FIGURE 24.1

FIGURE 24.2: TYPE SD - SHALLOW DISCRETE SPALLS FIGURE 24.3: TYPE SC - SHALLOW CONTINUOUS SPALLING

(a)Type Dimensions Treatment

AR

Arris rounding

(no limit on depth)

W < 30 mmSee Figure 25.1 for options

See Figure 24.1(a)

Minor spall M

See Figure 24.1(b)

- Discrete SD

Shallow spall

See Figure 24.1(c)

- Continuous SC

Shallow spall

(no limit on depth)

W ≤ 50 mm

H ≤ D/2

W > 50 mm

See Figure 24.3

Thin bonded repairs

Deep spall DH > D/2

W > 50 mm

D = Thickness of baseH = Depth of SpallW = Width of Spall(a)

Figure 24.2(a): Plan view

Figure 24.2(b): Stage 1 (Section view)

Figure 24.2(c): Stage 2 (Section view)


Remove any existing sealant to a minimum of 100 mm beyond the patch perimeter.(b)

100 mm and be at least 20 mm beyond all unsound concrete.

Mark out the square or rectangular perimeter area to be replaced. This area must have minimum dimensions of(a)

Figure 24.2(b) Notes:

scabbling tool is suitable for this removal.

Remove the concrete within the perimeter groove to produce a reasonably even surface. A single or multi-head(e)

shattered aggregate or concrete.

is recommended for minimising ingress of grit into joints and cracks. The compressed air is intended to remove any

Clean out the patch using a vacuum cleaner and/or oil-free compressed air (plus wire-brush if required). The vacuum(f)


the patch material is not sucked dry). Maintain the faces in a moist condition until the next stage.

For cementitious patches, saturate all patch faces with water (or wet rags) for at least 10 hours (to ensure that

For epoxy resin patches, prime the exposed surfaces in accordance with the manufacturer's recommendations.(h)

Immediately before placing the patch material, remove all free water (using oil-free compressed air and/or rags).(j)

Prime all surfaces by brushing with cement grout or other notified bonding agent.(k)

the primer must be protected against drying.

Place the repair material into the patch within the time limit specified by the manufacturer. Where a delay occurs,(l)

edges, and corners. Provide a timber-float or textured surface.

Thoroughly compact the material using a vibrating hammer, taking special care to work fine material into all faces,(m)

reaches the low-sheen condition.

Cementitious repairs must be cured with hydrocarbon resin curing compound. It must be applied as soon as the mix(n)

texture. Secure all edges of the sheeting to prevent drying.

Cover the patch with moist hessian and then polythene sheeting as soon as possible without marking the surface(o)

Figure 24.1(a): Minor (M) Figure 24.1(b): Shallow Discrete (SD) Figure 24.1(c): Shallow Continuous (SC)

Figure 24.3 Notes:

EXISTING SLAB JOINT

SAWCUTS

DEFINED WITH STRAIGHT

PERIMETER OF REPAIR

CONCRETE PATCH

THIN BONDED

SEALANT

SEALANT REMOVED

-

-

JOINT FORMER

PERIMETER GROOVE

DOWN TO SOUND CONCRETE

REMOVE FAILED AREA

OR EXPANSION JOINT, OR

EXISTING ISOLATION

FORMING GROOVE

SPALL PROFILE

S

GROOVE

PERIMETER

W

PATCH REPAIR PATCH REPAIR

JOINT SEALANT

NEW JOINT FILLER

DEBONDING STRIP

1

2

EDGE OF SPALLING

GROOVES

PERIMETER

OR CRACK

CONSTRUCTION JOINT

CONTRACTION OR

SPALL PROFILE

> 50

> 50

> 50

20 MIN100 MIN

100 MIN20 MIN

MIN

100

MIN

100

MIN

100 5 THICK JOINT FORMER

UNIFORM DEPTH

30 MIN

FORMING GROOVE10 MIN

MIN WIDTH OF REPAIR = 200

100 MIN

100 MIN 20 MIN

15 MIN20 MIN

15 MIN

10 MIN

24.2(b)

24.2(c)

20 MIN

PERIMETER GROOVE

15 MIN

MARK OUT OF PERIMETER

Table 24.1 Note:

See MJ12-MJ17

Full-depth repairs

Rout and seal; see MJ22 and MJ23:At Cracks

or Rout and seal; see MJ22 and MJ23

Resaw and seal; see MJ19-MJ21:At Joints

> 50

5 - 10 mm (TYP) wide.for tied construction joints:●

9 - 12 mm (TYP) wide.for PCP contraction joints:●

20 - 30 mm (TYP) wide.for isolation and expansion joints:●

be of a width suitable for the specific joint type, and desirably 2 to 5 mm wider than the existing joint, hence:●

extend at least 100 mm beyond each end of the patch perimeter.●

be at least 10 mm deeper than the deeper patch (where 2-sided).●

The forming groove must:

four slab corners, a former must be placed along each joint.

Saw or rout a joint forming groove along the line of the joint (to hold the joint former). For repairs at the junction of(c)

be rough; see Note 2 Schedule 25.2.

a single-head scabbling tool or a router and template. This must form vertical edges to the patch. All edges must

Chase out a perimeter groove around the other three sides, to a minimum depth of 15 mm. This should be done with(d)

paths and gaps where repair material could escape or contact adjoining slabs. See Notes 3 and 4 Schedule 25.2.

Fix a joint former securely into the forming groove so that the top is flush with the finished surface level. Caulk all(g)

can be roughened with an angle-grinder to maximise sealant bond.

resawing and sealing of joints is to follow, joint cleaning will be achieved during that program. Otherwise, the faces

Clean and seal the joint in accordance with MJ19-MJ21, and after removing the joint former. Where a program of(q)

Curing and protection should be maintained for a minimum of 24 hours, but preferably three days.(p)

See Figure 24.2

Thin bonded repairs

SPALLS

CONTINUOUS

DISCRETE SPALLS

CRACK

FULL-DEPTH

CRACK

FULL-DEPTH(INCLUDE JOINT)

< 50

< 50

< 50

CRACK

FULL-DEPTH

Chase this sawcut with a router to roughen the vertical faces. See also Note 2 Schedule 25.2.(c)

Initiate the perimeter groove by sawcutting.(b)

The minimum depth of patch must be 30 mm.(a)

Follow the procedure in accordance with Figure 24.2, except:

25

JOINT SPALL REPAIRS

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FIGURE 25.1: TREATMENT OF MINOR ARRIS ROUNDING

Figure 25.1(a): Option 1 Figure 25.1(b): Option 2 Figure 25.1(c): Option 3

Figure 25.1(a) Notes: Figure 25.1(b) Notes: Figure 25.1(c) Notes:

S

SCHEDULE 25.1 (S25.1) SCHEDULE 25.2 (S25.2)

NOTES METHOD

Scope

Workmanship

Spall types

Minimum repair depth

Workmanship

Patch preparation

Joint formers

S SS S S

50 M

AX

20 M

IN

FILLER

EXISTING FACE

ROUNDING ON

JOINT FACE

EXPOSED

W'

EXISTING SLAB

DEBONDING STRIP

OR BACKER ROD

RESIDUAL FILLER

EXISTING SLAB

EPOXY PATCH

NEW FILLER

FACE

EXPOSED

EXISTING SLAB

REMOVAL

SECTION FOR

EXISTING SLAB

SEALANT

S

STRIP

DEBONDING DEBONDING STRIP

R' S

D' S

SECTION FOR REMOVAL

S

D' S

NEW MATERIAL

S

NEW MATERIAL

of seals to view the extent of cracking.

Simple investigation techniques include tapping around the failure with a steel rod, and removal�

of deep spalling may look similar to shallow spalling.

It is desirable to determine the extent of failure before commencing repairs. The early stages�

Each spall type is treated differently; see Table 24.1.�

Joint spall repairs are typically classified as shown in Table 24.1.3.

to scabble without causing further spalling.

unacceptable. It is therefore preferable that failed concrete be chased out rather than sawn. Sawn faces are difficult

All bonded faces (both vertical and horizontal) must be rough to maximise bond strength. Sawn or smooth faces are2.

Thickness D' should be 7 mm minimum and the shape ratio W : D should be between 3 : 1 and 5 : 1.

For this application, the width may be varied between suggested limits of 18 mm and 60 mm.

(Routing is not required here.)

Table 22.1 provides guidelines for polyurethanes but gives only two options to suit routing widths.

In tied joints, a polyurethane can be used in lieu of the silicone, in which case higher width limits apply.(d)

18 mm maximum in longitudinal joints.

The controlling factor for the use of this option is likely to be the limit on silicone width, namely,(c)

resin patch.

This method is the same as Figure 25.1(b) except that it removes the step of placing an epoxy(b)

for the silicone option in Figure 25.1(a).

This option is suitable where the rounding and/or spalling exceeds the recommended operating range(a)

For the sealant design, refer to Figure 25.1(a).(d)

A polyurethane may be used in lieu of the epoxy resin.(c)

advanced than in MJ24.

This treatment is generally consistent with MJ24 but assumes the spalling and/or rounding is much less(b)

and/or dimensions) for the silicone option in Figure 25.1(a)

This option is suitable where the rounding and/or spalling exceeds the recommended operating range (in shape(a)

STAGE 1 STAGE 2

PLACE SEALANT.

PLACE NEW MATERIAL.

THE EXPOSED FACE.

FIX A SUITABLE FILLER TO

STAGE 1 STAGE 2 STAGE 3

CONCRETE AS SHOWN.

BY SAWCUTTING AND REMOVING

PROVIDE SQUARED RESERVOIR PLACE SEALANT.

EPOXY REPAIR.

FIX A SUITABLE FILLER AND PLACE

REMOVE FAILED MATERIAL.

STAGE 1 STAGE 2

NEED NOT BE INCREASED.

INCREASED AS SHOWN, BUT DEPTH

THE EFFECTIVE SEALANT WIDTH IS

PLACE SEALANT.

FIX A SUITABLE FILLER AND PLACE NEW MATERIAL.

SAWCUTTING AND REMOVING CONCRETE AS SHOWN.

PROVIDE SQUARED RESERVOIR BY

can be used in conjunction with slab removal (as shown on MJ12-MJ17) with only minor adaptation.

not involve full-depth slab removal. However, they are intended to cover many applications and so

This method applies to joints, cracks, and edges. The diagrams show repairs in situations which do1.

unless close attention to detail is given to every aspect. Also refer to Schedule 25.2.

Spall repairs are very sensitive to standards of workmanship and will yield a low success rate2.

so scabbling should be limited to the extent necessary to remove all unsound concrete.

Beyond these thicknesses, there is no value in making the repair deeper than necessary and

30 mm for cementitious repairs.●

10 mm for epoxy resin repairs.●

The practical minimum depth is:4.

the microtexture of scabbled faces and into corners and edges.

It is critical that a thorough bond be achieved over all patch faces. This requires that mortar be worked into

protection against early stress.●

curing.●

concrete/mortar compaction.●

bond strength.●

roughness and cleanliness of the parent concrete.●

The critical factors for success include:1.

without damaging the patch, it must be debonded and also preferably collapsible.

against the patch that is bonded to flexible material against adjacent slabs. To facilitate the removal of the filler

transferring stress into the patch. Some situations may require a composite former/filler comprising stiffer material

Any temporary joint formers or fillers must be flexible and compressible enough to absorb movement without4.

intersection of four slab corners, a former must be placed in each joint.

adjoining slabs and must not bridge across joints (including tied joints, which hinge due to curling). For repairs at the

It is critical that the repair not be stressed before it achieves adequate strength. It must be totally isolated from3.

For widths > 18 mm: not feasible, assess alternatives. Seek specialist advice.●

For design widths ≤ 18 mm, use a silicone in accordance with Table 19.1.●

For untied longitudinal joints:(iii)

Use a silicone in accordance with Table 19.1.

For untied transverse:(ii)

Use a silicone designed in accordance with Table 19.2. Adopt W' as low as feasible.

For tied joints, transverse or longitudinal:(i)

Recommendations are as follows:

The sealant type and width must be designed in accordance with MJ19-MJ21.(d)

This should be the key issue in assessing the suitability of this option.

The silicone is most likely to fail by adhesion failure (debonding) at the arris rounding.(c)

This method is suitable for both longitudinal and transverse joints, either tied or untied.(b)

rounding will result in spalling of the new edge.

This option is suitable where the rounding is only minor, but placement of concrete against that(a)

W'

NEW MATERIALNEW MATERIAL

W'

NEW MATERIAL

R'

W'

D'

W'

26

ANCHOR DEFECT REPAIRS

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CASE 6

KE

RB (

TIE

D)

OR

OR

CASE 4

CASE 5CASE 3

CASE 2 CASE 7

CASE 1

FIGURE 26.1: TYPICAL JPCP TERMINAL ANCHOR DEFECTS

JRCP JRCP JRCP

J2

OR

OR

J9 OR J10

J14

(REINFORCED)

SLAB

APPROACH

BRIDGE

ANCHORA

NOT TO SCALE

J7

J6

J1 J1

J2

J3 J3

J2

JRCP

JRCP JRCP

CASE 1: Shrinkage cracking over anchors

CASE 2: Transverse joint spalls

CASE 3: Corner cracking

CASE 4: Anchor rotation / sliding

CASE 5: Tranverse cracking

CASE 6: Longitudinal cracking

CASE 7: Longitudinal joint spalls

NOTES

Anchors


of various anchor designs.

Refer to Volume CJ Jointed Reinforced Concrete Pavement for standard details1.

only and is adjusted to suit grade and drainage requirements.

is deleted and the subbase is extended to the anchor. The depth of the drain is nominal

anchor falls towards the anchor. Where the grade falls away from the anchor, the drain

Anchor drains are constructed only where the longitudinal grade on that side of the3.

JRCP ANCHOR DEFECT CASES


Due to the serious repercussions of this defect, seek specialist advice.

and/or SFCP-R terminal slabs and/or bridge abutment/deck damage.

at the J14 or F7 and/or F4 joints. It may also lead to buckling of the JRCP

of the JRCP and/or SFRP-R terminal slabs and/or bridge approach slab

This defect usually manifests itself in the form of faulting and/or crushing(a)

JRCP terminal slabs constructed before 2003, this dimension was 4500 ± 500.2.

Rout and seal cracks in accordance with MJ22 and MJ23 if warranted.(a)

Repair in accordance with MJ24 and MJ25 if warranted.(a)

if approved) if secondary cracking occurs.

Repair in accordance with Case 9 shown on MJ12 (or Case 8(a)



Repair in accordance with MJ24 and MJ25 if warranted.(a)

SUBGRADE BEAM

(TY

PE 1

2)

1 2

00

MIN

600

LCSLCS

JRCP

BA

SE

D

MIN

600

LCS

JRCP

BA

SE

D

D

+– 0

2001100

CONSTRUCTION JOINT

AND BOTTOM)

MESH (TOP

JOINT

CONSTRUCTION

SU

BB

AS

E

MESH (TOP ONLY)

FOR ROAD SKEW ≥ 84°

FIGURE 26.2: SCHEMATIC TERMINAL DESIGN AT BRIDGES

TY

PE 1

2 : 1

200

MESH (TOP ONLY)

J14

JRCP

J9

SU

BB

AS

E

2

LENGTH OF SLABMAX

SEE NOTE 1 (S26.1)

JRCP

MAX2

LENGTH OF SLAB

MESH (TOP AND BOTTOM)

MESH (TOP ONLY)

SEE NOTE 2 S26.1

SEE NOTE 1 (S26.1)

JRCP

J10OR

J9 J10OR

SUBSURFACE DRAIN

FILLER

POSSIBLE THICKENING

SEE NOTE 3, S26.1

ANCHOR DRAIN

SEE NOTE 3, S26.1

ANCHOR DRAIN

POSSIBLE THICKENING

FIGURE 26.3: SCHEMATIC TERMINAL DESIGN AT FLEXIBLE PAVEMENT

BRIDGE

APPROACH SLAB

BRIDGE TERMINAL SLAB

4 000 MIN

12 000 MAX

1 500 MIN

2

PAVEMENT

FLEXIBLETERMINAL SLAB

1 500 MIN

2

RIGID PAVEMENT - Roads and Maritime Services

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