CITGO PRACTICE

PRACTICE NO. A-494

_______________________________________________________________

CITGO Adoption Date: May 1, 2002

Associated Process Industry Practice No. Practice No. – None

CITGO Refinery Practice: A-494 – July 1995

_____ __________________________________________________________

Specification for
Portland Cement Concrete Paving Repairs
_______________________________________________________________

Sites Using the CITGO Practice with NO Addendum to PIP

Corpus Christi
Lake Charles
Tulsa
_______________________________________________________________

Sites using the CITGO Practice with addendum to PIP

NONE
_______________________________________________________________

Addenda:
NONE
_______________________________________________________________

Sites not using this CITGO Practice

CITGO-Lyondell
Lemont
_____________________________________________________________________________

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 Spec. No. A-494
CITGO Refining & Petrochemicals Page 2 of 13

ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

REVISION RECORD

THIS PAGE IS RECORD OF ALL REVISIONS TO THIS SPECIFICATION. EACH TIME THIS
SPECIFICATION IS REVISED, THE REVISED SPECIFICATION SHALL REPLACE THE PREVIOUS
SPECIFICATION IN ITS ENTIRETY.

THE EXTENT OF THE REVISION IS BRIEFLY NOTED UNDER THE REMARKS COLUMN. THESE REMARKS
ARE FOR REFERENCE ONLY AND ARE NOT PART OF THE SPECIFICATION.

ADDITION AND / OR REVISIONS TO THE LAST REVISION NUMBER ARE NOTED BELOW AND SHOWN IN
BOLD FACE TYPE IN THE DOCUMENT.

APPROVAL REVISED
REV. DATE BY PAGES REMARKS

A 07/01/95 ISSUED FOR CONSTRUCTION FOR

REFINERY EXPANSION PROJECT

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

TABLE OF CONTENTS

SECTION &
ITEM PARAGRAPH PAGE

GENERAL........................................................ 1.0 4
Scope.................................................... 1.1 4
Related Specifications................................... 1.2 4
Reference Standards...................................... 1.3 4
Submittals............................................... 1.4 6
Quality Assurance........................................ 1.5 8

PRODUCTS....................................................... 2.0 8
Concrete Materials....................................... 2.1 8
Concrete Reinforcement................................... 2.2 10
Joint Devices and Filler Materials....................... 2.3 10

EXECUTION...................................................... 3.0 11
Preparation of Surface and Pavement Patching............. 3.1 11
Placing and Finishing Concrete........................... 3.2 11
Reinforcement Placement.................................. 3.3 11
Surface Texture.......................................... 3.4 12
Curing................................................... 3.5 12
Joints................................................... 3.6 12
Joint Sealing............................................ 3.7 12
Testing.................................................. 3.8 12
Opening to Traffic....................................... 3.9 13

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 Spec. No. A-494
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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

1.0 GENERAL

1.1 Scope

This specification is applies to Portland cement concrete bonded overlay

(resurfacing) work as designated on the drawings and specifications and
includes cleaning and preparation of existing depth patches and
associated work to provide new portland cement concrete surface to
existing portland cement concrete pavement.
Work covered by this section includes:

a. Preparation of Surface and Pavement Patching

b. Placing and Finishing Concrete
c. Joint Construction
d. Curing
e. Testing

1.2 Related Specifications

1. Spec. A-401: Specification for Cast-in-Place Concrete

2. Spec. A-403: Specification for Concrete Repair

3. Spec. A-421: Specification for Roadway Excavation, Back-

firing, and Compaction

4. Spec. A-491: Portland Cement Concrete Paving

1.3 Reference Standards (Latest Edition)

1. AASHTO T-42 Method of Test for Preformed Expansion Joint

Filler for Concrete Construction

2. AASHTO T-53 Method of Test for Softening Point of Asphalt

(Bitumen) and Tar in Ethylene Glycol

3. AASHTO T-187 Method for Testing Concrete Joint Sealers

4. ACI 211: Recommended Practice for Selecting Proportions

for Normal Weight Concrete

5. ACI 304: Recommended Practice for Measuring, Mixing,

Transporting, and Placing Concrete

6. ACI 305R: Recommended Practice for Hot Weather Concreting

7. ACI 306R: Recommended Practice for Cold Weather Concreting

8. ACI 315 Details and Detailing of Concrete Reinforcement

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

9. ACI 318: Building Code Requirements for Reinforced

Concrete

10. ACI 347R: Guide for Formwork for Concrete

11. ASTM A 82: Specification for Steel Wire, Plain for Concrete
Reinforcement

12. ASTM A 185: Specification for Steel Welded Wire, Fabric,

Plain for Concrete Reinforcement

13. ASTM A 615: Specification for Deformed and Plain Billet-

Steel Bars for Concrete Reinforcement

14. ASTM C 31: Test Methods of Making and Curing Concrete Test
Specimens in the Field

15. ASTM C 33: Specification for Concrete Aggregates

16. ASTM C 39: Test Method for Compressive Strength of

Cylindrical Concrete Specimens

17. ASTM C 94: Specification for Ready-Mixed Concrete

18. ASTM C 143: Test Method for Slump of Portland Cement Con-
crete

19. ASTM C 150: Specification for Portland Cement

20. ASTM C 172: Method of Sampling Freshly Mixed Concrete

21. ASTM C 260: Specification for Air-Entraining Admixtures for

Concrete

22. ASTM C 272 Test Method for Water Absorption of Core

Materials for Structural Sandwich Construction

23. ASTM C 494: Specification for Chemical Admixtures for

Concrete

24. ASTM C 920: Specification for Elastomeric Joint Sealanes

25. ASTM C 989: Specification for Ground Iron Blast-Furnace Slag

for Use in Concrete and Mortars

26. ASTM D 5 Test Method for Penetration of Bituminous

Materials

27. ASTM D 95 Test Method for Water in Petroleum Products and

Bituminous Materials by Distillation

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

28. ASTM D D 96 Test Methods for Water and Sediment in Crude Oil
by Centrifuge Method

29. ASTM D 113 Test Method for Ductility of Bituminous Mate-

rials

30. ASTM D 545 Methods of Testing Preformed Expansion Joint

Fillers for Concrete Construction

31. ASTM D 1056 Specification for Flexible Cellular Materials -

Sponge or Expanded Rubber

32. ASTM D 1190: Specification for Concrete Joint Sealer, Hot-

Poured Elastic Type

33. ASTM D 1751: Specification for Preformed Expansion Joint

Fillers for Concrete Paving and Structural
Construction (Non-extruding and Resilient
Bituminous Types)

34. ASTM D 1752: Specification for Preformed Sponge Rubber and

Cork Expansion Joint Filler for Concrete Paving
and Structural Construction

35. ASTM D 1850: Specification for Concrete Joint Sealer Cold-

Application Type

36. ASTM D 2048 Test Method for Solubility of Asphalt Materials

in Trichloroethylene

37. ASTM D 3574 Methods of Testing Flexible Cellular Materials -

Slab, Bonded, and Molded Urethane Foams

38. AWS D1.4: Structural Welding Code-Reinforcing Steel

1.4 Submittals

A. Mix Design

1. Thirty days minimum prior to concrete placement, submit a mix

design for each strength and type of concrete.

2. Furnish a complete list of materials including type, brand,

source, and amount of cement, and admixtures; applicable reference
specification, and copies of test reports showing that the mix has
been successfully tested to produce concrete with the properties
specified and will be suitable for the job conditions. Obtain
approval before concrete placement.

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

3. Submit additional data regarding concrete aggregates if the source

of aggregate changes.

B. Reinforcing

1. Shop Drawings: Before placing reinforcing steel, 2 copies

of a list of all reinforcing steel showing the location,
mark number, size and type bend shall be furnished to the
CITGO engineer at the site.

2. Reproduction of Contract Drawings are unacceptable.

C. Hot and Cold Weather Concreting

1. Submit proposed methods for compliance with hot and cold

weather requirements.

D. Certificates of Compliance

Submit certificate stating that the following materials meet the

specified requirements:

1. Aggregates
2. Admixtures
3. Reinforcement
4. Cement

E. Catalog Data

Submit for approval the following catalog data and manufacturer's

specifications:

1. Joint devices
2. Materials for curing concrete
c. Joint sealant
d. Joint filler
e. Epoxy bonding agents

F. Batch Tickets

Submit delivery ticket from the concrete supplier with each batch
delivered to the site setting forth the following information.

1. Name of batching plant and location

2. Date

3. Serial number of ticket

4. Truck number and batch number

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

5. Contract number and location

6. Volume of concrete (cubic yards)

7. Class of concrete (2500 psi, 3000 psi, or 4000 psi)

8. Time loaded and amount of water that can be added at the job
site

9. Type and brand of cement

10. Weight of cement

11. Maximum size of aggregate

12. Weights of fine and coarse aggregates

13. Types and amounts of admixtures

14. Water content

1.5 Quality Assurance

A. For actual placing and finishing of the cement concrete surfaces

and operation of the required equipment, use only personnel who
are thoroughly trained and experienced in the skills required.

B. Perform work in accordance with ACI 301.

C. Conform to ACI 305R when concreting during hot weather.

D. Conform to ACI 306R when concreting during cold weather.

E. CITGO Quality Control Form (see attachment) shall be filled out

and submitted to CITGO Contract Engineer prior to execution.

2.0 PRODUCTS

2.1 Concrete Materials

A. Cement

Cement shall be Type I Portland Cement, conform to ASTM C 150,

unless otherwise specified.

B. Fine and Coarse Aggregate

1. Coarse aggregate shall be gravel or crushed stone, well

graded from fine to coarse within prescribed grading limits.

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

Sieve Size Percent Passing (By Weight)

2" 100
1-1/2" 85-100
3/4" 40-88
No. 4 0-6

2. Fine aggregate shall be composed of clean, hard, durable,

uncoated grains of sand meeting the following gradation:

Sieve Size Percent Passing (By Weight)

3/8" 100
No. 4 95-100
No. 16 45-90
No. 50 7-30
No. 100 0-7

C. Water

1. Water used in mixing concrete shall be potable and free of

injurious amounts of oils, acids, alkalies, sulfates, and
other deleterious substances.

D. Admixtures

1. Air Entraining admixture shall meet the requirements of ASTM

C 260

2. Accelerating admixture shall meet the requirements of ASTM C

494.

E. Concrete Mix

1. Minimum recommended cement content shall be 564 lbs. per one

cu. yd. of concrete.

2. Water-cement ratio by weight (pounds of water per pound of

cement) should not exceed 0.53 (6 gal per U.S. bag of
cement). The maximum water-cement ratio (gal./sack) shall
be reduced 5 percent when a water reducing admixture is
used, and 10 percent when an air-entraining admixture, or
air-entraining and water-reducing admixtures, is used.

3. Slump shall be adjusted to be between 2 and 3 inches, if not

vibrated, or between 2 and 4 inches, if vibrated.

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

4. In areas subjected to many cycles of freezing and thawing

and to the application of deicing salts, adequate quantities
of entrained air must be added to the mix. Recommended
percentages are:

Maximum - Size Entrained Air

Aggregate (in.) (Percent)
_____________

1-1/2, 2, 2-1/2 5 + 1
3/4, 1 6 + 1
3/8, 1/2 7-1/2 + 1

The required percent of entrained air may be obtained by

using air-entrained portland cement or by using an air-
entrained admixture conforming to ASTM C 260.

5. The paving mix shall be proportioned to furnish 3000 psi

concrete at 28 days with air entrainment is used.

2.2 Concrete Reinforcement

A. Reinforcing steel shall be made from deformed new billet stock and
shall conform to ASTM A 615, Grade. 60 or ASTM A185 for steel
welded wire fabric with gages, spacing, and dimensions as shown on
the drawings.

B. Reinforcement chairs shall be non-corrosive.

C. All reinforcement shall be free from oil, mill scale and excessive
rust or other coatings that will destroy or reduce bond.

D. Tie wire shall be minimum 16 gage annealed type.

E. Chairs, bolsters, bar supports, spacers shall be sized and shaped

for support of reinforcement during concrete placement conditions.

F. Usage of the bricks or another unspecified material as a bar

supports are not allowed.

2.3 Joint Devices and Filler Materials

A. Preformed fillers joint sealers and devices shall be used in

joints when specified in accordance with the plans and project
specifications.

B. Joint devices, fillers and sealer materials shall conform to CITGO

A-491 Specification "Portland Cement Concrete Paving."

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

3.0 EXECUTION

3.1 Preparation of Surface and Pavement Patching

A. After all repairs have been completed and prior to placing of the
overlay, the surface shall be sweep clean of all dirt, dust, and
foreign material that may tend to break the bond between the
overlay and the existing pavement. Any extruding joint sealing
material shall be trimmed from rigid pavements.

B. Any deep spalls shall be filled with asphalt or concrete prior to

placing the overlay.

C. In areas where the pavement slab is experiencing excessive

cracking and deterioration or the slabs are moving or pumping
excessively, the pavement shall be removed full depth or stabi-
lized.

D. Any unsuitable subgrade encountered under the full-depth removals

shall be removed to the depth as directed by the engineer. The
unsuitable subgrade shall be replaced with suitable earth fill
material or suitable granular materials as directed by the
engineer.

E. All material removed shall be hauled to a designated dump site.

3.2 Placing and Finishing Concrete

A. The placing and finishing operations shall include placing of the

concrete overlay as shown on the plans and details.

B. The concrete to be used and concrete placement shall be as

specified by CITGO Specification A-491.

C. Operation shall include all items to place, finish, texture, cure,

joint and seal the concrete overlay.

D. The Contractor shall take every reasonable precaution to secure a

smooth-riding surface.

E. Prior to placement operations, he shall review his equipment,

procedures, personnel and previous results with the engineer, and
the inspection procedures shall be reviewed to assure coor-
dination. Precautions shall include the assurance that concrete
can be produced and placed within the specified limits,
continuously and uniformly.

3.3 Reinforcement Placement

A. Reinforcing mesh shall be placed in accordance with the CITGO

Standard Specification A-491, "Portland Cement Concrete Paving."

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

B. Dowels or other load transfer devices shall be placed in accor-

dance with the CITGO Standard Specifications A-491.

C. Tie bars shall be placed as detailed on the plans and in accor-

dance with the CITGO Standard Specifications A-491.

3.4 Surface Texture

A. When a tight, uniform surface has been achieved, the surface shall
be textured by a burlap or artificial turf drag, by brooming, or
by transverse tining.

3.5 Curing

A. After the surface has been textured, curing compound shall be

applied at the rate of 150 square feet/gallon.

B. Cure is to be applied immediately after texturing operations to

prohibit excessive moisture loss from the concrete.

3.6 Joints

A. Joints shall be constructed of the type and dimensions and at

locations shown on the plans or required by special provisions.

B. All transverse joints shall be sawn in the new concrete overlay as

soon as possible to prevent cracking of the overlay.

C. Joints shall be marked out and sawn within 1 inch of existing

joints as specified on the details.

D. All joints shall be cleaned and filled in accordance with Section

3.7 of this specification prior to the opening of the pavement
traffic.

3.7 Joint Sealing

A. Joint sealant shall meet the requirements of the standard spec-

ifications and shall be placed in accordance with the details
shown on the plans.

3.8 Testing

A. Slump

The slump of concrete, tested at the time of placement, measured

in accordance with ASTM C143, shall not exceed 3 inches for
concrete placed by vibration or 4 inches for hand placed concrete.

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ENGINEERING & CONSTRUCTION SPECIFICATIONS Rev. No. A

CLASS - “A” Civil - Portland Cement Concrete Paving Repairs- Date: 07/01/95

B. Percent Entrained Air

The entrained air content of the fresh, unvibrated concrete at the

time of placement, as determined by ASTM C260 shall be 6 percent,
plus or minus 1 percent.

C. Pavement Strength

The average compressive strength for 5 cores per lot, shall not be
less than 4,000 psi (3,000 psi when air entrainment is used). (A
lot shall be considered as 3,000 linear feet of pavement when a
single traffic line placed 1,500 linear feet when two lanes are
placed concurrently). When an individual core indicates
compressive strength less than 3,000 psi, it is the engineer's
judgment to remove or leave concrete in place. If removal is
warranted, the entire section shall be replaced with concrete of
the desired quality. The compressive strength of cores shall be
determined after a minimum of 28 days.

D. Pavement Thickness

After the pavement has met all surface smoothness requirements, cores
for thickness measurements shall be taken. Individual areas found
deficient in thickness by more than one inch shall be evaluated by the
engineer, and, if in his judgment the deficient areas warrant removal,
they shall be removed and replaced with concrete of the thickness shown
on the plans.

3.9 Opening to Traffic

A. The pavement shall not be opened to traffic until specimen beams

have attained a flexural strength of 600 psi when tested by the
third-point method in accordance with AASHTO Designation: T 97 or
a compressive strength of 3,000 psi when tested in accordance with
AASHTO Designation: T 22. If such tests are not conducted, the
pavement shall not be opened to traffic until 14 days after the
concrete has been placed.

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