Volume MJ Jointed Reinforced Concrete Pavement

PAVEMENT STANDARD DRAWINGS
RIGID PAVEMENT
STANDARD DETAILS - MAINTENANCE MD.M10.MJ
Volume MJ - Jointed Reinforced Concrete Pavement
RELATED CONCRETE PAVEMENT DRAWINGS

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M 10.
CONSTRUCTION MAINTENANCE
M D.
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BASE TYPE DRAWING VOLUME

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JRCP CJ MJ
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PAVEMENTS UNIT
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ASSET MAINTENANCE DIVISION

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APPROVED FOR USE REGISTRATION No OF PLANS SHEET No

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PAVEMENTS AND GEOTECHNICAL

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G. VOROBIEFF 28/05/2015
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SIGNED DATE
© COPYRIGHT ROADS AND MARITIME SERVICES

SHEET INDEX
REVISION REGISTER (See also MJ04)
ED/REV DATE SHEET AMENDMENT DESCRIPTION AUTHORISED DRAWING CONTENT SHEET No
1/0 30/04/2001 ALL Initial issue GM, RNIC COVER SHEET MJ01
2/0 14/03/2014 ALL Comprehensive revision PEPM&G * REVISION REGISTER AND SHEET INDEX MJ02
2/1 28/05/2015 ALL Comprehensive revision PEP&G ** LEGEND MJ03
INDEX OF SHEETS MJ04
JOINT CATALOGUE MJ05-MJ10
KERBS AND BARRIER MJ11
SLAB REPLACEMENT MJ12-MJ17
CROSS STITCHING OF CRACKS AND JOINTS - COMPROMISE PRACTICE MJ18
JOINT RESEALING MJ19-MJ21
ROUTING AND SEALING OF CRACKS AND JOINTS MJ22-MJ23
JOINT SPALL REPAIRS MJ24-MJ25
ANCHOR DEFECT REPAIRS MJ26

* PRINCIPAL ENGINEER PAVEMENTS, MATERIALS AND GEOTECHNICAL
** PRINCIPAL ENGINEER, PAVEMENTS AND GEOTECHNICAL
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SCALES: NOT TO SCALE, OR AS NOTED. A3 ORIGINAL PREPARED BY: PAVEMENTS UNIT REGISTRATION No OF PLANS SHEET No
ENGINEERING SERVICES BRANCH PAVEMENT STANDARD DRAWINGS
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ASSET MAINTENANCE DIVISION RIGID PAVEMENT

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JOINTED REINFORCED CONCRETE PAVEMENT (JRCP)

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FOR AMENDMENTS REFER TO SHEET No 02 PAVEMENTS AND GEOTECHNICAL
THIS SHEET MAY BE PREPARED USING COLOUR AND MAY BE INCOMPLETE IF COPIED © COPYRIGHT ROADS AND MARITIME SERVICES
TABLE 3.1: PRACTICE NOTES TABLE 3.2: JOINT TYPE NUMBERS AND DESCRIPTIONS TABLE 3.3: ABBREVIATIONS
1. Scope TYPE DESCRIPTION

SYMBOL DESCRIPTION
Definitions of terms is contained in the Specification.

TABLE A.B Sheet A, Table A.B
J1 Longitudinal: tied and sawn
These Drawings represent "Model" or "Standard" details which are intended for use by
S A.B Sheet A, Schedule A.B
project designers. Where design tables are provided (for example, Table 9.1 for tiebar J2 Longitudinal: tied and formed
spacings) they are intended solely as a guide to those designers and must not be FIGURE A.B Sheet A, Figure A.B
J2d Longitudinal: drill-tied and formed
reproduced in project-specific drawings for interpretation and/or application by site
TYP Typical
staff. Project-specific drawings must show precise details for items such as slab J3 Longitudinal: tied and ribboned
replacements, jointing, spall repairs, crack repairs, spacings of tiebars, and other NOM Nominal
J4 Longitudinal: untied and formed
reinforcing steel.
NTS Not To Scale
J5 Longitudinal: untied and sawn
2. Dimensions
MIN Minimum
J6 Longitudinal: edge
All dimensions are in millimetres (mm) unless noted otherwise.
MAX Maximum
3. Classification of maintenance practices J7 Transverse construction: tied and formed
The maintenance practices shown in these drawings are classified according to CRCP Continuously Reinforced Concrete Pavement
J7d Transverse construction: drill-tied and formed
whether they are structural or non-structural repairs. A structural repair is one which
LCS Lean-Mix Concrete Subbase
J9 Transverse contraction: sawn and dowelled
either fully or partially restores the load carrying capacity of the pavement. Structural
repairs are further classified according to Best Practice or Compromise Practice. SMZ Selected Material Zone
J10 Transverse contraction: formed and dowelled
Best Practice repairs are the preferred option for repair of concrete pavements and PCP Plain Concrete Pavement
J10d Transverse contraction: formed and drill-dowelled
must be adopted unless otherwise approved in writing by the Principal.
PCP-R Reinforced Plain Concrete Pavement (Discrete Slabs)
J12 Transverse contraction: knifed and dowelled
PCP-D Dowelled Plain Concrete Pavement

J14 Isolation: with subgrade beam
TABLE 3.6 REFERENCED DOCUMENTS
JRCP Jointed Reinforced Concrete Pavement
J15 Isolation: without subgrade beam
Roads and Maritime Services Specifications
SFCP Steel Fibre Reinforced Concrete Pavement
3204 Preformed Joint Fillers for Concrete Road Pavements and Structures J16 Expansion: dowelled
M258 Slab Replacement (Concrete Pavement) Steel Fibre Reinforced Concrete Pavement with mesh added
J16d Expansion: drill-dowelled SFCP-R
R15 Kerbs and Gutters (Discrete Slabs)
J17 Hinge: tied and sawn
R83 Concrete Pavement Base
R&R Remove And Replace
Roads and Maritime Services Test Methods J18 Longitudinal: edge and beamed
ACRS Australian Certification Authority for Reinforcing Steels
T366 Dowel Pull-out Test
Table 3.2 Notes:
T379 Cleanliness of Sawn Concrete Pavement Joints NA Not Applicable
(a) Details shown on MJ05 and MJ06 are indicative of joints which will be
T380 Field Adhesion of Joint Sealant to Concrete
encountered in existing pavements and those which will be used in slab
Other Roads and Maritime Services Documents
replacement work. They should not be confused with joint details on other
Pavement Standard Drawings Rigid Pavement Standard Details - Construction
sheets which show remedial activities such as joint resealing (MJ19-MJ21)
Volume CC - Continuously Reinforced Concrete Pavement
or routing (MJ22 and MJ23). TABLE 3.4: SYMBOLS
Pavement Standard Drawings Rigid Pavement Standard Details - Construction
(b) The suffix "d" relates to "drilled" tiebars or dowels.
Volume CP - Plain Concrete Pavement SYMBOL DESCRIPTION
Specification Guide NR82 Guide to QA Specification R82
Specification Guide NR83 Guide to QA Specification R83 D Joint type: 'D'

Standard Pavement Subsurface Drainage Details - Volume 5 - Rigid Pavement Details
Standard Drawing MD.R132.D08.A.1 Type ‘F’ Concrete Safety Barrier Cast-in-situ

Tiebars
Applications Single Sided Sections and Profiles
RMS Austroads Guide Supplements - Austroads Guide to Pavement Technology Part 2:
Pavement Structural Design
Australian/New Zealand Standards
AS 1379 Specification and Supply of Concrete
AS 3600 Concrete Structures
AS/NZS 4671 Steel Reinforcing Materials
Other Documents TABLE 3.5: GENERAL SLAB DIMENSIONAL LIMITS

Austroads Guide to Pavement Technology Part 2: Pavement Structural Design
JRCP SFCP SFCP - R LCS
TRAFFICKED (a) UN-TRAFFICKED (a) TRAFFICKED (a) UN-TRAFFICKED (a) TRAFFICKED (a) UN-TRAFFICKED (a)
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M J_03.
Minimum Corner Angles (b) 84° 80° (75°) 75° (70°) 70° (65°) 75° (70°) 70° (65°) 70°
M 10.
Slab Length L (c) L max 8.0 (10.0) 8.0 (10.0) 6.0 6.0 (6.5) 6.0 6.0 (6.5)
M D.
(metres)
L min 3.5 3.5 2.5 2.5 2.5 2.5 1.5
ngs -JRCP\
Slab Width W (d) W max 4.3 (4.5) 4.4 (4.6) 4.3 (4.5) 4.3 (4.5) 4.3 (4.5) 4.5 (4.7)
(metres)
W min 1.0 0.6 1.0 0.3 0.6 0.3 1.0
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R max 8.0 (10.0) 13.3 (16.7) NA NA NA NA

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Shape Factor R = L / W
R min 0.81 (0.78) 0.80 (0.76) NA NA NA NA
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Table 3.5 Notes:

42 PM
(a) See Note 1 in Table 3.1 (e) Values in brackets show compromise limits for exclusive use by designers where their use is
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(b) Corner angles should be maximised wherever possible. unavoidable. They must not be adopted by field staff without design review and approval.
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(c) Length is the largest edge measure between transverse contraction joints, or the longest chord (f) Where an un-trafficked slab is likely to become trafficked within 20 years, it must be designed
on curved slabs. for trafficked criteria.
(d) Width is the largest square measure between longitudinal edges or joints, or the largest radial
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JOINT CATALOGUE
● Joint types and section details

● Treatment of exposed joints (corrugated, keyed, and butt) SLAB REPLACEMENT
● Sealant design KERBS AND BARRIER
ANCHOR DEFECT REPAIRS ● Full and part-slab R & R
● Design of tiebars and drill-ties
● Schedule of R & R activities ● Kerb and barrier details
● Anchor slab cracking ● Dowel details
● Anchor rotation MJ26 ● Edge details MJ05 - MJ10 MJ12 - MJ17 MJ11
ANCHOR
J6
A
J2 J2
J7d J9 J9 J7d
J1 J2d J1
J9
J9 J9
OR
OR OR
J10
J10 J10
J2 J2
A
J6
JOINT RESEALING ROUTING AND SEALING CROSS STITCHING
● Joint resawing ● Joint routing and resealing ● Longitudinal joint stitching

JOINT SPALL REPAIRS
● Joint resealing ● Unplanned crack routing and sealing ● Longitudinal crack stitching
● Treatment of arris faults ● Partial-depth repairs ● Treatment of arris faults ● Compromise practice
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M J_04.
MJ19 - MJ21 MJ24, MJ25 MJ22, MJ23 MJ18

M 10.
M D.
KEY
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SHEET TITLE
● Issues covered
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Sheet Nos
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DETAIL SECTIONS
CORRUGATIONS : SEE TABLE 10.2
MESH KEYED : SEE FIGURE 16.3
E1-N12
SCABBLED/BUTT : SEE FIGURE 17.1
5±3
SEE TABLE 10.1 AT SPACING AS SHOWN IN TABLE 9.1 3 ± 1 WS
JOINT DIMENSIONS;
COVER 30 SAWCUT
A D/3 MIN MESH D/3 MIN SEE TABLE 8.1
MIN
RS
-
DEPTH OF BASE
DEPTH OF BASE
SEE TABLE 10.1
SILICONE SEALANT SILICONE SEALANT
DS
D
+10
0
CLOSED-CELL
3–
CLOSED-CELL
8±2
D/
POLYETHYLENE
POLYETHYLENE
+10
E1-N12
0
500 ± 35 D/3 MIN 500 ± 35 D/3 MIN BACKER ROD (TYP)
BACKER ROD
3–
N
AT SPACING AS
15
MI
D/
(TYP) WIDENING SAWCUT
SHOWN IN TABLE 9.1
JOINT TYPE J1 JOINT TYPE J2

BACKER ROD
LONGITUDINAL: LONGITUDINAL:
3 ± 1
TIED AND SAWN TIED AND FORMED
FIRST SAWCUT
CORRUGATIONS : SEE TABLE 10.2

KEYED : SEE FIGURE 16.3 DETAIL A DETAIL B
SCABBLED/BUTT : SEE FIGURE 17.1 - -
E4-N12
AT SPACING AS SHOWN IN TABLE 9.1
D/3 MIN MESH
RIBBON INDUCER 3 ± 1 WS WS
250MI JOINT DIMENSIONS;
DEPTH OF BASE
SEE TABLE 10.1 N WIDENING
FIRST SAWCUT
SAWCUT SEE TABLE 8.1
RS
CLOSED-CELL
CLOSED-CELL
D
POLYETHYLENE
POLYETHYLENE SILICONE SEALANT
DS
BACKER ROD
BACKER ROD (TYP)
+10
0
D/3 MIN (TYP)
TIEBAR FIXING : CLOSED-CELL
4–
35 ± 5
JOINT TYPE J3
D/
SEE NOTE 2 (S7.2) POLYETHYLENE
JOINT TYPE J2d
LONGITUDINAL: BACKER ROD (TYP)
LONGITUDINAL:
SCHEMATIC TIED AND RIBBONED
DRILL-TIED AND FORMED
NOTE: THIS JOINT TYPE IS NOT TO BE USED FOR NEW CLOSED-CELL
CONSTRUCTION OR MAINTENANCE WORK
POLYETHYLENE
CLOSED-CELL BACKER ROD (TYP)
POLYETHYLENE
G B BACKER ROD (TYP) SEAL FULL FACES;

MESH 06 MESH - SEE NOTE 2 (S7.1)
DEPTH OF BASE
DEPTH OF BASE
SEE TABLE 10.1 SEE TABLE 10.1
1 - PRELIMINARY SEALING 2 - TEMPORARY SEALING 3 - PERMANENT SEALING

D
DEVELOPMENT OF SAWCUT AND SILICONE SEAL JOINT
J4 JOINT TYPE J5 DETAIL C

JOINT TYPE
LONGITUDINAL: -
LONGITUDINAL:
UNTIED AND FORMED UNTIED AND SAWN
BUTT EDGE OR CORRUGATED EDGE TO MATCH EXISTING

(CORRUGATIONS AS SHOWN IN TABLE 10.2) CORRUGATIONS : SEE TABLE 10.2
CORRUGATIONS KEYED : SEE FIGURE 16.3
E7-N12
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AS SHOWN IN TABLE 10.2 SCABBLED/BUTT : SEE FIGURE 17.1

AT SPACING 500 C/C
M J_05.
E8-N12
50 MINIMUM OR MATCH AT SPACING 500 C/C
MESH D/3 MIN D/3 MIN MESH
M 10.
EXISTING WHERE GREATER 25

DEPTH OF BASE
SEE TABLE 10.1 SEE TABLE 10.1 0MI

DEPTH OF BASE
N
M D.
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D
06
JRCP
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D/3 MIN TIEBAR FIXING :

500 ± 35 D/3 MIN
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SEE NOTE 2 (S7.2)

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JOINT TYPE J6
LONGITUDINAL: EDGE JOINT TYPE J7 JOINT TYPE J7d
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TRANSVERSE CONSTRUCTION: TRANSVERSE CONSTRUCTION:

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FORMED AND TIED FORMED AND DRILL-TIED

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DETAIL SECTIONS
WS WS WS WS 3 ± 1
5±3
JOINT DIMENSIONS; JOINT DIMENSIONS; JOINT DIMENSIONS; JOINT DIMENSIONS;
SAWCUT
SEE TABLE 8.1 SEE TABLE 8.1 SEE TABLE 8.1 SEE TABLE 8.1
RS
RS
RS
RS
SILICONE SEALANT SILICONE SEALANT SILICONE SEALANT SILICONE SEALANT
8±2
SILICONE SEALANT
DS
DS
DS
DS
INITIAL CRACK
INDUCER PLACED
CLOSED-CELL DEBONDING STRIP CLOSED-CELL CLOSED-CELL
SQUARE (± 6°) TO
DJ
DJ
DJ
CLOSED-CELL
THE FINISHED POLYETHYLENE POLYETHYLENE POLYETHYLENE TRANSVERSE
POLYETHYLENE
+10
+10
0
0
TOP SURFACE BACKER ROD (TYP) BACKER ROD (TYP) BACKER ROD (TYP) +10
D/4–
4–
4–
0 BACKER ROD (TYP)
OF THE BASE
D/
D/
WIDENING SAWCUT JOINT FILLER
SEE NOTE 2 (S7.3) FOR SEE NOTE 2 (S7.3) FOR
CONSTRUCTION OPTIONS CONSTRUCTION OPTIONS
INITIAL CRACK INDUCER

DETAIL E
DETAIL H
- DETAIL F DETAIL G
-
- -
STAGE 1 STAGE 2
DETAIL D CROSSFALL VERGE OR APPROACH PAVEMENT
VERGE OR
- +0
APPROACH PAVEMENT EDGE OF CONCRETE BASE EDGE OF CONCRETE D/4–
30
OF BASE
DEPTH
D
D/2 ± 25 MESH D/2 ± 25 MESH
C F EDGE DRAIN IN
SEE TABLE 10.1
DEPTH OF BASE
SEE TABLE 10.1
DEPTH OF BASE
05 BUTT JOINT - ACCORDANCE WITH ROADS

60 ± 30
AND MARITIME SERVICES
SUBBASE
STANDARD PAVEMENT
D
D
SUBSURFACE DRAINAGE GEOTEXTILE IN ACCORDANCE WITH

DETAILS VOLUME 5 ROADS AND MARITIME SERVICES
DETAIL J1 DETAIL J2
STANDARD PAVEMENT SUBSURFACE
DOWELS 450 LONG @ 300 C/C DEBONDING AGENT DOWELS 450 LONG @ 300 C/C
- - DRAINAGE DETAILS VOLUME 5
DEBONDING AGENT
MINIMUM 275 MINIMUM 275 SEE TABLE 7.3 FOR DIAMETER
SEE TABLE 7.3 FOR DIAMETER LOW SIDE J6 /J18 EDGE DETAILS HIGH SIDE J6 /J18 EDGE DETAILS
J9 DETAIL J
JOINT TYPE JOINT TYPE J10
TRANSVERSE CONTRACTION: TRANSVERSE CONTRACTION: -
SAWN AND DOWELLED FORMED AND DOWELLED EDGE DETAILS
DEPTH OF BASE
MESH
E
D/2 ± 25 MESH SEE TABLE 10.1
F D/2 ± 25 MESH -
SEE TABLE 10.1
DEPTH OF BASE
DEPTH OF BASE
MESH
- SEE TABLE 10.1 E
DEPTH OF BASE
- SEE TABLE 10.1

-
D
D
EXISTING
D
D
BASE 300
SUBBASE
DEBONDING AGENT DOWELS 450 LONG @ 300 C/C
DEBONDING AGENT DOWELS 450 LONG @ 300 C/C
MINIMUM 275 DRILLED AND FIXED SUBGRADE BEAM
200
MINIMUM 275 SEE TABLE S7.3 FOR DIAMETER
SEE TABLE S7.3 FOR DIAMETER
SL92 MESH
JOINT TYPE J10d JOINT TYPE J12 OR
SUBBASE
TRANSVERSE CONTRACTION: TRANSVERSE CONTRACTION: L8TM 80 ± 20
80 ± 20
FORMED AND DRILL-DOWELLED KNIFED AND DOWELLED 600 JOINT TYPE J15
ISOLATION:
JOINT TYPE J14 WITHOUT SUBGRADE BEAM

dgn
ISOLATION: MESH
M J_06.
SEE TABLE 10.1 50 MINIMUM OR MATCH

WITH SUBGRADE BEAM
GEOTEXTILE EXISTING WHERE GREATER
M 10.
DEBONDING AGENT
FIXING
DOWEL CAP
MINIMUM 275
M D.
SEE NOTE 6 (S7.2) (J16d ONLY)

E COVER 80 ± 20
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DEPTH OF BASE
SEE NOTE 2 (S7.2)

- SEE NOTE 7 (S7.1) BASE J
H 30 MIN COVER -
DEPTH OF BASE
- SEE NOTE 7 (S7.1)

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SUBBASE
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BASE
D/2 ± 25
200
SUBGRADE BEAM
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D
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SL92 MESH
OR
80 ± 20
SUBBASE DOWELS 450 LONG @ 300 C/C L8TM
MESH CONTINUOUS ACROSS JOINT
46 PM
80 ± 20
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SEE TABLE S7.3 FOR DIAMETER D/3 MIN 600

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SEE TABLE 10.1

MESH SEE TABLE 10.1
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JOINT TYPE J16 AND J16d JOINT TYPE J17 JOINT TYPE J18
EXPANSION: DOWELLED / DRILL-DOWELLED HINGE: TIED AND SAWN LONGITUDINAL: EDGE AND BEAMED
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SCHEDULE 7.1 (S7.1) SCHEDULE 7.2 (S7.2) TABLE 7.1: REINFORCEMENT SCHEDULE AND BAR SPACING
NOTES MATERIALS AND NOTES (b)
MARK DIA SHAPE LOCATION / DESCRIPTION LENGTH (m) SPACING (mm)
Scope Steel grade and supply and fabrication of reinforcement
1. Details shown on MJ05 and MJ06 are indicative of joints which will be 1.Steel must comply with AS/NZS 4671, as follows:
Tiebars in longitudinal joints
encountered in existing pavements, and those which will be used in slab (a) Bar reinforcement (including tiebars) must be deformed ribbed, normal ductility E1 N12 1 1.0 See jointing plan and Table 9.1
E2 is acceptable alternative in J1 joints
replacement work. They should not be confused with joint details on other steel of grade 500 MPa (that is, D500N) which is notated in these drawings as
sheets which show remedial activities such as joint resealing (MJ19-MJ21) 'N' according to the diameter, for example, N12, N16, N20. Tiebars in longitudinal joints
(a)
E2 N12 7 1.0 See jointing plan and Table 9.1
or routing (MJ22 and MJ23). (b) Mesh reinforcement must be round or deformed, low ductility steel of grade alternative to E1 for J1 joints
500 MPa, which is notated in these drawings as 'RL' (rectangular mesh) or
Sealing of joint ends E4 N12 1 or 22 Drilled tiebars in longitudinal joints 0.75 See jointing plan and Table 9.1
'SL' (square mesh).
2. Where joints "daylight" at outer edges and formed joints, the sealant must
(c) Dowels must be round (plain) normal ductility steel of grade 250 MPa, which is E7 N12 1 Tiebars in J7 joints 1.0 500
extend down the vertical faces of the joint and down any underlying crack.
notated in these drawings as 'R' according to the diameter, for example, R24,
This is required to prevent the ingress of incompressibles such as verge E8 N12 1 or 22 Drilled-ties in J7d joints 0.75 500
R32.
material (in the case of outer edges) and mortar from subsequent paving
(d) The reinforcement material suppler must be certified by ACRS for the supply of Kerb types SA, SB, SO and SK
runs (in the case of formed joints). J1 N12 21 1.0 1 000 ± 50
reinforcement material. longitudinal joints. See Note (c).
Formed joint faces (e) The reinforcement fabricator must be certified by ACRS for fabrication of
Kerb types SE and SL
3. Details of formed joints are shown as follows: reinforcement material. J2 N12 1 1.0 1 000 ± 50
longitudinal joints
(a) corrugated: see Table 10.2
Fixing of tiebars and dowels
(b) keyed: see Figure 16.3 J3 N12 5 Kerb types SF and SM 0.5 500 MAX; See MJ11
2.(a) Drilled tiebars and dowels must be fixed using a suitable two-component epoxy
(c) scabbled: see Figure 17.1
or polyester setting system (resin) which is thoroughly mixed within the injection J4 N12 9 Kerb types SF and SM when installed as 0.325 500 MAX; See MJ11
Joint debonding drill-ties into an existing base slab.
delivery system.
4. All pavement joints are required to hinge to relieve curling stresses. (b) For tiebars, it must provide an anchorage strength of at least 85% of the yield
MESH - - JRCP. See Figure 7.1. See Table 10.1. - -
Hence, whilst aggregate interlock is beneficial, intimate microtexture bond strength of the bar. Tiebars may be drilled at an inclination of up to 10°
must be prevented because it causes joint spalling, particularly at arrises. to facilitate fixing. Table 7.1 Notes:
Positive debonding is therefore required, as follows: (c) Cleanliness is critical to achieving good pull-out strength. Drilling dust and other (a) E2 tiebars must be securely fixed against rotation during paving.
(a) The first-placed face must be dense and fully compacted and be free of debris must be cleaned out of the holes using an industrial vacuum cleaner or (b) See Table 7.2.
honeycombing and re-entrant angles. Defects must be repaired before oil-free compressed air. In both cases, a nozzle must be used which reaches (c) Tiebars in kerbs (Shape 21) must be bent to satisfy cover requirements. They may be bent insitu.
adjoining concrete is placed. The repair material must not be placed the end of the hole to ensure that no dust remains in the hole.
integrally with the adjoining concrete. (d) A nozzle must be used which reaches the end of the hole to ensure the resin
(b) The first-placed face must be sprayed with wax emulsion curing completely fills the hole when the tiebar is inserted.
TABLE 7.2: BAR REINFORCEMENT SHAPES TABLE 7.3: DOWEL DIAMETER
compound as the debonding agent in accordance with M258.
Tiebars and drill-ties L2
/ L/2 L3
/ 2L/3 BASE SLAB DOWEL
(c) Tiebars must not be sprayed with the debonding agent.
3.In longitudinal joints, tiebars must be designed in accordance with Table 9.1
L
THICKNESS (mm) DIA (mm)
5. Reserved. and be placed:
( ) SEE NOTE (c) 10° MAX 150 < D ≤ 175 24
Subgrade beams (a) not closer than 300 mm to a transverse untied joint (for example, a contraction 100 *
SEE NOTE 2(b) S7.2
or isolation joint). 175 < D ≤ 200 28
6. Beams must be of Grade N32 concrete and have a steel-float surface finish. 1 21
(b) not closer than 150 mm to a transverse tied joint. 22
200 < D ≤ 260 32
Mesh cover
(c) to ensure a minimum vertical clearance of 30 mm to any proposed crack inducer C JOINT
7. (a) Mesh must be placed to provide the following cover unless 30 MIN D > 260 36
or sawcut. 500 ± 75 500 ± 75 300
otherwise shown: SEE NOTE (d)
4.In transverse tied construction joints, tiebars must be provided at 500 c/c (and 500 c/c
- to joints and edges: 80 ± 20 mm.
for drill-ties) and be placed not closer than 150 mm to a longitudinal joint or slab edge. 300
175
- top and bottom cover:80 ± 20 mm.
5.The following practices apply to drill-ties: 150 300 300 150
(b) Mesh top cover must be increased to the extent necessary to achieve
(a) the volume of the chemical anchor should be determined so that the resin just 9
175
30 mm cover under sawcuts. Bottom cover must not be less than D/3. 50 50
fills the hole once the tiebar is inserted.
(c) Maximum of three layers of mesh at any one point. 5 7
(b) the tiebar must be rotated in the hole to maximise bond between the resin and SEE NOTE 2 S7.2
Anchors both the tiebar and the concrete.
8. See MJ23
Dowels Table 7.2 Notes:
Kerbs 6.Dowels must be installed ahead of paving and must:
(a) Bending pin diameter to be 5 times bar diameter.
9. Fixtures such as kerbs and islands must be structurally compatible with the (a) be 450 mm long and of diameter in accordance with Table 7.3. (b) All dimensions are to intersections of straight portions at outside of bends.
adjoining base. See MJ11. (b) be straight and free of irregularities which could hinder their movement (such as (c) ( ) =8 for SA and SB kerbs.
burrs and protrusions).
*
Edge drains 20 for SO and SK kerbs.
(c) be fully galvanised. (d) Or as required to meet cover requirements under the sawcut.
10. Edge drains are normally only provided on the lower side. A geotextile is
dgn
(d) be coated at one end with a tough, durable debonding agent of thickness
M J_07.
provided on the high side to minimise ingress of fines as shown in Detail J

0.75 ± 0.25 mm. At formed joints, the debonding must be on the section
on MJ06.
which lies within the second-placed slab.
M 10.
(e) unless otherwise shown on the Drawings, be placed at mid-depth (± 25 mm),

M D.
SCHEDULE 7.3 (S7.3) parallel to the pavement surface and parallel with the local relevant control line,
ngs -JRCP\
S2 S2
PROCEDURES with tolerances as given below.
MESH MESH
1. Drill holes (for tiebar and dowel fixing) must be thoroughly cleaned of dust (f) be supported so that no part of the assembly, except the dowel, crosses the joint.
awi
using dry oil-free compressed air through a probe inserted into the hole. (g) be equally positioned about the line of the intended joint within a tolerance
d Dr
2. In Details F and G on MJ06, the sealant reservoir may be created by of ± 25 mm.

S1 S1
andar
sawcutting or (in the case of formed joints) by fixing a temporary filler to the (h) be placed not closer than 150 mm to a longitudinal joint.
(a) S = S (b) S < S
enance St
(i) when tested in accordance with T366, have an average pull-out bond stress 1 2 1 2
first-placed face. Where a filler is used, the joint must be prepared for
sealing by sawing in accordance with MJ19-MJ21. not more than 0.15 MPa.
FIGURE 7.1: LAPPED SPLICE FOR WELDED MESH
47 PM
(j) at expansion joints, have the debonded end capped to provide a clearance for
nt
d Pavem entM ai
(ADAPTED FROM FIGURE 13.2.3 AS 3600)

movement equal to the width of the joint plus 15 ± 5 mm.
21:
at 12:
NOT TO SCALE
7.The alignment tolerance of individual dowels is:
OVERLAP THE TWO OUTERMOST CROSS-BARS AS SHOWN IN FIGURE 7.1
(a) before placing concrete: ± 2 mm.
THE MINIMUM LENGTH OF OVERLAP = 100 mm
2015
(b) in the finished slab: ± 2 mm.

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TABLE 8.1: UNTIED JOINTS - SILICONE SEALANT DIMENSIONS
1 2 3 4 5 6 7
Slab Length L Recess

(b) Table 8.1 Notes:
e (e)
Design Joint (d)
or Width Depth Joint depth (a) For details of tied joints, refer to Table 8.2. (d) Values given for the depth of joint DJ are indicative only. Allowance must be made for factors
RS (mm)
(f) Opening
Width W WS (mm) DS (mm) D (mm) such as the depth of the backer rod after lateral compression into the joint.
e Contractions Isolations and (b) The recess varies according to joint type because of the relative potential for joint closure,
OD (mm) J
(b(2)) (b(1)) It is important that the upward pressure on the sealant (in hot weather) is minimised.
(m) and butt expansions and the risk (in hot weather) of the sealant being ejected.
≤ 4.6 2.1 7 (+3, -0) 7 (+3, -0) 5 ± 3 8 ± 2 35 ± 5 The difference is as follows: (e) Width OD refers to the maximum winter opening, that is, maximum extension of the sealant.
(1)In isolation and expansion joints, the joint can close up to significantly less than its original
4.6 < L ≤ 6.5 2.9 9 (+3, -0) 8 (+3, -0) 5 ± 3 8 ± 2 35 ± 5 (f) See Table 8.3 for calculation of effective slab length L
e
and width W .
e
width. If the recess is inadequate, this will squeeze the sealant above the surface, where it
6.5 < L ≤ 8.0 3.5 10 (+3, -0) 8 (+3, -0) 6 ± 3 8 ± 2 40 ± 5 will be damaged by traffic. The values listed in Column 6 are intended as guidelines only. (g) The backer rod diameter should typically be about 25% larger than the joint width WS .
There are many factors which will influence the magnitude of joint closure and so it may
8.0 < L ≤ 9.5 4.0 11 (+3, -0) 9 (+3, -0) 6 ± 3 8 ± 2 45 ± 5 (h) The width of longitudinal silicone joints is limited to 18 mm maximum. See Table 8.2 Note (f)
vary substantially between different sites. for interpretation of "longitudinal".
9.5 < L ≤ 11.5 4.4 12 (+4, -0) 10 (+4, -0) 7 ± 3 10 ± 4 45 ± 5
(2)In contraction and butt joints, the joint cannot close beyond the point at which the faces
(j) Refer to Figure 8.2 for key to dimensions WS , D
S , R
S , and D
J .
11.5 < L ≤ 13.0 4.8 14 (+4, -0) 11 (+4, -0) 8 ± 4 10 ± 4 45 ± 5 regain contact. Hence, the risk of sealant ejection is low, being related to the width of the
induced crack at the time of sealant installation.

13.0 < L ≤ 15.0 6.0 17 (+5, -0) 14 (+4, -0) 10 ± 4 12 ± 4 50 ± 5
(c) Closure of bridge approach joints will normally be minimised by adjacent pavement terminal
> 18
See Note (h) anchors. If experience at a particular location indicates a high degree of movement, the
longitudinal
recess may need to be increased.
Bridge approach (c)
25 ± 4 14 (+4, -0) 10 ± 4 12 ± 4 50 ± 5
slabs
TABLE 8.2: TIED JOINTS - SILICONE SEALANT DIMENSIONS

1 2 3 4
Width
(b)
Depth
(c)
Recess
(d) (e)
Joint depth
Table 8.2 Notes:
(a) For untied joints, refer to Table 8.1. (e) However, tooling is still necessary to enhance the bond. Values given for the depth of joint DS are indicative only.
WS (mm) DS (mm) R S (mm) DJ (mm)
Allowance must be made for factors such as the depth of the backer rod after lateral compression into the joint.
3 < WS ≤ 6 7 (+3, -0) 5 ± 3 30 ± 5 (b) In tied joints, hingeing is the only cause of sealant extension and hence its magnitude will typically be small.
Width WS is therefore not affected by slab dimensions but is dictated by other issues such as ease of sealant (f) The terms "transverse" and "longitudinal" relate to the direction of trafficking. Hence, an isolation joint which runs
6 < WS ≤ 10 7 (+3, -0) 5 ± 3 35 ± 5
installation. In the case of resawing (for sealing), the width is dominated by the need to provide clean faces parallel with the through-carriageway within a median crossing is still "transverse" relative to traffic movements.
10 < WS ≤ 15 8 (+3, -0) 6 ± 3 40 ± 5 which are largely free of spalling; see MJ19-MJ21 for further details. A similar joint separating a ramp from the through-carriageway would be deemed to be "longitudinal".
15 < WS ≤ 18 10 (+4, -0) 7 ± 3 50 ± 5 (c) Following from (b), sealant shape factor is less important than in untied joints. Hence, design of depth (g) The backer rod diameter should typically be about 25% larger than the joint width WS .
(f) DS is dominated by issues such as durability and penetration resistance (against stones etc).
transverse 12 (+4, -0) 7 ± 3 60 ± 5 (h) Refer to Figure 8.2 for key to dimensions WS , D
S , R
S , and D
J .
18 < WS ≤ 22
(f) (d) The recess R S can be reduced (relative to untied joints) because there is little chance of the joint closing,
longitudinal Use a polyurethane sealant
hence expulsion of the sealant is unlikely.
(f)
transverse 14 (+4, -0) 7 ± 3 65 ± 5
> 22
(f)
TABLE 8.3: SEALANT WIDTH CALCULATIONS
Calculation of effective slab

Sealant under
length L or width W for Comments
e e
design
input to Table 8.1 Column 1
L1+ L2 Note that the length L1 is measured between contraction

W S1 L =
e joints and is independent of the J7 tied joint. J2
2
The magnitude of joint opening is proportional to the mean

L3+ L4 length of adjacent slabs. Hence, joints between:
W S2 L = KERB W S
e (TI
ED)
2 two slabs 3.8 m and 4.6 m, and
J9
W 4
two slabs each 4.2 m
W2
OR
W S5
will open by the same amount.
RS
J10
W1+ W 2 W1 , W2 , W
W S3
(a)
W = 3 and W4 are measured to the nearest relief
e SILICONE SEALANT
2 edge, independent of tied joints. J2 J2
DS
DJ
W3+ W 4 Tied kerbs must be included.
(a) J4 J14 OR J15
dgn
W S4 W =
e Untied joints and outer edges constitute "relief edges".
2
M J_08.
J7 CLOSED-CELL
W S5 For tied joints, refer to Table 8.2. POLYETHYLENE
J9 OR J10 J9
M 10.
W S4 W S3 BACKER ROD (TYP)

M D.
Table 8.3 Notes:

ngs -JRCP\
J2 J2 J1
(a) The width of silicone sealants is restricted as follows:
L3 L4 L1 L2
N
in longitudinal joints: 18 mm
AND M I
10 NOM
W S5
W1
in transverse joints: 24 mm (guide only)
W 3
awi
For larger widths, treat in accordance with MJ24 and MJ25.

d Dr
W S2 W S1
andar
(b) Refer to Figure 8.1 for key to dimensions L, W and WS .

J2 J2
enance St
FIGURE 8.2: SEALANT DIMENSIONS

48 PM
nt
SEE TABLE 8.1 FOR UNTIED JOINTS

d Pavem entM ai
KERB (TIED)
21:
SEE TABLE 8.2 FOR TIED JOINTS

at 12:
FIGURE 8.1: TYPICAL JOINT TYPES

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TABLE 9.1: PROVISION OF TIEBARS
(a)
Average tiebar spacing (mm) and number of tiebars per 8.0 m slab Example tiebar layout for 8.0 m slab
Relief-edge
Distance Bar size (b) Actual Cover to

BASE THICKNESS 'D' (mm) Number of
RED (m) Tiebar Spacing Transverse Joint
Tiebars
180 200 210 220 230 240 250 260 270 280 (mm) (mm)
EXAMPLES OF SUGGESTED LAYOUTS
< 3.1 1300 6 1300 6 1300 6 1300 6 1300 6 1140 7 1140 7 1140 7 1140 7 1000 8
3.1 - 3.5 1300 6 1140 7 1140 7 1140 7 1140 7 1000 8 1000 8 1000 8 890 9 890 9 S/2 S/2 S S S S/2 S/2
3.6 - 4.0 1140 7 1140 7 1000 8 1000 8 1000 8 890 9 890 9 890 9 800 10 800 10
S ≥ 700 300 ≤ S/2 < 1 000
4.1 - 4.5 1140 7 1000 8 1000 8 890 9 890 9 800 10 800 10 730 11 730 11 730 11
4.6 - 5.0 1000 8 890 9 800 10 800 10 800 10 730 11 730 11 665 12 665 12 615 13
5.1 - 5.5 890 9 800 10 800 10 730 11 730 11 665 12 665 12 615 13 615 13 570 14
5.6 - 6.0 800 10 730 11 730 11 665 12 665 12 615 13 615 13 570 14 570 14 530 15 425 425 14 TIEBARS 425 425
6.1 - 6.5 730 11 665 12 665 12 615 13 615 13 570 14 570 14 530 15 530 15 500 16 13 SPACES AT 550 C/C
6.6 - 7.0 N12 730 11 615 13 615 13 570 14 570 14 530 15 530 15 500 16 470 17 470 17 14 550 425
7.1 - 7.5 665 12 615 13 570 14 530 15 530 15 500 16 470 17 470 17 445 18 420 19
7.6 - 8.0 615 13 570 14 530 15 500 16 500 16 470 17 445 18 445 18 420 19 400 20
8.1 - 8.5 615 13 570 14 530 15 500 16 500 16 470 17 445 18 445 18 420 19 400 20
625 625 16 TIEBARS 625 625

8.6 - 9.0 570 14 500 16 470 17 470 17 445 18 420 19 400 20 400 20
15 SPACES AT 450 C/C
9.1 - 9.5 530 15 470 17 445 18 445 18 420 19 400 20
16 450 625
9.6 - 10.0 500 16 445 18 445 18 420 19 400 20
10.1 - 10.5 470 17 445 18 420 19 400 20 Use N16 tiebars
10.6 - 11.0 470 17 420 19 400 20
≥ 11.1 Specialist advice is required

600 600 18 TIEBARS 600 600
17 SPACES AT 400 C/C
6.1 - 6.5 1000 8 890 9 890 9 18 400 600
6.6 - 7.0 Use N12 tiebars 1000 8 890 9 890 9 890 9 800 10
7.1 - 7.5 890 9 890 9 890 9 800 10 800 10 800 10
7.6 - 8.0 1000 8 890 9 890 9 800 10 800 10 800 10 730 11 730 11
8.1 - 8.5 890 9 890 9 890 9 800 10 800 10 730 11 730 11 730 11 665 12 675 675 20 TIEBARS 675 675
N16 19 SPACES AT 350 C/C
8.6 - 9.0 890 9 890 9 800 10 800 10 730 11 730 11 665 12 665 12 665 12
20 350 675
9.1 - 9.5 890 9 890 9 800 10 800 10 730 11 730 11 665 12 665 12 615 13 615 13
9.6 - 10.0 890 9 800 10 800 10 730 11 730 11 665 12 665 12 615 13 615 13 570 14
10.1 - 10.5 890 9 800 10 730 11 730 11 665 12 665 12 615 13 570 14 570 14 570 14
10.6 - 11.0 800 10 730 11 730 11 665 12 665 12 615 13 570 14 570 14 570 14 530 15
≥ 11.1 Specialist advice is required
Table 9.1 Notes:

(a) Tiebar spacing based on 12 mm deformed 500N steel and a value of interlayer friction µ = 1.5.
J6
150
N
(b) Base Thickness = Concrete base + asphalt surfacing.
MI
300
dgn
(c) Actual tiebar spacing determined as follows: J7

MIN
150
N
M J_09.
MI
Provide 300 mm to 1000 mm clearance from the end of the tiebar to transverse contraction joints.
Space the remaining tiebars evenly in between.

M 10.
J1
M D.
(d) 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.
TIEBARS
ngs -JRCP\
150
(e) 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
MIN
contributors such as connected kerbs and for future widening.
J9 OR J10
awi
(f) 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.
d Dr
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.
J2
andar
(g) Maximum tiebar spacing is 1400 mm.

enance St
(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.
J6
50 PM
nt
d Pavem entM ai
21:
FIGURE 9.1
at 12:
NTS
2015
MINIMUM TIEBAR OFFSETS FROM JOINTS

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TABLE 10.1: MESH REINFORCEMENT TABLE 10.2: JOINT CORRUGATION DESIGN
(a) BASE MINIMUM MINIMUM
Mesh size (and Limiting RED ) NUMBER OF CORRUGATION MINIMUM
THICKNESS CORRUGATION VERTICAL
Slab length CORRUGATIONS DEPTH 'd' FLAT 'g'
BASE THICKNESS 'D' (mm) 'D' HEIGHT 'h' 'v'
(m)
< 200 3 9 ± 3 20 10 45
≤ 150 155 - 165 170 - 190 195 - 205 210 - 240 245 - 255
(c) (c) (c) (c) (c) (c) 200 - 240 3 or 4 10 ± 3 25 12 50

≤ 7.5 SL82 (7.0) SL82 (6.5) SL82 (6.5) SL82 (6.5) SL82 (5.5) SL82 (5.0)
(c) (c) (c) (c) > 240 3 or 4 12 ± 3 30 15 50

8 SL82 (7.0) SL82 (6.5) SL82 (6.5) SL82 (6.5) SL82 (5.5) SL82 (5.0)
(c) (c) (c)

10 SL82 (7.0) SL82 (6.5) SL82 (6.5) SL82 (6.5) SL82 (5.5) SL92 (6.5)
v d
(c) (c)
12 SL82 (7.0) SL82 (6.5) SL82 (6.5) SL82 (6.5) SL92 (6.5) SL92 (6.5) VERTICAL FACE CORRUGATION DEPTH
(b)
15 SL82 (8.0) SL82 (8.0) SL92 (9.0) SL92 (9.0) SL718 (5.5) SL718 (5.0)
20 SL92 (10.0) SL718 (8.0) SL718 (6.5) SL818 (6.5) SL818 (5.5) SL918 (5.0) h
CORRUGATION
CKNESS
Table 10.1 Notes: HEIGHT
BASE
FLATS MAY BE
FLAT
(a) The values in brackets indicates the upper limit for relief-edge distance (RED) for the indicated mesh size. At larger distances, there is inadequate
D
FLAT
REPLACED BY
g
transverse steel to contain unplanned longitudinal cracking, hence a design check is required. See example in Note (b).
THI
(b) 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 CURVED PROFILE
exceeding 10.0 m, the central lanes require increased transverse steel. (SL718 would be adequate in the outer lanes where the RED is lower.)
Tied kerbs must be included in the calculation of RED.
(c) 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
Roads and Maritime Services projects. v
TYPICAL FORM SECTION
VERTICAL FACE
Table 10.2 Notes:

(a) The top and bottom corrugations must be concave in the first-placed face (ie convex on the form).
(b) Two alternative form profiles are shown, one suited to slipforming and the other suited to fixed-form work.
(c) It is not necessary to match the corrugation type of existing slabs during full or part slab replacement.
d Dr
andar
awi M 10.
M D. dgn
M J_10.
51 PM
nt
d Pavem entM ai
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500 ± 50 SL SE
J1-N12-1000-1000 J2-N12-1000-1000
D/3 MIN D/3 MIN
80 ± 20 MESH (SEE TABLE 10.1)
MESH (SEE TABLE 10.1)
SE & SL
50 50
MIN MIN
D
J2
BASE BASE
SUBBASE D/3 MIN SUBBASE D/3 MIN 1.

0
m
M
IN
DETAIL K1 DETAIL K2
SCALE 1:20 - SCALE 1:20 -
J7
TYPE SA TYPE SE AND SL J2
J2
REINFORCEMENT NOT SHOWN FOR CLARITY
500 MIN JOINT OMITTED IN THIS SLAB

SEE NOTE (b)
0.
80 ± 20 6
m
M
I
DETAIL K5
SF & SM N
SCALE 1:20 -
35 ± 10
J1-N12-1000-1000
500 ± 50 SM
MESH (SEE TABLE 10.1) D/3 MIN INTEGRAL KERB/BASE
SF
(WHERE SLAB WIDTH < 1.0m)
50 50
D
MIN MIN
D
BASE
D/3 MIN SUBBASE
J3-N12 @ 500 C/C IN ACCORDANCE WITH TABLE 7.1 WHEN INSTALLED INTEGRALLY WITH BASE SLAB. ALSO SEE NOTE (d).
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).
DETAIL K3
DETAIL K4
SCALE 1:20 -
SCALE 1:20 -
TYPE SB, SO AND SK
MODIFIED TYPE SF AND SM
MAXIMUM 3 300
REFER TO TABLE 3.5 GENERAL SLAB DIMENSIONAL LIMITS.
ALLOWANCE MUST BE MADE FOR THE KERB WEIGHT
IN DETERMINING SLAB DIMENSIONS AND TIEBAR SPACINGS.

Notes:
(a) Unless otherwise allowed in the Specification, kerb types SA, SB, SC, SE, SK and SL must be strength grade N32
TYPE 'F' BARRIER (NOM 500 mm WIDE) in accordance with AS 1379 and must be either slipformed or fixed-formed (that is, they must not be extruded).
dgn
REFER TO ROADS AND MARITIME SERVICES STANDARD DRAWING MD.R132.D08.A.1 Such kerbs are deemed to satisfy the "with shoulder" criteria for pavement thickness design purposes (as long as
M J_11.
they are also tied). Other kerb types (for example, SF) may be extruded.
PROVIDE DOWEL
M 10.
REFER TO ROADS AND MARITIME SERVICES STANDARD DRAWING MD.R132.D08.A.1 (b) An integral slab widening may be required in order to comply with Austroads Guide to Pavement Technology Part 2
M D.
TIEBARS "with shoulder" criteria.

ngs -JRCP\
(c) Edge drains fulfill an important function in draining the water which commonly runs along the base/subbase interface.
A geotextile fulfills an important function in keeping granular material from entering the base/subbase interface.
See Detail J on MJ06 and Schedule S7.1 for further details.
awi
BASE BASE
d Dr
(d) At least one tie must be placed in any discrete section bounded by joints (for example, at kerb noses).
SUBBASE
andar
(e) Joints in kerbs (etc.) must be located to coincide with joints in the adjoining base, in accordance with R15.
enance St
Where the kerb is placed on top of base pavement, the kerb joint must be aligned with the underlying joint.
Otherwise, kerb joints must be aligned at 90° ± 6° to the kerb line.
52 PM
nt
DETAIL K6
d Pavem entM ai
(f) The location of base joints relative to the extremities of islands and kerbs is critical. The dimensions so specified must be
21:
SCALE 1:20 -
at 12:
used as a control for the location of adjacent joints. Where a base joint intersects the nose of an adjoining kerb (that is,
excluding mounted kerbs such as types SF, SG, SM) the angle of intersection must be 90° ± 6°, and the intersection
TYPE F BARRIER
must be such as to prevent the occurrence of re-entrant angles in the base.
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(g) Base joints must be extended into the adjoining kerb/median in like type.
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G. VOROBIEFF KERBS AND BARRIER

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SCHEDULE 12.1 (S12.1) SCHEDULE 12.2 (S12.2) CASE STUDIES (REFER TO FIG 12.1) SCHEDULE 12.2 (S12.2) CONTINUED
NOTES CASE 1 : Longitudinal central strip repair - Compromise Practice CASE 9 : Transverse joint repair - Best Practice
(a)The repair must extend between existing transverse joints. (a)The repair must extend between existing longitudinal joints.
Typical slab replacements and repairs
(b)The new transverse joints are expansions (Type J16d) to provide an expansion cavity CASE 10 : Full-slab replacement - Best Practice
1. Figure 12.1 shows various allowable JRCP slab repair configurations. S12.2
consistent with the cavity in the adjoining (existing) Type J9. See Note 5 (S12.1) (a)The repair must extend between existing longitudinal joints.
describes each JRCP slab repair case. Repairs must comply with one of these
(c)See Note 10 (S12.3)
J1 TIED AND SAWN
configurations, or a conforming combination.
CASE 2 : Longitudinal edge strip repair - Compromise Practice
JRCP cracking SCHEDULE 12.3 (S12.3) KEY AND NOTES (REFER TO FIG 12.1)
(a)The repair must extend between existing transverse joints.
2. Certain types of transverse cracking in JRCP are to be expected and will usually NOTE DIMENSION
(b)The new transverse joints are expansions (Type J16d) to provide an expansion cavity
SYMBOL DESCRIPTION AND COMMENTS
not be injurious as long as they meet accepted guidelines for location and orientation, No (where applicable)
consistent with the cavity in the adjoining (existing) Type J9. See Note 5 (S12.1)
and as long as the reinforcement is adequate. These cases have been labelled
(c)See Note 10 (S12.3) 1 A 1.5 m MIN A: Length of slab R & R
as "design cracking".
CASE 3 : Transverse strip repair - Best Practice 2 B 1.5 m MIN B: Length of residual slab. A minimum value of 1.5 m
3. Longitudinal cracking in JRCP is undesirable because the resulting elongated slabs
J2 TIED AND FORMED (a)The repair must extend between existing longitudinal joints. 0.8W preferred MIN is acceptable but 0.8W is preferred, where W is
are susceptible to transverse cracking which will be more closely spaced than
The new sections of longitudinal joint must be consistent with the existing. the width of that particular slab. A ratio of 0.8
the desirable "design cracking".
Hence, if the existing longitudinal joint is untied, the joint in the strip repair must provide yields an elongation ratio of 1.25 (maximum).
Existing transverse joints
an expansion cavity of similar width. A shorter residual length increases the risk of
4. The drawings in this Set typically show existing transverse joints as Type J9 (sawn premature longitudinal cracking.
(b)The transverse joints need not be parallel but all corner angles must comply with
contraction) whereas they may actually be Type J10 (formed contraction) or Type J16
Schedule 12.3 limits. 3 C Trafficked: 1.0 m MIN C:Width of a longitudinal strip repair.
(expansion), depending on the original construction method.
CASE 4 : Full-slab replacement - Compromise Practice Untrafficked: 0.6 m MIN See notes to Case Study.
(Before the adoption of sawcutting, JRC pavements were typically constructed using
J2d DRILL-TIED (a)See Note 10 (S12.3) 4 D Trafficked: 1.0 m MIN D:Width of residual slab.
the "chequerboard" method whereby alternate slabs were fully formed and paved, and
Untrafficked: 0.6 m MIN
CASE 5 : Part-length repair; mid-slab - Best Practice
the missing slabs were infilled at a later date.)
5 J J = 0, or J: Offset between adjacent transverse tied joint;
(a)The repair must extend between existing longitudinal joints.
5. In longitudinal strip repairs, a full-depth expansion cavity must be provided otherwise
J > 1.5 m refer to Figure 13.2 for details.
The new sections of longitudinal joint must be consistent with the existing.
the repaired strip will bear the compressive forces of the full slab width when expansion
Hence, if the existing longitudinal joint is untied, the joint in the strip repair must 6 L L: Length of slab
acts later to close all transverse joints. In these cases (for example, Cases 1, 2, and 6),
provide an expansion cavity of similar width. 7 W W:Width of slab
the width of the new expansion cavity should be not less than the width of existing joint
(b)If the joint layout cannot be arranged such that J=0 then J should preferably exceed 8 84° MIN Slab corner angle
(below any sawcut and/or sealant).
J3 TIED AND RIBBONED 1.5 m so that cracking will be transverse (which resembles 'design cracking') rather 9 JRCP slab (or part-slab) replacement
In full-width slab repairs, it is assumed that the full section will have the capacity to
than the corner cracking shown in Figure 13.2 (which leads to secondary distress). 10 # There is a risk that in the process of constructing a
withstand these compressive forces. However, where doubt exists, it is recommended
(c)Where 0 < J < 1.5 m is unavoidable, the initial pour must overlap the second pour. J10d or J16d joint, the existing slab will be damaged
that a filler be provided of nominal thickness 7 ± 3 mm.
(Refer to Figure 13.2 and Figure 13.2 Notes) by the action of drilling large holes to install the
J6b J6c CASE 6 : Multiple repair - Compromise Practice dowels and that the dowels will not be installed within
(a)The transverse repair should precede the longitudinal repair. If the reverse applies, the tolerance for alignment.
there is a risk that the Type J2d joint will reflect into the transverse repair. 11 Imprint the date of casting of the replacement slab in
J6 LONGITUDINAL EDGE (b)See Note 10 (S12.3) a corner of the concrete in the format dd-mm-yyyy.
CASE 7 : Termination of a longitudinal joint

Two options are allowed:
(a)Terminate at a Type J7 as shown (that is, mid-slab).
(b)Terminate at a Type J10 at the plan location of an existing Type J9 or Type J10.
CASE 8 : Part-length repair; slab end - Compromise Practice

(a)The repair must extend between existing longitudinal joints.
J7d DRILL-TIED
(b)See Note 10 (S12.3)
L
J2
FIGURE 12.1: TYPICAL SLAB REPLACEMENTS
B A A B A A
J9 SAWN AND DOWELLED W
J9 OR J10
J2d J2d J2d J2d J2

B B CASE 7
CASE 5 J7 J2 B
CASE 8 CASE 9
J7d J7d 4 300
dgn
# # #
J10d CASE 4 J10d MAX 1 000 J10d
J7d J7d J9 J7d
M J_12.
J10 FORMED AND DOWELLED J2 OR J2d MIN

J7 A
M 10.
OR
M D.
J2d J1 J2d J2d J2d J2d J1 OR J2 OR J3 J2

J
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SEE FIGURE 13.2 #
C J16d J7
J2d
J16d
#
C CASE 1 J16d
# J7d J7d J9 OR J10 J2d # J9 OR J10 J9 OR J10
J10d
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J10d # DRILL-DOWELLED
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J2d J1 J2d J2d J1 OR J2 OR J3 J2
enance St
# # OR CASE 3 B
J16d C CASE 2 J16d J1 OR J2 OR J2d
53 PM
J2 OR J2d
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J2d J7d J7d

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J9 OR J10 J7d J9 CASE 10 J9 J7d

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EXPANSION: J9 OR J10 D J9 OR J10

J16d # CASE 5
DRILL-DOWELLED
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G. VOROBIEFF SLAB REPLACEMENT

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SCHEDULE 13.1 (S13.1) CASE STUDIES (REFER TO FIGURE 13.1) SCHEDULE 13.2 (S13.2) KEY AND NOTES
CASE 1 : Kerb replacement (REFER TO FIGURES 13.1 AND 13.2)
(a)Where trapezoidal shaped JRCP slabs develop corner cracks near intersecting J7
NOTE DIMENSION
joints as shown, the side of the JRCP slab and abutting kerb should desirably be SYMBOL DESCRIPTION AND COMMENTS
No (where applicable)
J1 TIED AND SAWN J17F HINGE: TIED AND SAWN reconstructed as shown in details K5 to provide adequate shoulder support.
1 A 1.5 m MIN A: Length of slab R & R
CASE 2: Single detector loop; slab-end
2 B 1.5 m MIN B: Length of residual slab. A minimum value of 1.5 m
(a)Replace existing part-slab with SFCP. Seek specialist advice regarding the use of
0.8W preferred MIN is acceptable but 0.8W is preferred, where W is
mesh or bar reinforcement in detector slabs.
the width of that particular slab. A ratio of 0.8
CASE 3: Single detector loop; mid-slab
yields an elongation ratio of 1.25 (maximum).
(a)Replace existing part-slab with SFCP. Seek specialist advice regarding the use of
A shorter residual length increases the risk of
premature longitudinal cracking.
J2 TIED AND FORMED CASE 4: Double detector loop
3 E 4.8 m MIN E: length of SFCP patch for a single detector loop.
(a)Replace existing part-slab with SFCP. Seek specialist advice regarding the use of 6.0 m MAX
4 F 0.15 m MIN F: edge distance to detector sawcuts in SFCP.
1.0 m MAX
5 J J = 0, or J: Offset between adjacent transverse tied joint;

FIGURE 13.2: MISMATCH OF TRANSVERSE JOINTS
J > 1.5 m refer to Figure 13.2 for details.
6 L L: Length of slab
J2d DRILL-TIED
POUR B 7 W W:Width of slab
J9 J7d J7d J9 8 JRCP slab (or part-slab) replacement
9 # There is a risk that in the process of constructing a
J J J10d joint, the existing slab will be damaged by the
action of drilling large holes to install the dowels and

REFLECTION
POUR A that the dowels will not be installed within the
CRACKING
tolerance for alignment.
J3 TIED AND RIBBONED B A B
10 Imprint the date of casting of the replacement slab in
a corner of the concrete in the format dd-mm-yyyy.
Figure 13.2 Notes:
Scenario 1: Pour B follows Pour A.
J6b J6c There is a risk of reflection cracking in Pour B (as shown) within days of casting.
The risks are magnified by early trafficking because heavy vehicles will induce
hinge deflections at the transverse joints of Pour A.

J6 LONGITUDINAL EDGE
If the joint layout cannot be arranged such that J=0 then J should preferably exceed
1.5m so that cracking will be transverse (which resembles "design cracking") rather
than corner cracking (which leads to secondary distress).
Where 0 < J < 1.5 m is unavoidable, provide ancilliary reinforcement in the form of
4-N12 1200 long 200 spacing trimmer bars across the potential crack path, and
omit tiebars from the longitudinal joint within the overlap length "J". B E
J7d DRILL-TIED
Scenario 2: Pour A follows Pour B.
Reflection cracking will not occur if the initial pour overlaps the second pour.
1 000 MIN TRAFFIC #

J7d J10d
CASE 1 J7d
KERB LIP LINE SIGNAL
J9 SAWN AND DOWELLED DETECTORS
J2 J2 J2
J2d
CORNER CRACK CASE 2

#
J9 J10d
J7 F
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J10 FORMED AND DOWELLED SEE FIG 13.2

F
J1 OR J2 OR J3 J2
M 10.
M D.
B E B
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CASE 3
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J10d # DRILL-DOWELLED
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J9 OR J10 J10d J17F J7d J10
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EXPANSION:
J16d J6
DRILL-DOWELLED F 4.5 ± 0.1 m F B RELIEF EDGE
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FIGURE 13.1: MISCELLANEOUS WORK

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G. VOROBIEFF SLAB REPLACEMENT - MISCELLANEOUS WORK

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SCHEDULE 14.1 (S14.1) CASE STUDIES UNACCEPTABLE PRACTICES SCHEDULE 14.1 (S14.1) CONTINUED
CASE 1: Skewed trench - crossing a transverse contraction joint CASE 8: Patch repair - corner or part-width or part-length
(a)Corner angles more acute than 80°-85° are at risk of corner cracking and/or spalling. (a)A Type J17 joint would increase the risk of block cracking because it would reduce the size of
This applies both to the residual (original) slabs and to the new trench slab. the residual slab.
(b)All contraction joints must be continuous between free edges. If the contraction joint is not (b)Comments under Case 7 also apply.
reinstated across the new trench slab, unplanned cracking will result (regardless of reinforcement). CASE 9: Service pit - mid slab, circular
CASE 2: Skewed trench - mid-slab (a)A circular pit located within the central third (length-wise) of the slab is likely to generate a single
(a)Consistent with Case 1, corner angles more acute than 80°-85° are at risk of corner cracking. transverse crack which is unlikely to cause distress because it effectively constitutes
This applies to both the original slab and to the replacement slab. "design cracking".
CASE 3: Drainage pit - slab corner (b)A Type J17 joint is desirable to produce a controlled crack which would reduce the risk of acute
(a)The slab cut-out is located in an area of high stress and so creates a risk of corner cracking. intersections at the pit.
Skewed cracking produces acute corners which are then prone to secondary cracking. (c)The relative contraction movements between the pit and the slab will increase with increasing
(b)Because of the high deflections within corner cracks, mesh and/or bar reinforcement provides distance of the pit from the slab centroid. The design of the isolation joint must cater for the worst
limited benefit. Large crack deflections (and openings) expose the reinforcement to rapid case.
corrosion and possibly also to yield failure. CASE 10: Patch repair or utility- mid slab, rectangular
CASE 4: Drainage pit - mid-slab (a)The cut-out is certain to generate cracking. If the crack runs square to the adjacent longitudinal
(a)The transverse cracks induced by the pit resemble "design cracking" and so are unlikely to cause joint there is an increased risk of longitudinal cracking (resulting in block cracking). There is a high
distress unless they intersect joints (or cracks) at skew angles less than 80°-85°. risk that the cracking will be skewed.
(b)However, the existence of two close-spaced parallel cracks increases the risk of longitudinal (b)The relative contraction movements between the pit and the slab will increase with increasing
cracking (resulting in block cracking). distance of the pit from the slab centroid. The design of the isolation joint must cater for the worst
case.
CASE 5: Service pit - slab corner
CASE 11: Patch repair or utility - edge
(a)Consistent with Case 3, mesh and/or bar reinforcement provides limited benefit. Large crack
deflections (and openings) expose the reinforcement to rapid corrosion and possibly also to yield (a)The comments for Case 10 apply.
failure. CASE 12: Longitudinal trench

(b)There will be large contraction movements of the slab relative to the pit because of the distance (a)Trenching will produce elongated slabs which will lead to reduced life unless dimensional limits
to the slab centroid. The design of the isolation joint must cater for the worst case. are observed.
CASE 6: Service pit - slab end (b)Comments under Case 7 also apply.
(a)Consistent with Cases 3 and 5, mesh and/or bar reinforcement provides limited benefit. CASE 13: Mismatched transverse construction joint
Large crack deflections (and openings) expose the reinforcement to rapid corrosion and possibly (a)This is similar to Cases 7 and 8.
also to yield failure. The relative contraction movements between the pit and the slab will increase CASE 14: Detector loop sawcutting
with increasing distance of the pit from the slab centroid. (a)Sawcuts act as crack initiators, particularly under flexural fatigue loading.
CASE 7: Patch repair - corner (b)It is difficult to establish safe limits for sawcut depth because fatigue is a highly variable distress
(a)The cut-out is certain to generate cracking. If the crack runs square to the adjacent longitudinal mechanism, and stress levels vary widely in different zones of the slab.
joint then further distress may occur because of the increased risk of longitudinal cracking (c)The presence of reinforcing mesh within the slab can significantly reduce the sensitivity of the loop
(resulting in block cracking). If the crack intersects at a skew then secondary distress is inevitable. to detect the presence of vehicles.
SLAB REPLACEMENT OR UTILITY

R
TTE
GU
ND
RBA
CONSEQUENTIAL UNPLANNED CRACKING KE
TRAFFIC SIGNAL DETECTORS
dgn
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CASE 4 CASE 5
U CASE 13
CASE 3 SCHEMATIC
M 10.
SCHEMATIC DESIGN
DESIGN CRACKING
SCHEMATIC
M D.
CRACKING
DESIGN
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CASE 12
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CASE 1
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CASE 9
CASE 2 SCHEMATIC
57 PM
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CASE 10
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CASE 7 CASE 11
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FIGURE 14.1: UNACCEPTABLE WORK PRACTICES

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SEE SCHEDULE 14.1 FOR EXPLANATORY NOTES

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G. VOROBIEFF SLAB REPLACEMENT (UNACCEPTABLE PRACTICES)

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SCHEDULE 15.1 (S15.1): FULL AND PART-SLAB R & R (S15.1): CONTINUED (S15.1): CONTINUED
ACTIVITY METHOD ACTIVITY METHOD ACTIVITY METHOD
1. Sawcutting 1. Two types of sawcuts are typically required: 3. Preparation 1. General 7. Cleaning out All waste material resulting from the above operations must be removed.
(a) Perimeter cuts along existing joints (or with a minor offset) to: of exposed (a) Exposed faces must be assessed and treated in accordance with Schedule 16.1. the repair
● assist in slab removal. joint faces (b) Where remedial treatment (such as spall repair) is needed, it must be completed
8. Subbase 1. It is important to achieve a suitable level of debonding between the subbase and base
● reduce the risk of edge and arris damage on the slabs which are to remain. independently of the placement of adjoining concrete (that is, the repair material must not
debonding layers, for the following reasons:
● correct defects in the joints or adjacent slabs. be placed integrally with the adjoining concrete).
● strong bonding may initiate unplanned base cracking.
(b) Internal cuts within the slab to break it in to manageable pieces to facilitate Spall repairs must be completed in accordance with MJ24 and MJ25.
● very low friction can result in poor induction of joints.
removal with a minimum of damage to adjacent slabs / joints and to the subbase. (c) Where remedial sawing is required (to correct defects in adjoining joint faces), it may
2. Debonding must conform with M258.
2. Internal cuts are typically just less than full-depth, but should not be deep enough to touch be easier if carried out before removal of the failed slab. However, the defect repair
The typical debonding treatment on LCS is wax emulsion applied at a rate of 0.5 litre/m².
a concrete subbase. Their location will depend on whether existing tiebars are to be saved itself may be best deferred until after the slab R & R (because the R & R may cause
For granular subbases (including rolled concrete), a bitumen emulsion must be used.
or cut. additional spalling).
A cover aggregate may be warranted to facilitate access by workers and construction
(a) To save tiebars, sawcuts must be located to provide lap lengths of 300 mm for N12 bars (d) The exposed face must be dense and fully compacted, and be free of honeycombing
vehicles. An alternative method of debonding the subbase and base is to place polyethylene
and 400 mm for N16 bars. Shorter lengths are allowed (in accordance with AS3600) and re-entrant angles. Minor defects may be corrected by plastering with an appropriate
sheeting on the subbase in accordance with M258.
for welded splices. material.
(b) If existing tiebars are to be replaced by drill-ties, sawcuts would typically be about (e) In addition to those defects listed in Schedule 16.1 (and related Detail drawings) minor 9. Joint 1. Faces
200 mm from joints, but may be varied to suit individual conditions. arris rounding may require treatment in accordance with Figure 25.1. debonding Before the replacement base is placed, the full face of all joints must be thoroughly
3. Perimeter cuts may be either full-depth or part-depth, and their precise location relative to the 2. Longitudinal joints and sealing cleaned and then treated with a debonding agent in accordance with Schedule 7.1.
joint needs consideration. Factors include: (a) The following joints may be butt joints: 2. Joints and cracks
(a) whether tiebars are to be saved or cut. ● any untied joint (a) All corners, joints and any underlying cracks in the exposed slabs must be sealed with
(b) whether defects in the exposed face need to be corrected (for example spalling and/or ● dowelled joints a silicone sealant to prevent ingress of mortar.
rounding). (b) All other longitudinal joints must be corrugated, keyed, or scabbled unless the joint is (b) The exposed horizontal gap between the subbase and the base should also be sealed
(c) whether the existing corrugations or keyways are to be saved; see also Activity 3. located 0.5 m or more outside a trafficked lane (for example ≥ 0.5 m outside an edge with a silicone sealant where it exceeds about 0.5 mm. (Ingress of grout will create
Where existing corrugations are conforming, it is preferable to retain them (perhaps with line), in which case it may be a butt joint. uneven bedding under the adjacent slab when the direction of curling reverses).
minor corrections) rather than replacing them with a scabbled face. 3. Transverse joints
10. 1. Replacement slabs must be reinforced with mesh as shown in Table 10.1.
4. Longitudinal sawcuts which precisely follow an existing longitudinal joint may extend up to (a) The following joints may be butt joints:
Reinforcement 2. Mesh must be placed to provide cover as specified in Note 7 Schedule 7.1.
250 mm beyond the limits of removal. Longitudinal sawcuts which are offset from an existing ● any untied joint
longitudinal joint must not extend beyond the limits of removal. Transverse sawcuts must ● dowelled joints 11. Concrete mix 1. The concrete mix must be designed with consideration of:
not extend beyond the limits of removal. (b) All other transverse joints must be corrugated, keyed, or scabbled. In many cases, design (a) structural and thickness design requirements.
5. Every effort must be made to prevent sawcutting slurry from entering joints or cracks the face will be smooth as a result of sawing and hence must be treated in accordance (b) construction logistics.
in the slabs which are to remain. with Schedule 16.1. (c) strength development needed to suit trafficking requirements.
2. Concrete There are two common methods of slab removal: 4. Reinstatement 1. Drill-ties must be provided to replace or supplement existing tiebars. The final tiebar spacing 12. Placing of 1. Work must be in accordance with M258.
removal 1. Excavator removal of tiebars must be as follows: new concrete 2. Placing of concrete must also accord with the principles detailed in NR82 and NR83, which
(a) Internal sawcuts are used to break the slab into smaller pieces for removal. ● transverse construction joints:at 500 c/c cover issues such as:
(b) The perimeter strip is then removed manually using jack-picks (taking great care not to ● longitudinal joints: design spacings in accordance with Table 9.1. ● paving ● compaction ● texturing ● curing ● protection
spall the edges of the abutting slabs). 2. All other tiebar details must be in accordance with Schedule 7.2.
13. Jointing New joints must be designed and constructed in accordance with MJ05-MJ09.
2. Crane lift 3. Where two adjoining slabs (joined by a common longitudinal joint) are to be replaced by
14. Opening to 1. The pavement should not be opened to traffic until the concrete has attained insitu
(a) The slab (within the full-depth cuts) is lifted in a single piece. single-lane R & R, tiebar drilling can be avoided by placing L-shaped tiebars into the
traffic compressive strength of 20 MPa.
(b) The lifting hooks should be eye bolts which are resin-grouted into the top of the slab first-placed slab for later straightening before the second pour. They need be placed close
2. In order to monitor the rate of strength gain actually achieved on site, additional cylinders
using chemical anchors. They must be designed by a Chartered Professional Engineer. to the form to minimise edge damage during recovery.
should be cast and cured alongside the slab and in a similar manner. Progressive testing
(c) The perimeter strip is then removed manually, in accordance with Note 2.1.
5. Dowels 1. Dowels must be provided in accordance with Schedule 7.2.
of these cylinders will provide the best guidance for timing of access to the repair area.
(d) This method can be difficult because:
2. At formed joints the dowel length within the second-placed slab must be debonded (to
3. In cases where the requirements of Note 14.2 are not practicable, experience with particular
● Subbase bond/suction can exceed 50 t per slab (for an 8 m long x 4 m wide slab);
minimise early stress on the fresh concrete).
materials and work processes may be used for guidance.
● Skewing of the slab often jams it in place and damages adjoining edges and arrisses.
● 8 m long, 4 m wide, 230 mm thick JRCP slabs typically have a mass of 18 t. 6. Subbase 1. Seek specialist advice for assessment and repair of subbase.
Note:
repairs 2. Cracks in the subbase should be examined for spalls, stepping, and for excessive crack
(a) Notes in this Schedule are referred to by both Activity and Method number. For example, Note 14.1 relates
widths. The major risks associated with such defects are:
to trafficking strength.
(a) reflection of subbase cracks into the new base.
(b) high interlayer bonding, which may initiate unplanned base cracking.
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SCHEDULE 16.1 (S16.1): TREATMENT FIGURE 16.1:
OF JOINTS EXPOSED DURING R & R (S16.1): CONTINUED EXISTING JOINT RECESS FIGURE 16.2: CORRUGATED JOINTS
EXPOSED EXPOSED
NEW SLAB Case 1: Exposed concave face Case 2: Exposed convex face
JOINT DESCRIPTION NOTES JOINT DESCRIPTION NOTES
(a) (a)
TYPE TYPE VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN
D/3 TYP
Refer to Figure 16.1. Transverse Treat in accordance with Type J10. NEW SLAB NEW SLAB
Longitudinal: (a)Remove any lip to minimise the risk of crack initiation contraction: REMOVE LIP
J1 J9
tied and sawn in the new slab. sawn and POTENTIAL SPALL
SAWCUT
(b)The joint effectively converts to a Type J2, scabbled. dowelled INDUCED
SAWCUT
(a)Untied joints do not need to be scabbled. CRACK
Refer to Figure 16.2.
J2 Longitudinal: Further remedial treatment may be required on the underlying (b)Carry out spall repairs in accordance with MJ24 and MJ25. SCABBLE
Transverse Scabble to remove any lip which might cause
corrugations if they depart substantially from the advice (c)Design a sealant in accordance with MJ08. 3
corrugated tied and formed
contraction: cracking in the new slab. MIN
provided on MJ05-MJ09. J10 (d)Debond all exposed dowels. (This applies even where
formed and 1
the embedded length is also debonded because any bond
Longitudinal: Refer to Figure 16.3. dowelled
J2, keyed with the new concrete will cause distress before the patch KEY TO FIGURES
tied and formed
Sawcut (if necessary) to provide the specified Option 1:
gains its design strength.) 16.1 AND 16.2
Longitudinal: Refer to Figure 17.1. minimum vertical face dimension. Sawcut and scabble as shown to provide
J2, butt
tied and formed Transverse Not valid. Shading indicates the following: the specified minimum vertical face (to
J11 contraction:
Refer to Figure 17.2. prevent future spalling on the concave side).
knifed material removed from the exposed faces.
(a)Treat in accordance with Cases 2-7. Option 2:
Longitudinal:
(b)Formed tied joints normally do not require sealing, but a (a)Untied joints do not need to be scabbled. Sawcut to the bottom of the top corrugation.
J3 tied and the resulting face after treatment.
(sealed) joint cavity may be desirable in some situations (b)Carry out spall repairs in accordance with MJ24 and MJ25. Scabble the sawn section which is more than
ribboned Transverse
to minimise the stress on the abutting arrises, particularly (c)Design a sealant in accordance with MJ08. D/3+10 from the top (as shown in Figure 17.1).
contraction:
where a spall repair has been carried out. J12 (d)Debond all exposed dowels. (This applies even where the
knifed and
embedded length is also debonded because any bond with
Where an existing J4 face is exposed, the required treatment dowelled
the new concrete will cause distress before the patch
FIGURE 16.3: KEYED JOINTS
will depend on whether the new joint will be tied or untied.
gains its design strength.)
The alternatives are as follows. Case 1: Typical keyed joint Case 2: Exposed convex face Case 3: Exposed concave face
Transverse Not valid.
New tied joints 15 ± 5 15 ± 5
J13 contraction: 25 60 NEW SLAB NEW SLAB
(a)If the exposed face is smooth, assess the warrant for
formed COMMON
scabbling in accordance with Schedule 15.1 Activity 3.
FAILURE MODE SAWCUT SAWCUT
(b)Carry out any spall repairs in accordance with Isolation: (a)Scabbling is not required.
MJ24 and MJ25. J14 with subgrade (b)Carry out spall repairs in accordance with MJ24 and MJ25.
Longitudinal:
(c)Design a sealant in accordance with Table 8.2. beam (c)Design a filler and sealant in accordance with MJ08.
J4 untied and
Formed tied joints normally do not require sealing, but they
formed Isolation: Treat in accordance with Type J14.
should be sealed to maintain consistency with adjacent joint J15
without
lengths. They are also beneficial to minimise stresses on 30
subgrade TIEBAR
spall repairs.
beam
New untied joints (a)This shows typical dimensions for keyed joints, (a)The type of failure described under Case 1 (a)Replacement of the convex slab does not
Expansion: (a)Treat in accordance with Type J10.
(d)Untied joints are not expected to transfer shear loads J16 which were common in NSW until the mid-1980s. could also occur in replacement slabs, carry the same risk as with the concave slab.
dowelled (b)Design a filler and sealant in accordance with MJ08.
and so do not need to be scabbled. (b)They were susceptible to failure of the concave arris hence special care is warranted when However, the top section on the concave
Refer to Figure 16.1.
(e)Carry out spall repairs in accordance with MJ24 and MJ25. (as shown) and were very difficult to slipform replacing or repairing keyed slabs. side remains at risk of future failure
Hinge: (a)Remove any lip (by scabbling) to minimise the risk of crack
(f) Design a sealant in accordance with Table 8.1. successfully. (For these reasons, they were (b)To minimise stresses on the new concave (particularly if the top vertical face is less
J17
tied and sawn initiation in the new slab.
superseded in the mid-1980s by corrugated faces.) arris, the convex key should be reduced than about 45 mm) and so preventive work
Longitudinal: (a)Carry out any spall repairs in accordance with
J5, (b)The joint effectively converts to a Type J2, scabbled.
MJ24 and MJ25.
(c)The concave side is more sensitive than the convex to 15 mm ± 5. is warranted in conjunction with replacement
untied and
sawn side to the high arris stresses which are generated This could be done by: of the convex side.
sawn (b)Design a sealant in accordance with MJ08. Longitudinal: Where widening is required at a Type J18, treat the edge
J18 edge and according to the new joint type. by load deflections and slab curling. Microcracking (i) sawcutting before slab removal (b)The sawcut (as shown) may also be
Longitudinal: Refer to Figure 17.2.
J5 beamed can occur within days of construction while the (as shown above, possibly arranged desirable in order to:
untied and (a)Treat in accordance with Cases 2-7.
ribboned concrete shear strength is low. Hence, specifications to assist with the slab removal), or (i) remove arris spalling (or rounding),
ribboned (b)Design a sealant in accordance with MJ08.
Note: typically require that the concave side be placed first, (ii)scabbling, after removal of the failed slab. and/or
Where widening is required at a Type J6, treat the edge (a) Treatments are based on the joint types encountered in the field, not the intended so that it gains strength before being subjected to (c)If the key is totally removed (by mistake, or (ii)assist in slab removal.
Longitudinal:
J6 according to the new joint type. See MJ24 and MJ25 joint type.
edge stress from the adjoining slab. In fixed-form paving, otherwise), scabble the face in accordance (c)If the key is totally removed (by mistake, or
for remedial treatments on rounded/spalled edges.
it is also easier to construct in this orientation (by with Figure 17.1. otherwise), scabble the face in accordance
dgn
Refer to Figure 16.2. attaching extra moulds to the form). with Figure 17.1.
Transverse
M J_16.
J7 Further remedial treatment may be required on the underlying (d)In trying to identify the orientation of the keyway (and
construction:
corrugated corrugations if they depart substantially from the advice in the absence of clear evidence), it is reasonable to
M 10.
tied
provided in Table 10.2. assume, following from (c), that the concave side will
M D.
be in the first-placed slab, which can be identified by

Transverse Refer to Figure 16.3.
ngs -JRCP\
surface mortar.
J7, keyed construction:
tied
awi
Transverse Refer to Figure 17.1.

d Dr
J7, butt construction:

andar
tied
enance St
Transverse Not valid.

J8 construction:
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FIGURE 17.1: BUTT AND SCABBLED FACES FIGURE 17.2: RIBBONED JOINTS
Case 1: Model ribboned joint Case 2: Curled and vertical Case 3: Curled and inclined Case 4: Curled and inclined
NEW SLAB 45 MIN
D/3+10 MAX
1±1
PERIMETER GROOVE 15
VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN
NEW SLAB
D
SCABBLED FACE
NEW SLAB NEW SLAB NEW SLAB
SAWCUT
SECTION
25 ± 15
+10
POTENTIAL SPALL
0
= 90° ± 5° FOR REMOVAL SAWCUT RIBBON
3–
SAWCUT
D/
RIBBON SAWCUT RIBBON SPALL
(a)The warrant for scabbling is detailed under Activity 3 (S15.1). RIBBON REPAIR
(b)The top and bottom sections must be left smooth to prevent RIBBON SCABBLE
3
damage from scabbling and to minimise arris spalling. SCABBLED
SCABBLE TO NEAR MIN
(c)Scabbling must be thorough enough to expose coarse aggregate SCABBLE 1
VERTICAL FACE 1 FACES
INDUCED CRACK
over a large proportion of the scabbled face and to achieve a rough 3
surface with indentations 4-6 mm deep that will provide a key for MIN
OPTION 1 OPTION 2
the new slab.
(d)The face must be debonded in accordance with Activity 9 (S15.1). (a)Specifications required that ribbons be placed as (a)Remove the ribbon by a combination of (a)The location of the sawcut is dictated by Option 1: Option 2:
shown here. However, their accuracy was highly sawing and scabbling, or by deeper sawing. the vertical face dimension (of 45 mm Sawcut and scabble. Carry out a spall repair as shown on
variable and they will often be found deeper and/or (b)Where deep sawing is used, the face must minimum) and the need to transition the MJ24 and MJ25.
curled and/or inclined. be scabbled below the line D/3+10 mm underlying face at a slope not greater
(b)Where the ribbon was well installed, joint exposure from the top (as shown in Figure 17.1). than 1 in 3.
will leave a face which requires little or no treatment

(apart from debonding) before concrete placement. Case 5: Curled and vertical Case 6: Curled and inclined Case 7: Curled and inclined
(c)Where the ribbon is curled and/or inclined, treat in
accordance with Cases 2-7. VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN VERTICAL FACE 45 MIN PERIMETER GROOVE 15
(d)The selected method of repair is likely to vary NEW SLAB NEW SLAB NEW SLAB NEW SLAB
according to the length of nonconformity.
REMOVE REMOVE
SAWCUT SAWCUT
A technique which is suitable for an isolated short
CONCAVE ARRIS CONCAVE ARRIS
length may be impractical over longer lengths. RIBBON SPALL
RIBBON
(e)Consideration also needs to be given to the resulting REPAIR
SECTION
plan alignment of the joint. Stepped offsets are SAWCUT
FOR REMOVAL RIBBON
SAWCUT
nonconforming because they create joint mismatches
(which are likely to initiate unplanned cracking).

3
RIBBON 3 SCABBLED
Frequent lateral deflections will complicate future MIN
MIN FACES
sawing for joint resealing. 1
1
OPTION 1 OPTION 2
Locate the sawcut to achieve the required Locate the sawcut to achieve the required Option 1: Option 2:
vertical face dimension. vertical face dimension, and the limiting slope Sawcut and scabble. Carry out a spall repair as shown on
on the underlying face. MJ24 and MJ25.
Figure 17.2 Notes:

1. Ribboned joints are no longer used for new construction or maintenance work.
2. 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.
3. Shading indicates the following: material removed from the exposed faces.
the resulting face after treatment.
sawcut
d Dr
andar
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M D. dgn
M J_17.
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SCHEDULE 18.1 (S18.1)
TABLE 18.1: STITCHING NOTES TABLE 18.3:
NOTES
CASE 1 : Longitudinal cracking STITCH-BAR SPACINGS FOR
1. Cross Stitching Compromise Practice is a technique which may extend the
(a) May be suitable for stitching. LONGITUDINAL CRACKS AND JOINTS
(b) Success is improved for d1 greater than 1 m. service life of a slab before more extensive repairs such as slab replacement
CASE 12 Relief- Joint offset are necessary.
(c) Cracking could be due to an inactive shoulder joint which may need sawing and/or deepening. (a,b)
Spacing C (mm)
edge A 2. Cross stitching may only be used with the written approval of the Principal.
CASE 2 : Skewed longitudinal cracking
A ANCHOR A distance (mm) 3. Cross stitching of JRCP cracks or tied joints is only needed where the
(a) May be suitable for stitching if completed before the crack reaches another longitudinal joint or (c) Base thickness D (mm)
RED (m) cracks/tied joints open up beyond 0.5 mm, due to causes such as inadequate or
a slab edge. 180 200 220 240 260 280
corroded mesh reinforcement or tiebars (as applicable). Cracks that are not
RED * (b) Secondary corner cracking is likely if β is less than 70°. < 3.1 1200 1200 1200 900 900 900
opening (that is, are stable) should not be stitched and may also not need to be
CASE 3 : Transverse mid-slab cracking 3.1 - 3.5 1200 900 900 900 900 900
routed. See Note 2 S12.1.
3.6 - 4.0 900 900 900 700 700 700
A
(a) May be suitable for stitching.
4. Stitching is unlikely to be effective where:
β 4.1 - 4.5 900 900 700 700 700 600 ½C (± 200)
(b) Success is improved for d3 greater than 1.5 m.
J1 J1 4.6 - 5.0 900 700 700 600 600 600 but
(a) the slab has two or more cracks, or
C
B
(c) See Note 2 S12.1.
(b) the concrete has low strength (less than 25 MPa), or
OR OR 5.1 - 5.5 700 700 600 600 500 500 300 mm
J6 J6 CASE 4 : Large corner cracks (c) where base thickness is less than 180 mm.
CASE 2 5.6 - 6.0 700 600 600 500 500 450 MIN
J2 J2 (a) May be suitable for stitching where d
4 is greater than 0.6 m and concrete is sound. 6.1 - 6.5 600 600 500 500 450 450 5. Crack stitching will be most successful if it is completed very soon after
OR OR (b) Success is reduced if other distress such as advanced arris spalling is present because this 6.6 - 7.0 600 500 500 450 450 450 formation of the crack, before it widens. Poorly tied joints should also be stitched
could indicate low strength concrete. 7.1 - 7.5 600 500 450 450 400 400 before they widen. Early stitching will:
J3 J3
CASE 1 (c) For d4 less than 0.6 m (approximately), refer to Case 5. 7.6 - 8.0 500 500 450 400 400 400 (a) maximise load transfer between slabs, hence:
CASE 5 : Small corner cracks > 8 (i) Check the total tied width. (b) significantly reduce the chances of secondary slab cracking;
RED *
C
d1 (c) keep out incompressibles and water, hence:

(a) Not suitable for stitching where d5 is less than 0.6 m (approximately). Treat according to Case Table 18.3 Notes:
d4 9 shown on MJ12 (or Case 8 if approved). (a) This table is based on a coefficient of friction of 1.5 at (d) avoid the need for routing and sealing.
A
the underside of base and on the use of N12 stitch-bars. For the same reason, stitch-bars are best fixed (that is, epoxied) during warmer
CASE 6 : Multiple cracking
weather (or during the middle of the day) when the crack is most tightly closed.
d4
(b) Spacings may be varied by ±10% to suit site conditions.

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

(c) Relief-edge distance (RED) is measured from the joint 6. The decision to stitch (in preference to alternatives such as slab replacement)
CASE 7 : End-slab transverse cracking
should take into consideration factors such as:
C
B or crack being stitched to the nearest relief edge.

(a) Not suitable for stitching where d7 is less than 1.0 m (approximately) because of the risk of
It must include tied kerbs. (a) the quality of the concrete (as indicated by distress additional to cracking,
A CASE 4
secondary cracking. Treat according to Case 9 shown on MJ12 (or Case 8 if approved).
such as arris spalling, surface abrasion, condition of adjacent slabs).
CASE 8 : Late sawcut cracking (b) intensity of heavy vehicle traffic.
TABLE 18.4:
(a) Not suitable for stitching. (c) previous success under similar conditions.
RED * (b) This crack is effectively operating as the contraction joint and so stitching would lock up the joint.
STITCH-BAR SPACINGS FOR
7. Protection must be provided in accordance with Figure 18.2 if the crack is wider
(c) Treat According to Case 9 shown on MJ12 (or Case 8 if approved). TRANSVERSE AND CORNER CRACKS than 0.5 mm. Suitable protection is provided by bituminous paint with a
CASE 9 : Late sawcut cracking Spacing B (mm) Joint offset A (mm) thickness of 0.2 to 0.5 mm.
CASE 5
MAX (TYP AND MIN) 8. Use compressible self expanding polyurethane resin (foam) to seal wider cracks
(a) Not suitable for stitching. Similar to Case 8.
d5
Transverse cracks 500 300 and joints only.

CASE 10 : Longitudinal tied joint
J9 OR J10 Corner cracks 300 250
d5 (a) May be suitable for stitching (to supplement tiebars).
(b) Do not stitch joints which are intended to be untied. Table 18.4 Note:
1. These dimensions apply for all slab sizes.
CASE 11 : Kerbs
d3
(a) May be suitable for stitching.
(b) For convenience, insert all stitch-bars from the pavement side.
CASE 3
CASE 12 : Anchor Slabs
J2 CASE 6
(a) Stitching is not required or warranted in reinforced anchor slabs.
(b) In unreinforced anchor slabs (that is, superseded design) stitching has had only moderate
A B B A success because secondary cracking is likely.
d3
Lb/2
= =
d7
A
C
Lp
CASE 7
ED)

FIGURE 18.2: STITCH-BAR PROTECTION
TI
METHOD
dgn
KERB (
SEE NOTE 7 (S18.1)

M J_18.
1. Investigate base thickness, determine the required length of stitch-bar, and offset of drill holes.
CASE 10
2. Mark hole locations.
M 10.
TABLE 18.2: STITCHING LENGTHS 3. Drill holes (drill hole vertically for the first 10 mm to start). If crack sealing is required, the initial hole
M D.
Base thickness Offset: drill Length of drill Length of Length of diameter must be less than the final hole diameter of 16 mm.
ngs -JRCP\
CASE 11 D hole to crack hole stitch-bar protection 4. Where the crack width exceeds 1 to 2 mm, seal it (at the level of the stitch-bar) with self expanding resin
Lc
Lh
CASE 8 (mm) Lc (mm) Lh (mm) Lb (mm) Lp (mm) CAPPING (foam) to prevent escape of the epoxy.
A
Lb
awi
190 165 330 280 5. Where sealing has been undertaken, ream the hole after the self expanding resin (foam) has set using a
J9
d Dr
200 175 350 300 16 mm diameter drill bit and ensure that a clean concrete face results.
andar
210 180 370 320 6. Thoroughly clean holes using a vacuum cleaner.
CASE 9
t
enance St
* 220 190 390 340 7. Inject the resin/epoxy to the manufacturer's instructions to fill approximately 1/3 depth of the hole.
D
RED
230 200 410 360 BASE 8. Insert the stitch-bar while gently oscillating the bar. Push the bar to the required depth.
03 PM
240 210 430 380 9. Inject further resin if required:

nt
SUBBASE
t
d Pavem entM ai
250 215 450 400 a) to the surface if the resin is the capping material, or
22:
at 12:
FIGURE 18.1: TYPICAL CROSS-STITCHING APPLICATIONS Table 18.2 Notes: FIXING COMPOUND b) to approximately 25 mm below the surface.
NOT TO SCALE (a) To suit drill angle = 30° and cover t = 25 mm STITCH-BAR 10. If the capping material is different from the resin, top off with the capping material after the resin has set.
2015
DENOTES RELIEF-EDGE DISTANCE (b) See Fig 18.2 for protection details N12 DEFORMED BAR 11. After the capping material has set, open to traffic.
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G. VOROBIEFF CROSS STITCHING OF CRACKS AND JOINTS - COMPROMISE PRACTICE

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SCHEDULE 19.1 (S19.1) SCHEDULE 19.2 (S19.2)
NOTES DESIGN
SEE FIG 21.3
1. This procedure is suitable for the resealing of transverse and longitudinal joints in JRCP. (It is not suitable 1. Measure typical existing joint widths. The selected (re)sawing width should just exceed the
J16 for cracks; see MJ22 and MJ23 for routing and sealing of cracks.) It is also suitable for sawing and existing width to ensure the complete removal of sealant and to produce fresh concrete faces.
sealing of joints which were previously unsawn and/or unsealed. Examples are: transverse construction (It is also possible that the existing joint width was incorrectly designed and/or sawed, which
J6
joints; longitudinal formed tied joints; kerb joints. (Some of the reasons for sawing these joints are to might be one of the reasons for the sealant's failure.)
minimise arris spalling, to minimise water ingress and to protect tiebars against corrosion.) 2. For untied joints:
2. Sealant performance is critically affected by the adhesion with the concrete, hence: (a) Determine the effective slab length (or width) using the method shown on Figure 8.1.
(a) the old sealant must be fully removed because it may be incompatible with the new one. (b) From Table 19.1, read the design joint width W'S which corresponds to the calculated
SEE FIG 21.2 (b) compressed air must be oil-free and should be at a pressure of about 610 kPa. W or L .
e e
J9 (c) cleaning (preferably by washing) should be undertaken immediately after sawing (before the slurry (c) If W'S exceeds the existing joint width, adopt the values in that row for the (re)sawing.
J12 dries) to minimise adherence of fines to the joint faces. (d) If the existing joint width exceeds W'S , move down Column 3 to the smallest value which
J6 (d) at the time of sealing, the reservoir must be thoroughly clean and dry, and must be free from all exceeds the current width. Adopt the values in that row for the (re)sawing.
SEE FIG 21.1
loose debris (such as dust from sawn concrete) and any other material which may reduce the bond. 3. For tied joints:
(e) The cleanliness of the joint faces must be tested in accordance with T379. An acceptable result (a) Select a (re)sawing width W'S which only just exceeds (by 1 or 2 mm) the existing width,
J7
J6 is when Grade 1 (None) visual rating category is achieved. The adhesion of the sealant must be or the width required to remove the desired amount of spalling.
J2
tested in accordance with T380. (b) In Table 19.2, select the row corresponding to the nominated W'
S .
3. Grit blasting should not be required if wet cleaning has been satisfactory. Grit blasting may create further
dust, in which case the joint must be thoroughly recleaned before sealing. SCHEDULE 19.3 (S19.3)
SEE FIG 21.2
4. Ingress of solids into existing joints (and underlying cracks) should be minimised. If there is a spline in the METHOD
old sawcut below the reservoir, it should not be disturbed. Where no spline is found, the sawcut below
J9 J10 J6 1. Establish traffic control and job safety in accordance with Safe Work Method Statements (SWMS),
J10 the reservoir should be thoroughly flushed out with high pressure air or water during the cleaning process.
including "Wet Road" signs where water will flow across traffic lanes.
In order to maximise the progressive flushing of sawcutting debris, cutting should proceed from the high
2. Refer to Figure 19.1 for typical joint resealing applications.
J1 SEE FIG 20.1 side of the pavement towards the low side.
3. Install sedimentation controls around drainage pits for saw slurry and debris.
OR 5. Sealants and their backer rods should be continuous between longitudinal joints. At joint junctions,
4. Immediately after sawing, clean joints and pavement surfaces with high pressure air or water
J4 priority must be given to the joint which will undergo the greatest movement. For example:
J2 SEE FIG 20.2 J2 J2 to remove all debris.
J2 (a) transverse contraction joints must be continuous across longitudinal tied joints.
SEE FIG 20.4 OR 5. Install closed-cell polyethylene backer rod or temporary seal as soon as possible after cleaning.
OR (b) longitudinal isolation joints should be continuous, with priority over contraction joints.
6. Trafficking may be necessary before sealing. Any damaged backer rod must be replaced.
J5 6. The permanent sealant must be an insitu cast silicone sealant, stored and installed in accordance with
J3 SEE FIG 20.3 7. Depress the temporary seal to provide the required sealant thickness.
the manufacturer's written instructions.
8. Place the sealant in accordance with the specification and in accordance with manufacturer's
7. Sealants must extend down the full vertical face of joints at all edges to prevent the ingress of verge
instructions (including a primer, where required). Tool it to enhance the bond and to provide the
J9 J10 material into the joint. At longitudinal joints, the edge sealant must prevent the ingress of concrete into the
J10 required recess. Extend the sealant down all edges in accordance with Note 7 Schedule 19.1.
transverse joints during subsequent paving runs.
9. Allow trafficking only after the sealant has become tack free.
ED)
8. In selecting the width of (re)sawing, it is not necessary to remove all spalling. Even in new construction,
J14 SEE FIG 21.3
TI
minor spalling (3-6 mm) is unavoidable and does not usually affect the performance of silicone sealants.
KERB (
R83 contains suitable criteria. If wider spalling is present, refer to Table 24.1 for
guidance on treatment of joint spalls.
9. A limit of 18 mm has been imposed on longitudinal silicone seals (see Table 19.1, for example).
(a) In tied joints, polyurethane sealant can be used for greater widths.
(b) In untied joints, polyurethane (alone) is unlikely to have adequate extension capacity.
FIGURE 19.1: TYPICAL JOINT RESEALING APPLICATIONS
Specialist advice should be sought in this situation.
TABLE 19.2:
TIED JOINTS - SILICONE SEALANT DIMENSIONS
1 2 3 4
TABLE 19.1: UNTIED JOINTS - SILICONE SEALANT DIMENSIONS
(b) (c) (d)
Width Depth Recess Joint depth
1 2 3 4 5 6 7
W'S (mm) D'S (mm) R'S (mm) D'J (mm)
(c)
Slab Length (L ) Design Joint Recess R'S (mm) Joint
e
(g) Width Depth (e) 3 < W'S ≤ 6 5 (+ 4,- 0) 5 ± 3 30 ± 5
or Opening Contractions Isolations and depth
W'S (mm) D'S (mm)
Width (W )
(b)
(m) OD (mm) (f) (f) D'J (mm) 6 < W'S ≤ 10 6 (+ 4,- 0) 5 ± 3 35 ± 5
e (etc) expansions
W S W'
S ≤ 4.6 2.1 7 (+ 3,- 0) 7 (+ 3,- 0) 10 < W'S ≤ 15 8 (+ 4,- 0) 6 ± 3 40 ± 5
4.6 < L ≤ 6.5 2.9 9 (+ 3,- 0) 8 (+ 3,- 0) 15 < W'S ≤ 18 10 (+ 5,- 0) 7 ± 3 50 ± 5

6.5 < L ≤ 8.0 3.5 10 (+ 3,- 0) 8 (+ 3,- 0) (e) 12 (+ 5,- 0) 7 ± 3 60 ± 5
transverse
RS
S
R'
8.0 < L ≤ 9.5 4.0 11 (+ 3,- 0) 9 (+ 3,- 0) 18 < W'S ≤ 22

(e)
dgn
9.5 < L ≤ 11.5 4.4 12 (+ 4,- 0) 10 (+ 4,- 0)

M J_19.
(e) 14 (+ 5,- 0) 7 ± 3 65 ± 5
11.5 < L ≤ 13.0 transverse
DS
S
D'
SILICONE SILICONE 4.8 14 (+ 4,- 0) 11 (+ 4,- 0)

> 22
DJ
J
D'
(e)
SEALANT SEALANT 13.0 < L ≤ 15.0 6.0 17 (+ 5,- 0) 14 (+ 4,- 0) longitudinal Use a polyurethane sealant
M 10.
CLOSED-CELL > 18 See Table 8.3 Note (a) regarding maximum desirable Table 19.2 Notes:
M D.
CLOSED-CELL POLYETHYLENE longitudinal silicone sealant width. (a) For untied joints, refer to Table 19.1.
ngs -JRCP\
POLYETHYLENE BACKER ROD Bridge approach (b) Refer to MJ08 for further details of the original joint design.
25 ± 4 14 (+ 4,- 0) 10 ± 4 12 ± 4 50 ± 5
BACKER ROD RESAWN JOINT slabs (c) Tooling is necessary to force the sealant against the faces, thereby
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ORIGINAL JOINT Table 19.1 Notes: enhancing its bond.

d Dr
(a) For tied joints, refer to Table 19.2. (d) Values given for the depth of joint D'J are indicative only. Allowance
AND M I
10 NOM
andar
N
AND M I
10 NOM
(b) See Table 8.3 for calculation of effective slab length L and width W . must be made for factors such as the depth of the backer rod after
e e
enance St
(c) Tooling is necessary to force the sealant against the faces, thereby enhancing its bond. lateral compression into the joint.
(d) The backer rod diameter should typically be about 25% larger than the joint width W'
S . (e) In this context, the terms "transverse" and "longitudinal" relate to the
05 PM
EXISTING JOINT RESAWN JOINT (e) Values given for the depth of joint D'
J are indicative only. Allowance must be made for factors direction of trafficking. Hence, an isolation joint which runs parallel
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22:
such as the depth of the backer rod after lateral compression into the joint. It is important that the with the through-carriageway within a median crossing is still
FIGURE 19.2: JOINT DIMENSIONS
at 12:
upward pressure on the sealant (in hot weather) is minimised. "transverse" relative to traffic movements. A similar joint separating a
(f) The distinction between joint types is explained in Table 8.1. ramp from the through-carriageway would be deemed "longitudinal".
2015
(g) Width OD refers to the maximum winter opening, that is, maximum extension of the sealant. (f) The backer rod diameter should typically be about 25% larger than
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G. VOROBIEFF JOINT RESEALING

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FIGURE 20.1: LONGITUDINAL SAWN AND TIED JOINTS (Type J1) FIGURE 20.2: LONGITUDINAL FORMED AND TIED JOINTS (Type J2)
Longitudinal sawn and tied joint (Type J1) Figure 20.2(a): Butt face (Type J2b) Figure 20.2(b): Corrugated face (Type J2c)
W'
S
NEW SAWCUT W'
S W'
S W'
S W'
S
NEW SAWCUT NEW SAWCUT NEW SAWCUT VERTICAL FACE NEW SAWCUT
LESS THAN
S
R'
TARGET 50 ± 5
NEW D'
NEW D'
J
J
SILICONE SEALANT
S
D'
POTENTIAL SEE NOTE (c)
D'
J
SPALLING
CLOSED-CELL
ORIGINAL JOINT
POLYETHYLENE POTENTIAL
BACKER ROD (TYP) LOOSE WEDGE
ORIGINAL JOINT
WS CASE 1 CASE 2 CASE 1 CASE 2

(PREFERRED) (POOR) (TO AVOID) (PREFERRED)
Figure 20.2(a) Notes: Figure 20.2(b) Notes:

(a) Assess the integrity of existing tiebars. Variability in joint width could indicate (a) Assess the integrity of existing tiebars, consistent with Figure 20.2(a).
Figure 20.1 Notes:
inadequate tying (for example, by pull-out and/or yielding, and/or corrosion). Where warranted, cross-stitch in accordance with MJ18 before resawing.
(a) Assess the integrity of existing tiebars. Variability in joint width could indicate
Where warranted, cross-stitch in accordance with MJ18 before resawing. (b) Where there are early signs of joint spalling, resawing can be used to relieve
inadequate tying (for example, by pull-out and/or yielding and/or corrosion).
(b) Where the existing joint is inclined beyond the range 90° ± 5° (to the surface), stresses on the arris in order to minimise further failure.
Where warranted, cross-stitch in accordance with MJ18 before resealing.
resawing should aim to minimise future arris spalling. Case 1 is the clearly (c) Spalling is often related to an inadequate vertical top face (which should be 50 ± 5).
(b) Select the resawing dimensions in accordance with Note 3 Schedule 19.2.
preferred option because Case 2 does not reduce the acute arris. Failure is typically on the concave side, hence the resawing line should be
Also, the existing joint intersects the side of the new sealant which will impose selected within this zone (Case 2) to maximise spall removal and to minimise
concentrated stresses at the top of the sealant; see Figure 21.4 for explanation. potential loose wedges.
(c) Select the resawing dimensions in accordance with Note 3 Schedule 19.2. (d) Select the resawing dimensions in accordance with Note 3 Schedule 19.2 unless
variations are warranted to address issues raised above.
(e) See Figure 20.3(b) Note (c) regarding wedge treatment.
FIGURE 20.3: LONGITUDINAL RIBBONED AND TIED JOINTS (Type J3)

Figure 20.3(a): Conforming ribbon Figure 20.3(b): Curled ribbon Figure 20.3(c): Inclined ribbon
1±1
W' POTENTIAL SPALL CERTAIN SPALL W' W'

S S S
NEW SAWCUT NEW SAWCUT NEW SAWCUT
SEE NOTE (b) SEE NOTE (e)
+10
0
= 90° ± 5°
3–
D/
RIBBON POTENTIAL
WEDGE
FIGURE 20.4:
SEE NOTE (c)
POTENTIAL LONGITUDINAL FORMED AND UNTIED JOINTS (Type J4)
WEDGE
Also applicable to longitudinal induced and untied joints (Type J5)
INDUCED CRACK SEE NOTE (d)
W'
S
NEW SAWCUT
CASE 1 CASE 2 CASE 3 CASE 1 CASE 2
(BEST) (WORST) (TO AVOID) (PREFERRED)
S
R'
dgn
SILICONE SEALANT
S
D'
M J_20.
Figure 20.3(a) Notes: Figure 20.3(b) Notes: Figure 20.3(c) Notes:

(a) The accuracy of ribbon insertion was highly Case 1 (a) Case 1 should be avoided because the silicone could
M 10.
CLOSED-CELL
D'
J
variable. Specifications required that they be (a) Case 1 shows the preferred treatment. The selected sawing line minimises the risk of future joint or arris distress. be damaged if it bridges the ribbon's point of entry to
M D.
POLYETHYLENE
placed as shown above. By contrast, they (In this case, the preferred line also happens to maximise the depth of ribbon to be removed.) the new sawcut; see Figure 21.4 for explanation.
ngs -JRCP\
BACKER ROD (TYP)

will often be found much deeper and/or Case 2 (b) Case 2 is the preferred option because it minimises
curled, and/or inclined. This sawcut leaves the following potential problems: the risk noted under (a).
awi
(b) Where the ribbon was reasonably well (b) The acute arris may spall. However, sawing may also reduce spalling by relieving arris stress.
d Dr
installed, resawing should be in accordance (c) The sawcut produces a wedge which could dislodge and jam the joint's hinge action. If the formation of a wedge (As a general rule, it appears that the preferred line will be
andar
with Figure 20.2(a). is unavoidable, a filler should be placed in the sawcut before sealing (to hold the wedge in place). the one which intersects the surface crack and also
enance St
(c) Where the ribbon is curled and/or inclined, Case 3 maximises the depth of ribbon to be removed.)
see Figure 20.3(b) and Figure 20.3(c). This sawcut leaves the following potential problems: EXISTING JOINT OR
07 PM
(d) A potential wedge; see Figure 20.3(b) Note (c). INDUCED CRACK
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(e) The residual piece is certain to spall under traffic. Where the optimal sawing line leaves residues like this,
22:
at 12:
they must be removed, possibly by localised routing.
General Figure 20.4 Note:

In all cases select the resawing dimensions in accordance with Note 3 Schedule 19.2. (a) Select the resawing dimensions in accordance with Note 2 Schedule 19.2.
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FIGURE 21.2: FIGURE 21.3:
FIGURE 21.1: TRANSVERSE FORMED AND TIED JOINTS (Type J7) TRANSVERSE SAWN CONTRACTION JOINTS (Type J9) ISOLATION JOINTS (Type J14)
Figure 21.1(a): Butt face Figure 21.1(b): Corrugated face Also applicable to Types J10, J12, and J17. Also applicable to Types J15 and J16
W'
S
W' W' W' W' NEW SAWCUT W'
S S S S S
NEW SAWCUT NEW SAWCUT NEW SAWCUT NEW SAWCUT W S NEW SAWCUT
VERTICAL FACE
LESS THAN
R'
S
TARGET 50 ± 5
NEW D'
NEW D'
J
J
POTENTIAL SPALL SEE NOTE (b) SILICONE SEALANT
D'
S
SEE NOTE (a)
DJ
D'
CLOSED-CELL
D'
ORIGINAL JOINT
J
POTENTIAL POLYETHYLENE
LOOSE WEDGE BACKER ROD (TYP)
NEW JOINT
ORIGINAL JOINT
CASE 1 CASE 2 CASE 1 CASE 2
(PREFERRED) (POOR) (TO AVOID) (PREFERRED)
Figure 21.1(a) Notes: Figure 21.1(b) Notes:

EXISTING JOINT
(a) Where the existing joint is inclined beyond the range 90° ± 5° (to the surface), (a) Where there are early signs of joint spalling, resawing can be used to relieve
JOINT FILLER
resawing should aim to minimise future arris spalling. stresses on the arris to minimise further failure.
Case 1 is the clearly preferred option because Case 2 does not reduce the (b) Spalling is often related to an inadequate vertical top face (which should be
acute arris. Also, the existing joint intersects the side of the new sealant which 50 ± 5). Failure is typically on the concave side, hence the resawing line
Figure 21.3 Notes:
(a) This detail is applicable to longitudinal and transverse J14, J15, and J16.
will impose concentrated stresses on it; see Figure 21.4 for explanation. should be selected within this zone (Case 2) to maximise spall removal and
(b) Select the resawing dimensions in accordance with Note 2 Schedule 19.2.
(b) Select the resawing dimensions in accordance with Note 3 Schedule 19.2. to minimise potential loose wedges. Figure 21.2 Notes:
(a) Select the resawing dimensions in accordance with Note 2 Schedule 19.2. (c) Replace the joint filler if:
(c) Select the resawing dimensions in accordance with Note 3 Schedule 19.2
● there are signs of deterioration, or
unless variations are warranted to address issues raised in (a).
● it is permanently compressed to a width significantly less than the
(d) See Figure 20.3(b) Note (c) regarding wedge treatment.
existing joint width (and hence will admit incompressible material).
FIGURE 21.4: SEALANT RESERVOIR FAULTS FIGURE 21.5: SEALANT INSTALLATION - GENERAL
Figure 21.4(a): Ineffective reseal Figure 21.4(b): Short lived reseal Figure 21.4(c): Effective reseal Figure 21.5(a): Good practice Figure 21.5(b) : Poor practice
CLOSED-CELL CLOSED-CELL
dgn
WEAK WEAK POLYETHYLENE POLYETHYLENE

M J_21.
WEDGE WEDGE BACKER ROD BONDED FACES

BACKER ROD
M 10.
(TYP) (TYP)
M D.
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RIBBON RIBBON TYPICAL SEALANT DESIGN TYPICAL DESIGN FOR ROUTING UNSATISFACTORY DESIGN
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INDUCER SLAB CONTRACTION INDUCER SLAB CONTRACTION

CASE 1 CASE 2
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RESAWN AND RESEALED ROUTED AND RESEALED

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Figure 21.4(a) Notes: Figure 21.4(b) Note: Figure 21.4(c) Notes:

enance St
(a) The sealant must bridge the moving joint and (a) If the moving joint intersects the side of the sealant (a) One possible remedy is to break off the wedge of concrete
so selection of the resawing line is important. (as shown), the sealant will either tear or debond. as shown. Figure 21.5(a) Note: Figure 21.5(b) Note:
08 PM
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(b) The reseal shown here actually misses the joint, hence (b) Care is required to prevent the fragments falling into the joint. (a) Good sealant design and installation ensures that expansion and If the sealant is bonded along the bottom face, the
d Pavem entM ai
22:
the sealant will be dormant and the joint remains unsealed. Hence, it is preferable that they be pushed towards the sawcut. compression movements are spread evenly throughout the sealant. concentrated strain at the joint will tear the sealant.
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TABLE 22.1: ROUT DIMENSIONS - TIED AND STITCHED CASES
Rout width Rout depth Backer rod shape Sealant thickness Sealant recess
Sealant
(mm) (mm) and size (mm) (mm)
type
STITCHING W DR (HB ) DS RS
R
SEE MJ18
Silicone or 15 mm cut to ½ round
15 ± 3 (b) 15 (+ 5, - 0) 7 (+ 3, - 0) 3 (+ 2, - 0)
Polyurethane (HB = 5 mm)
J1
WU or W S W R
T 30 mm cut to ½ round
OR 30 ± 5 Polyurethane 30 (+ 7, - 0) 10 (+ 5, - 0) 3 (+ 2, - 0)
RS
J2 23 (HB = 15 mm)
J2 J14
T
50 mm, slit segment
DS
DR
23
OR X 50 ± 7 Polyurethane 30 (+ 7, - 0) of height 14 mm 11 (+ 5, - 0) 4 (+ 2, - 0)
23 (HB = 14 mm)
HB
U J3
W
23 Table 22.1 Notes:
23
J9 (a) For untied/unstitched cases, this table may be used on the condition that the sealant is silicone of width less
than 18 mm and that all dimensions satisfy criteria in accordance with Table 19.1.
J9 (b) In tied joints, polyurethane is preferable to silicone where distillate fuels are likely to be in concentration.
J9 OR (c) Routing widths listed in Table 22.1 are limited to 3 categories. The values (and the number of 3) are
OR J10
X suggested for logistical purposes only and may be varied if deemed desirable. However, the maximum width
J10
23
of 50 ± 7 mm should only be varied after careful consideration and after suitable trialling.
T U
OR X
23 23
23
TABLE 22.2: NOMENCLATURE
SYMBOL DESCRIPTION
X SCHEDULE 22.1 (S22.1)
J9 OR W Width of crack (without spalling)
23 J10 C
NOTES
W SP Width of crack plus spalling
1. This procedure is mainly applicable to treatment of cracks but may also be used for joints
ED)
where resawing is unsuitable. Where the joint to be routed is inclined and/or curled, the W R1 Width of rout - 1st pass
treatments detailed in MJ19-MJ21 are equally applicable to routing by substitution of a
TI
J7 J7 W R2 Width of rout - 2nd pass
(
routing cut for the sawcut.
KERB
J2 W 85% spalled width. (b)
2. The purpose of routing and resawing is: 85
V W
OR
23 23 (a) to produce a reservoir shape with vertical sides and which is suitable for sealing. W S Width of silicone sealant
(b) to clean the faces to maximise sealant adhesion.
W U Width of polyurethane sealant
3. Wherever possible, cracks should be stitched; see MJ18. Stitching should be completed
J9 OR
ED)
J10 before routing/sawing (to reduce the stress on sealants). Table 22.2 Notes:
4. For (re)sealing of joints, sawing should be considered in preference to routing, but sawing (a) Refer to Details T-X, MJ23 for applicability.
TI
KERB (
J4 , J14 , J15 )
will rarely be feasible for cracks. (b) Refer to Note (b) Schedule 23.1 for commentary.
NT
5. The resawing/routing width is typically governed by two criteria:

ED JOI
(a) the width of spalling.

(b) the required operating parameters of the sealant. The design of sealants in tied joints
UNTI
J2 J2 J2
will be different to those in untied joints because of the differing magnitude of movement.
6. Crack widths should be assessed in the warmer part of the day because they will increase at
other times due to contraction and curling. METHOD
EG
7. At the time of sealant installation, side walls of the reservoir must be thoroughly clean and 1. Establish traffic control and work safety in accordance with Safe
(
free from all loose debris, pulverised concrete dust, and other material which may be Work Method Statements (SWMS).
deleterious to the adhesion of the sealant. Grit blasting is not required when the routed 2. Mark areas to be treated.
concrete faces have been prepared in accordance with the guidelines. The cleanliness of the 3. Determine required rout width, WR > W85 .
joint faces must be tested in accordance with T379. An acceptable result is when Grade 1 4. Repair joints and cracks in accordance with Schedule 23.1 to
(None) visual rating category is achieved. The adhesion of the sealant must be tested in Schedule 23.5 as applicable.
FIGURE 22.1: TYPICAL ROUTING APPLICATIONS accordance with T380.
dgn
5. Clean out joints/cracks with high pressure water. This must be

M J_22.
NOT TO SCALE 8. The backer rod shown in Table 22.1 must be continuous closed-cell polyethylene. It must be done immediately after sawing/routing and before the residue dries.
accurately slit in a jig to the required shape. The backer rod is to be depressed to the bottom 6. Inspect to ensure effective removal of all loose debris.
M 10.
of the reservoir so as to seal the exposed crack/joint. If necessary, the backer rod must be 7. Install backer rod to provide the required sealant depth.
M D.
held in place by a suitable flexible adhesive such that the rod will not be dislodged with the 8. In routings, install sealant in accordance with Table 22.1.
ngs -JRCP\
actions of wind or sealant installation. In sawcuts, install sealant in accordance with MJ19-MJ21.
9. At slab edges and formed joints, sealants must extend down the vertical face of the routed For polyurethanes, apply sand to the surface.
section, including any underlying cracks. 9. Allow trafficking only after sealant has become tack free.
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10. Where a polyurethane sealant will cross an untied joint, a joint filler must be placed within
d Dr
that joint so that the polyurethane is discontinuous.

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11. Where a polyurethane is used in a longitudinal joint, its surface must be blinded with sand to
enance St
increase friction values.

09 PM
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Typical Routing Procedure DETAIL T

W1 W1
(a) This procedure is applicable to joints and cracks where sawcutting - -
is not feasible. It is applicable to both longitudinal and transverse LOCALISED WIDE SPALL
cases. It is applicable only to tied and/or stitched applications USE A STRUCTURAL REPAIR IN
WSP SCHEDULE 23.4 (S23.4)
DTH ACCORDANCE WITH MJ24 AND MJ25
ALLEDWI where structural spall repairs are not required.
SP W R Combined Routing and Repairing Procedure DETAIL W
(b) The width of rout should generally be such that it will impact on
ROUT WIDTH
about 85% of the total length of spalled crack within a selected (a) This procedure is applicable to multiple spalling types where a combination of routing and
WC TREAT IN ACCORDANCE WITH
section. This is referred to as the "85th percentile spalled width", structural repair is needed. It is applicable only to tied or stitched joints and cracks.
DTH
CRACKWI DETAIL T, U, OR V AS APPLICABLE
which is abbreviated to "85% spalled width" or W85 . However, (b) The suggested sequence of operations is as follows:
selection criteria for the rout width may differ between sites, (i) Rout (or sawcut) the length of crack (or joint) adjoining the wide spall. (Routing or sawing at
WR1
1
. depending on factors such as: DETAIL W a later date may damage the repair).
ROUTNo
(i) the curvature (or "crookedness") of the spalled crack, in terms PLAN - (ii) Insert a temporary filler to width WS .
of the capacity of the router to follow its path. (iii) Repair the wide spall in accordance with MJ24 and MJ25.
(ii)the economics of doing a single rout versus multiple passes. WU OR WS WR (iv) Install the sealant over the full length of routed crack plus repair, in accordance with
(c) Routing will generally not be warranted where: Detail T, U, or V as applicable.
(i) the crack width WC < 0.5 mm.

WR2
(ii)the 85% spalled width W85 < 5 mm (NOM).
ROUTNo.
2
SILICONE OR POLYURETHANE AS APPLICABLE
CLOSED-CELL POLYETHYLENE BACKER ROD (TYP)
USE A STRUCTURAL REPAIR

IN ACCORDANCE WITH MJ24 AND MJ25
DETAIL T
PLAN -
ORIGINAL JOINT OR CRACK
SECTION W1
SCHEDULE 23.2 (S23.2) -
Tied Longitudinal Joint Routing Procedure DETAIL U
(a) This procedure is applicable to longitudinal joints which are tied or

WS AND WR stitched, and have only minor spalling.
(b) Sawcutting should always be considered before routing. WR
(c) The cutting width (either sawn or routed) should generally
be such that it will impact on about 85% of the total length of WSP SCHEDULE 23.5 (S23.5)
WSP spalled joint within a selected section. However, the width
Untied Joint Routing Procedure DETAIL X
may differ between sites depending on factors such as the X1 X1
economics of doing a single cut versus multiple passes. - - (a) This procedure is applicable to untied joints, either longitudinal or transverse (such as isolation,
(d) For rout and seal dimensions: see Table 22.1. expansion, untied butt) and which contain sections of substantial spalling.
For saw and seal dimensions: see MJ19-MJ21. (b) Because of the magnitude of cyclic movement, at least part of the repair width must be a silicone
RESAW AND RESEAL
(e) WR ≤ 18 mm: Seal with silicone IN ACCORDANCE WITH MJ19-MJ21
(of width designed in accordance with MJ19-MJ21).
WR > 18 mm: Seal with polyurethane (c) For WR = 18/22 # mm : resaw and seal in accordance with MJ19-MJ21
WS = 18/22 # MAX
For 18/22 # mm < WR = 57 : treat in accordance with Detail X
DETAIL X For WR > 57 mm : treat in accordance with MJ24 and MJ25.

DETAIL U # adopt : 18 mm in longitudinal joints
PLAN -
PLAN - 22 mm in transverse joints
(d) The suggested sequence of operations (following routing) is as follows:
WR (i) Insert a temporary filler to width WS .

(ii) Prepare and repair the wide spall in accordance with MJ24 and MJ25. Allow adequate curing time.
SCHEDULE 23.3 (S23.3) 18/22 # MAX
dgn
(iii) Sawcut (or rout) the length of spalled joint (excluding the repair) in preparation for sealing.
M J_23.
Tied Transverse Joint Routing Procedure DETAIL V WU WS WU (iv) Install silicone sealant over the full length of joint in accordance with MJ19-MJ21.
M 10.
(a) This procedure is applicable to transverse joints which are tied
and/or stitched and which have only minor spalling.

M D.
WR
W SP
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WS OR W (b) Sawcutting should always be considered before routing.

U SILICONE SEALANT
(c) The cutting width (either sawn or routed) should generally be
IN ACCORDANCE WITH MJ19-MJ21
such that it will impact on about 85% of the total length of spalled
CLOSED-CELL POLYETHYLENE BACKER ROD (TYP)
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joint within a selected section. However, the width may differ

d Dr
between sites depending on factors such as the economics of

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doing a single cut versus multiple passes.

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

DETAIL V For saw and seal dimensions: see MJ19-MJ21. FILLER
11 PM
PLAN - (e) WR ≤ 22 mm: Seal with silicone

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22:
WR > 22 mm: Seal with polyurethane

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TABLE 24.1: CLASSIFICATION OF SPALLS AND SELECTION OF REPAIR METHOD FIGURE 24.1
(a)
Type Dimensions Treatment Figure 24.1(a): Minor (M) Figure 24.1(b): Shallow Discrete (SD) Figure 24.1(c): Shallow Continuous (SC)
Arris rounding W < 30 mm

See Figure 25.1 for options
AR (no limit on depth)
At Joints :Resaw and seal; see MJ19-MJ21

Minor spall M W ≤ 50 mm
or Rout and seal; see MJ22 and MJ23 CONTINUOUS
See Figure 24.1(a) (no limit on depth) < 50
At Cracks :Rout and seal; see MJ22 and MJ23 SPALLS FULL-DEPTH
(INCLUDE JOINT) > 50 FULL-DEPTH
FULL-DEPTH
Shallow spall CRACK CRACK
Thin bonded repairs CRACK
- Discrete SD
See Figure 24.2
See Figure 24.1(b) < 50 > 50
W > 50 mm
Shallow spall H ≤ D/2

Thin bonded repairs DISCRETE SPALLS
PERIMETER
- Continuous SC
See Figure 24.3 GROOVES > 50
See Figure 24.1(c) < 50
> 50
W > 50 mm Full-depth repairs
Deep spall D
H > D/2 See MJ12-MJ17
Table 24.1 Note:

(a) W = Width of Spall H = Depth of Spall D = Thickness of base
FIGURE 24.2: TYPE SD - SHALLOW DISCRETE SPALLS FIGURE 24.3: TYPE SC - SHALLOW CONTINUOUS SPALLING
Figure 24.2(a): Plan view Figure 24.2(a) Notes:

(a) Mark out the square or rectangular perimeter area to be replaced. This area must have minimum dimensions of
EXISTING SLAB JOINT
MARK OUT OF PERIMETER 100 mm and be at least 20 mm beyond all unsound concrete.
24.2(b) EDGE OF SPALLING
(b) Remove any existing sealant to a minimum of 100 mm beyond the patch perimeter.
20 MIN -
100 MIN PERIMETER OF REPAIR
Figure 24.2(b) Notes:
DEFINED WITH STRAIGHT
(c) Saw or rout a joint forming groove along the line of the joint (to hold the joint former). For repairs at the junction of
SAWCUTS
four slab corners, a former must be placed along each joint.
The forming groove must:
● be at least 10 mm deeper than the deeper patch (where 2-sided).

SEALANT 100 MIN
20 MIN ● extend at least 100 mm beyond each end of the patch perimeter. 20 MIN
SEALANT REMOVED 100 100 100 ● be of a width suitable for the specific joint type, and desirably 2 to 5 mm wider than the existing joint, hence: 5 THICK JOINT FORMER
MIN MIN MIN ● for isolation and expansion joints: 20 - 30 mm (TYP) wide.
24.2(c) ● for PCP contraction joints: 9 - 12 mm (TYP) wide.
- ● for tied construction joints: 5 - 10 mm (TYP) wide.
(d) Chase out a perimeter groove around the other three sides, to a minimum depth of 15 mm. This should be done with 15 MIN
Figure 24.2(b): Stage 1 (Section view) 30 MIN
a single-head scabbling tool or a router and template. This must form vertical edges to the patch. All edges must PERIMETER GROOVE
JOINT FORMER UNIFORM DEPTH
100 MIN be rough; see Note 2 Schedule 25.2.
100 MIN 10 MIN
20 MIN (e) Remove the concrete within the perimeter groove to produce a reasonably even surface. A single or multi-head THIN BONDED
FORMING GROOVE
20 MIN scabbling tool is suitable for this removal. CONCRETE PATCH
15 MIN MIN WIDTH OF REPAIR = 200
SPALL PROFILE
(f) Clean out the patch using a vacuum cleaner and/or oil-free compressed air (plus wire-brush if required). The vacuum
PERIMETER is recommended for minimising ingress of grit into joints and cracks. The compressed air is intended to remove any
GROOVE shattered aggregate or concrete. Figure 24.3 Notes:
Follow the procedure in accordance with Figure 24.2, except:
15 MIN (g) Fix a joint former securely into the forming groove so that the top is flush with the finished surface level. Caulk all
SPALL PROFILE (a) The minimum depth of patch must be 30 mm.
PERIMETER GROOVE paths and gaps where repair material could escape or contact adjoining slabs. See Notes 3 and 4 Schedule 25.2.
(b) Initiate the perimeter groove by sawcutting.
FORMING GROOVE Figure 24.2(c) Notes:
REMOVE FAILED AREA (c) Chase this sawcut with a router to roughen the vertical faces. See also Note 2 Schedule 25.2.
(h) For epoxy resin patches, prime the exposed surfaces in accordance with the manufacturer's recommendations.
DOWN TO SOUND CONCRETE 10 MIN
For cementitious patches, saturate all patch faces with water (or wet rags) for at least 10 hours (to ensure that
1 EXISTING ISOLATION
the patch material is not sucked dry). Maintain the faces in a moist condition until the next stage.
OR EXPANSION JOINT, OR
(j) Immediately before placing the patch material, remove all free water (using oil-free compressed air and/or rags).
2 CONTRACTION OR (k) Prime all surfaces by brushing with cement grout or other notified bonding agent.
CONSTRUCTION JOINT (l) Place the repair material into the patch within the time limit specified by the manufacturer. Where a delay occurs,
dgn
OR CRACK the primer must be protected against drying.

M J_24.
(m) Thoroughly compact the material using a vibrating hammer, taking special care to work fine material into all faces,
Figure 24.2(c): Stage 2 (Section view)
M 10.
edges, and corners. Provide a timber-float or textured surface.

M D.
(n) Cementitious repairs must be cured with hydrocarbon resin curing compound. It must be applied as soon as the mix
WS JOINT SEALANT
ngs -JRCP\
reaches the low-sheen condition.

PATCH REPAIR PATCH REPAIR (o) Cover the patch with moist hessian and then polythene sheeting as soon as possible without marking the surface
texture. Secure all edges of the sheeting to prevent drying.

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(p) Curing and protection should be maintained for a minimum of 24 hours, but preferably three days.
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(q) Clean and seal the joint in accordance with MJ19-MJ21, and after removing the joint former. Where a program of
andar
DEBONDING STRIP
resawing and sealing of joints is to follow, joint cleaning will be achieved during that program. Otherwise, the faces
enance St
can be roughened with an angle-grinder to maximise sealant bond.

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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
SECTION FOR REMOVAL

W'
S W'
S EPOXY PATCH
W' W' SECTION FOR W'
R'
S
EXISTING SLAB S S S
NEW MATERIAL NEW MATERIAL
R'
S
NEW MATERIAL NEW MATERIAL REMOVAL
ROUNDING ON SEALANT
DEBONDING STRIP
EXISTING FACE
D'
S
50 M AX
D'
S
N
EXISTING SLAB EXISTING SLAB
D'
S
20 M I
EXISTING SLAB
FILLER
NEW FILLER DEBONDING DEBONDING STRIP
RESIDUAL FILLER
STRIP
OR BACKER ROD NEW MATERIAL
EXPOSED
FACE
EXPOSED
JOINT FACE
STAGE 1 STAGE 2 STAGE 3 STAGE 1 STAGE 2
PROVIDE SQUARED RESERVOIR REMOVE FAILED MATERIAL. PLACE SEALANT. PROVIDE SQUARED RESERVOIR BY PLACE SEALANT.
STAGE 1 STAGE 2 BY SAWCUTTING AND REMOVING FIX A SUITABLE FILLER AND PLACE SAWCUTTING AND REMOVING CONCRETE AS SHOWN. THE EFFECTIVE SEALANT WIDTH IS
FIX A SUITABLE FILLER TO PLACE NEW MATERIAL. CONCRETE AS SHOWN. EPOXY REPAIR. FIX A SUITABLE FILLER AND PLACE NEW MATERIAL. INCREASED AS SHOWN, BUT DEPTH
THE EXPOSED FACE. PLACE SEALANT. NEED NOT BE INCREASED.
Figure 25.1(a) Notes: Figure 25.1(b) Notes: Figure 25.1(c) Notes:

(a) This option is suitable where the rounding is only minor, but placement of concrete against that (a) This option is suitable where the rounding and/or spalling exceeds the recommended operating range (in shape (a) This option is suitable where the rounding and/or spalling exceeds the recommended operating range
rounding will result in spalling of the new edge. and/or dimensions) for the silicone option in Figure 25.1(a) for the silicone option in Figure 25.1(a).
(b) This method is suitable for both longitudinal and transverse joints, either tied or untied. (b) This treatment is generally consistent with MJ24 but assumes the spalling and/or rounding is much less (b) This method is the same as Figure 25.1(b) except that it removes the step of placing an epoxy
(c) The silicone is most likely to fail by adhesion failure (debonding) at the arris rounding. advanced than in MJ24. resin patch.
This should be the key issue in assessing the suitability of this option. (c) A polyurethane may be used in lieu of the epoxy resin. (c) The controlling factor for the use of this option is likely to be the limit on silicone width, namely,
(d) The sealant type and width must be designed in accordance with MJ19-MJ21. (d) For the sealant design, refer to Figure 25.1(a). 18 mm maximum in longitudinal joints.
Recommendations are as follows: (d) In tied joints, a polyurethane can be used in lieu of the silicone, in which case higher width limits apply.
(i) For tied joints, transverse or longitudinal: Table 22.1 provides guidelines for polyurethanes but gives only two options to suit routing widths.
Use a silicone designed in accordance with Table 19.2. Adopt W'

S as low as feasible. (Routing is not required here.)
(ii) For untied transverse: For this application, the width may be varied between suggested limits of 18 mm and 60 mm.
Use a silicone in accordance with Table 19.1. Thickness D'S should be 7 mm minimum and the shape ratio W : D should be between 3 : 1 and 5 : 1.
(iii) For untied longitudinal joints:
● For design widths ≤ 18 mm, use a silicone in accordance with Table 19.1.
● For widths > 18 mm: not feasible, assess alternatives. Seek specialist advice.
SCHEDULE 25.1 (S25.1) SCHEDULE 25.2 (S25.2)
NOTES METHOD
Scope Workmanship
1. This method applies to joints, cracks, and edges. The diagrams show repairs in situations which do 1. The critical factors for success include:
not involve full-depth slab removal. However, they are intended to cover many applications and so ● roughness and cleanliness of the parent concrete.
can be used in conjunction with slab removal (as shown on MJ12-MJ17) with only minor adaptation. ● bond strength.
Workmanship ● concrete/mortar compaction.
2. Spall repairs are very sensitive to standards of workmanship and will yield a low success rate ● curing.
unless close attention to detail is given to every aspect. Also refer to Schedule 25.2. ● protection against early stress.
Spall types It is critical that a thorough bond be achieved over all patch faces. This requires that mortar be worked into
3. Joint spall repairs are typically classified as shown in Table 24.1. the microtexture of scabbled faces and into corners and edges.
� Each spall type is treated differently; see Table 24.1. Patch preparation
�
dgn
It is desirable to determine the extent of failure before commencing repairs. The early stages 2. All bonded faces (both vertical and horizontal) must be rough to maximise bond strength. Sawn or smooth faces are
M J_25.
of deep spalling may look similar to shallow spalling. unacceptable. It is therefore preferable that failed concrete be chased out rather than sawn. Sawn faces are difficult
� Simple investigation techniques include tapping around the failure with a steel rod, and removal to scabble without causing further spalling.
M 10.
of seals to view the extent of cracking. Joint formers

M D.
Minimum repair depth 3. It is critical that the repair not be stressed before it achieves adequate strength. It must be totally isolated from
ngs -JRCP\
4. The practical minimum depth is: adjoining slabs and must not bridge across joints (including tied joints, which hinge due to curling). For repairs at the
● 10 mm for epoxy resin repairs. intersection of four slab corners, a former must be placed in each joint.
● 30 mm for cementitious repairs. 4. Any temporary joint formers or fillers must be flexible and compressible enough to absorb movement without
awi
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Beyond these thicknesses, there is no value in making the repair deeper than necessary and transferring stress into the patch. Some situations may require a composite former/filler comprising stiffer material
andar
so scabbling should be limited to the extent necessary to remove all unsound concrete. against the patch that is bonded to flexible material against adjacent slabs. To facilitate the removal of the filler
without damaging the patch, it must be debonded and also preferably collapsible.
enance St
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BRIDGE BRIDGE TERMINAL SLAB
APPROACH SLAB SCHEDULE 26.1 (S26.1)

NOTES
LENGTH OF SLAB
MAX
12 000 MAX 2
Anchors
4 000 MIN 1 500 MIN
1. Refer to Volume CJ Jointed Reinforced Concrete Pavement for standard details
BRIDGE SEE NOTE 2 S26.1
of various anchor designs.
BASE
POSSIBLE THICKENING
APPROACH
D
MESH (TOP ONLY) 2. JRCP terminal slabs constructed before 2003, this dimension was 4500 ± 500.
SLAB J14 J9 OR J10
3. Anchor drains are constructed only where the longitudinal grade on that side of the
(REINFORCED)
anchor falls towards the anchor. Where the grade falls away from the anchor, the drain
JRCP JRCP JRCP
J14 is deleted and the subbase is extended to the anchor. The depth of the drain is nominal
LCS
LCS only and is adjusted to suit grade and drainage requirements.
SUBBASE
MESH (TOP ANCHOR DRAIN
ED)
FILLER
TYPE 12)
AND BOTTOM) SEE NOTE 3, S26.1
1 200
TI
KERB (
CASE 6 CONSTRUCTION
SUBGRADE BEAM
JOINT
(
CASE 3
CASE 5 600
JRCP MIN
JRCP JRCP
J7 FIGURE 26.2: SCHEMATIC TERMINAL DESIGN AT BRIDGES
FOR ROAD SKEW ≥ 84°
CASE 7 SEE NOTE 1 (S26.1)

CASE 2
TERMINAL SLAB FLEXIBLE JRCP ANCHOR DEFECT CASES
A ANCHOR PAVEMENT CASE 1: Shrinkage cracking over anchors
LENGTH OF SLAB
MAX + 200
1100 –
2 0 (a) Rout and seal cracks in accordance with MJ22 and MJ23 if warranted.
CASE 4
BASE
CASE 1 1 500 MIN
D
CASE 2: Transverse joint spalls
J9 OR J10 MESH (TOP ONLY)
J9 OR J10
(a) Repair in accordance with MJ24 and MJ25 if warranted.
D
J2 JRCP JRCP POSSIBLE THICKENING
J1 J1 CASE 3: Corner cracking
LCS
JRCP OR JRCP OR JRCP J6 (a) Repair in accordance with Case 9 shown on MJ12 (or Case 8
SUBSURFACE DRAIN
SUBBASE
TYPE 12 :1200
ANCHOR DRAIN if approved) if secondary cracking occurs.
J2 J2
SEE NOTE 3, S26.1
MESH (TOP AND BOTTOM)
OR OR CASE 4: Anchor rotation / sliding
MESH (TOP ONLY)
CONSTRUCTION JOINT
J3 J3 (a) This defect usually manifests itself in the form of faulting and/or crushing
of the JRCP and/or SFRP-R terminal slabs and/or bridge approach slab
at the J14 or F7 and/or F4 joints. It may also lead to buckling of the JRCP
and/or SFCP-R terminal slabs and/or bridge abutment/deck damage.

FIGURE 26.1: TYPICAL JPCP TERMINAL ANCHOR DEFECTS
600 Due to the serious repercussions of this defect, seek specialist advice.
NOT TO SCALE
MIN
CASE 5: Tranverse cracking
FIGURE 26.3: SCHEMATIC TERMINAL DESIGN AT FLEXIBLE PAVEMENT (a) Rout and seal cracks in accordance with MJ22 and MJ23 if warranted.
SEE NOTE 1 (S26.1)
CASE 6: Longitudinal cracking
(a) Rout and seal cracks in accordance with MJ22 and MJ23 if warranted.
CASE 7: Longitudinal joint spalls
(a) Repair in accordance with MJ24 and MJ25 if warranted.

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M D. dgn
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G. VOROBIEFF ANCHOR DEFECT REPAIRS

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Volume MJ Jointed Reinforced Concrete Pavement

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PAVEMENT STANDARD DRAWINGS

Volume MJ - Jointed Reinforced Concrete Pavement

RELATED CONCRETE PAVEMENT DRAWINGS

BASE TYPE DRAWING VOLUME

ENGINEERING SERVICES BRANCH

ASSET MAINTENANCE DIVISION

APPROVED FOR USE REGISTRATION No OF PLANS SHEET No

PAVEMENTS AND GEOTECHNICAL

ISSUE DATE VOLUME No OF SHEETS

© COPYRIGHT ROADS AND MARITIME SERVICES

ED/REV DATE SHEET AMENDMENT DESCRIPTION AUTHORISED DRAWING CONTENT SHEET No

2/1 28/05/2015 ALL Comprehensive revision PEP&G ** LEGEND MJ03

INDEX OF SHEETS MJ04

JOINT CATALOGUE MJ05-MJ10

KERBS AND BARRIER MJ11

SLAB REPLACEMENT MJ12-MJ17

CROSS STITCHING OF CRACKS AND JOINTS - COMPROMISE PRACTICE MJ18

JOINT RESEALING MJ19-MJ21

ROUTING AND SEALING OF CRACKS AND JOINTS MJ22-MJ23

JOINT SPALL REPAIRS MJ24-MJ25

ANCHOR DEFECT REPAIRS MJ26

ASSET MAINTENANCE DIVISION RIGID PAVEMENT

APPROVED FOR USE 28/05/2015 STANDARD DETAILS - MAINTENANCE MD.M10.MJ

ISSUE DATE VOLUME No OF SHEETS

JOINTED REINFORCED CONCRETE PAVEMENT (JRCP)

G. VOROBIEFF REVISION REGISTER AND SHEET INDEX

FOR AMENDMENTS REFER TO SHEET No 02 PAVEMENTS AND GEOTECHNICAL

1. Scope TYPE DESCRIPTION

Definitions of terms is contained in the Specification.

PCP-D Dowelled Plain Concrete Pavement

Specification Guide NR83 Guide to QA Specification R83 D Joint type: 'D'

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

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

Pavement Structural Design

Australian/New Zealand Standards

AS 1379 Specification and Supply of Concrete

AS 3600 Concrete Structures

AS/NZS 4671 Steel Reinforcing Materials

Other Documents TABLE 3.5: GENERAL SLAB DIMENSIONAL LIMITS

R max 8.0 (10.0) 13.3 (16.7) NA NA NA NA

Table 3.5 Notes:

on curved slabs. for trafficked criteria.

measure on curved slabs.

ASSET MAINTENANCE DIVISION RIGID PAVEMENT

APPROVED FOR USE 28/05/2015 STANDARD DETAILS - MAINTENANCE MD.M10.MJ

ISSUE DATE VOLUME No OF SHEETS

JOINTED REINFORCED CONCRETE PAVEMENT (JRCP)

FOR AMENDMENTS REFER TO SHEET No 02 PAVEMENTS AND GEOTECHNICAL

● Joint types and section details

JOINT RESEALING ROUTING AND SEALING CROSS STITCHING

● Joint resawing ● Joint routing and resealing ● Longitudinal joint stitching

MJ19 - MJ21 MJ24, MJ25 MJ22, MJ23 MJ18

ASSET MAINTENANCE DIVISION RIGID PAVEMENT

APPROVED FOR USE 28/05/2015 STANDARD DETAILS - MAINTENANCE MD.M10.MJ

ISSUE DATE VOLUME No OF SHEETS

JOINTED REINFORCED CONCRETE PAVEMENT (JRCP)

G. VOROBIEFF INDEX OF SHEETS

FOR AMENDMENTS REFER TO SHEET No 02 PAVEMENTS AND GEOTECHNICAL

SILICONE SEALANT SILICONE SEALANT

JOINT TYPE J1 JOINT TYPE J2

CORRUGATIONS : SEE TABLE 10.2

CLOSED-CELL BACKER ROD (TYP)

G B BACKER ROD (TYP) SEAL FULL FACES;