449Bridge Deck Joint Seals

449.1General Description

This work consists of furnishing and installing bridge deck joint sealing systems at the locations shown on the plans. These bridge deck joint sealing systems consist of a joint seal and may include concrete headers. Use a joint seal material that conforms to one of the following: • A preformed elastomeric neoprene profile seal, or • A low-density, closed cell cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen-blown seal. Use either epoxy concrete or elastomeric concrete for header material. Mix and use elastomeric and epoxy concrete material according to the manufacturer’s guidelines. 449.1.01 Definitions General Provisions 101 through 150. 449.1.02 Related References

GDT 111 ASTM A 36 ASTM D 395 ASTM D 570 ASTM D 588 ASTM D 624 ASTM D 638 ASTM D 1299 ASTM D 2240 ASTM D 2628 ASTM D 4070 582 582 582 582 582 582 582

449.1.03 Submittals

Furnish working drawings covering the proposed joint installation. Before the joint is installed, the Bridge Engineer will review these drawings and indicate this review on the drawings. The Department is not responsible for the accuracy of the drawings. Assume responsibility for conforming to the specifications and plans. Include these items in the submission: • Manufacturer’s brochure on the proposed joint, showing component physical dimensions, installation procedures, material certifications, and a table of variable temperatures and dimensions • Drawings that detail the joint installation and indicates the length of component members, treatment of directional changes, and field splicing of steel locking rails • Expansion joint fabricator documentation Ensure that the expansion joint fabricator is AISC Category I, shop approved. Supply documentation with the shop drawings.

Furnish the manufacturer of the performed elastomeric neoprene profile seal a working drawing for each installation. This drawing shall include all of the following information: • Identification and orientation of each joint • Length of each joint including a minimum 6 in. (150 mm) turn up at both barrier faces • Total projected movement range of the joint • Use a full-length seal if a full bridge width installation can be made. If traffic conditions require that the joint seal installation be in stages, indicate the splice points In addition to the above, if existing edge beams are to remain as joint headers, furnish the manufacturer of the seal the following: • Joint width measurements taken at 2 ft. (600 mm) intervals along the full length of the joint plus a measurement of the joint width of each barrier in the area of the turn ups • Ambient temperature, taken when width measurements are made Have the manufacturer of the preformed elastomeric neoprene profile seal use this information to determine quantities of materials needed and the profile size or sizes for each joint. Have the manufacturer enter this data on the working drawing and verify that the data is accurate and submit a copy to the Engineer for review. Show an indication of such verification on the drawings. Engineer approval is required before installing the joint seal. The Department review will be considered a service to assist the Contractor. The Department will assume no responsibility for the accuracy of the drawings, and the Contractor will not be relieved of any responsibility for conforming to the specifications and plans.

449.2Materials

Elastomeric concrete material includes two-component elastomer and prebagged fillers. Mix the elastomeric concrete material and use it according to the manufacturer’s recommendations. This may require using heat to accelerate curing and ensure a quality bond to the concrete and steel. Use the Elastomeric Concrete Material with these features: • Compatible with the concrete and steel to which it is bonded • Smooth riding surface across the joint • Can be mixed using normal equipment • Can be mixed and placed between 45 ºF to 100 ºF (7 ºC to 38 ºC) 583 583 583 583 583 583 583

Use a joint sealing system designed for HS 20 truck loading and impact according to AASHTO design parameters. Ensure that the system can accommodate the movements indicated in the Plans.

The preformed elastomeric neoprene profile seal shall as a minimum: • Have the capability to be evacuated of air during installation • Have the capability to be pressurized with air during the adhesive curing time • Be compatible with the epoxy and elastomeric concrete header materials (if required) • Be designed to withstand 50% expansion, 50% contraction (total 100%) • Withstand the effects of vertical and lateral movements, skew movement and rotational movement without adhesive or cohesive failure. Ensure the preformed elastomeric neoprene profile meets the requirements of ASTM D 2628. Ensure the adhesive used with the preformed elastomeric neoprene profile seals is a two-component epoxy based thixotropic paste meeting the seal manufacturer’s requirements.

The low-density, closed cell, cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen-blown seal shall as a minimum be: • Held in place by a two-component, 100% solid, modified epoxy adhesive. • Compatible with the epoxy and header materials. • Preformed, resistant to abrasion, oxidation, oils, gasoline, salt, and other materials that may be spilled on or applied to the surface. • Grooved, with the grooves approximately 1/8 in. (3 mm) wide by 1/8 in. (3 mm) deep and spaced between 1/4 in. to 1/2 in. (6 mm to 13 mm) apart and run along the entire length of the bond surface side of the seal. • Designed so that, when compressed to 50% of original width, the center portion of the top will not extend upward above the original height of the seal by more than 1/4 in. (6 mm). • Recessed below the riding surface throughout the normal limits of joint movement. • Resistant to ultra violet rays. • Beige or gray color. • Shop marked to indicate the top or bottom side of the seal in such a way as to be clearly visible during installation. Ensure the low-density, closed cell, cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen-blown seal has a working range of 30% tension and 60% compression. Ensure the seal meets the following physical properties: Test Requirements Test Method Tensile Strength 50 psi (345 kPa) ASTM D3575 (Suffix T) Elongation at break 255% min. ASTM D3575 (Suffix T) Weather/Deterioration No deterioration for at least 8 years AASHTO T42 (Accelerated Weathering) Compression/Deflection 10 psi (69 kPa) min., 60 psi (414 kPa) max. @ 50% deflection of original width ASTM D3575 (Suffix B) Tear Strength 13 psi (90 kPa) ASTM D624 Density 2.8 to 3.4 pcf (45 to 54 kg/m3) ASTM D545 584 584 584 584 584 584 584

The adhesive used with the low-density, closed cell, cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen-blown seals shall be a two-component, 100% solid, modified epoxy adhesive meeting the requirements of ASTM C881, Type I, Grade 2, Class B & C. The adhesive shall also have the following physical properties: Tensile Strength 3500 psi (24 MPa) min. Compressive Strength 7000 psi (48 MPa) min. Shore D Hardness 75 psi (0.5 MPa) min. Water Absorption 0.25% by weight For applications on moist or hard to dry concrete surfaces, the adhesive shall be as specified by the joint material manufacturer.

Ensure the epoxy concrete material is as a minimum: • Compatible with all allowable joint seal materials, and concrete or steel to which it is bonded. • Capable of providing a smooth riding surface across the joint. • Capable of being mixed using normal equipment. • Capable of being mixed and placed at temperatures of 55 ºF (13 ºC) and above. Use header material that is a two-component rapid curing epoxy with aggregate that cures to a dense semi-flexible, weather, abrasion, and impact-resistant epoxy concrete. Ensure the material has the following physical properties: Test Requirements Test Method Mixed Epoxy without Aggregate: (Before and after oven aging at 158o F (70° C) for 72 hours) Tensile Strength (min.) 900 psi (6.2 MPa) ASTM D 638 Elongation at Break (min.) 40% ASTM D 638 Shore “D” Hardness 45-75 ASTM D2240 Pot Life (max.) 45 minutes GDT 111 Mixed Epoxy with Aggregate: Compressive Strength at 24 hours (min.) 2,500 psi (17.2 MPa) ASTM C-39 (3” cylinders) Resilience at 5% Deflection (min.) 75% GDT 111 Bond Strength to Concrete (min.*) 375 psi (2.6 MPa) GDT 111 Wet Bond Strength to Concrete (min.*) 250 psi (1.7 MPa) GDT 111 Thermal Compatibility No Delamination ASTM C 884 *Minimum psi or concrete failure. 585 585 585 585 585 585 585

Have the manufacturer furnish the aggregate used in epoxy concrete. Use well-graded, clean and dry aggregate meeting the following gradation requirement: Size Percent Passing by Weight No. 4 Sieve 100 No. 80 Sieve 0-5 Note: Test according to AASHTO T 27.

Ensure the elastomeric concrete material is as a minimum: • Compatible with all allowable joint seal materials and concrete or steel to which it is bonded. • Provides a smooth riding surface across the joint. • Capable of being mixed using normal equipment. • Capable of being mixed and placed between 45 ºF and 100 ºF (7 ºC and 38 ºC).

Ensure elastomeric concrete cured binder material (without filler) has the following physical properties: Test Requirements Test Method Before oven aging: Tensile strength (min.) 750 psi (5.2 MPa) ASTM D 638 Elongation at break 200 – 350% ASTM D 638 Hardness Type D durometer 38, ± 8 ASTM D 2240 Compression set, 22 hrs at (max.) 158° F (70° C ) 50% ASTM D 395 Method B Tear resistance (min.) 150 lbs./in. (2.7 kg/mm) ASTM D 624—2 in./min (50 mm/min) Water absorption (max.) 1.2% ASTM D 570 Heat shrinkage (max.) 1.6% ASTM D 1299 Impact strength (min.) 7 ft..-lbs../min. (9.5 N ·m) GDT 111 Properties after oven aging at 158° F (70° C) for 72 hrs.: Tensile strength (min.) 750 psi (5.2 MPa) ASTM D 638 Elongation at break 150 – 350% ASTM D 638 Hardness Type D durometer 42, ± 5 ASTM D 2240 Impact strength (min.) 7 ft.-lbs./min. (9.5 N ·m) GDT 111 586 586 586 586 586 586 586

Ensure that the elastomeric concrete binder material (with filler) has the following physical requirements: Test Requirements Test Method Resilience at 5% deflection (min.) 80% GDT 111 Bond strength to concrete (min.*) 375 psi (2.6 MPa) GDT 111 Wet bond strength to concrete (min.*) 250 psi (1.7 MPa) GDT 111 Pot life (min.) 5 minutes GDT 111 *Minimum psi (MPa) or concrete failure

Use temporary joint filler when epoxy concrete material is used. The temporary joint filler shall be an extruded rigid cellular polystyrene with enough compressive strength to maintain the correct joint width and to obtain relatively smooth and straight faces upon removal of the material. 449.2.01 Delivery, Storage, and Handling General Provisions 101 through 150.

449.3Construction Requirements

449.3.01 Personnel General Provisions 101 through 150. 449.3.02 Equipment General Provisions 101 through 150.

449.3.03 Preparation

Ensure that the compressed air used to sandblast and/or blow debris is free of moisture and oil. Use air

compressors for cleaning joints that are equipped with suitable traps capable of removing surplus water and oil

in the compressed air. Check the compressed air daily for contamination. Do not use contaminated air. Use a

compressor that can deliver compressed air at a continuous pressure of at least 90 psi (620 kPa).

Remove loose, eroded, and unsound concrete from the surface within the joint area. Provide horizontal

bonding areas by cutting all angular areas of concrete blockouts. Immediately before placing the epoxy or

elastomeric concrete, sandblast the concrete surfaces or abrade free of oil, dust, dirt, traces of asphaltic

concrete, or other contaminants.

Remove loose, eroded, and unsound concrete from the surface within the joint area. Immediately before

placing the seal, sandblast the concrete surfaces or abrade free of oil, dust, dirt, traces of asphaltic concrete,

or other contaminants. Saw-cutting of the concrete deck maybe necessary to provide an acceptable

attachment surface for the joint seal. 587587587587587587587

449.3.04 Fabrication

Have the joint fabricated full width of the bridge deck, except in stage construction (one lane at a time) or when

joint length prohibits shipment.

449.3.05 Construction

Use an installer trained by the manufacturer to install the bridge deck joint sealing system. A manufacturer’s

representative shall be present during the installation of the epoxy or elastomeric concrete headers. Install the joint

system according to the manufacturer’s recommendations and the following:

Blockouts shall be according to the Plan details.

Do not perform any part of the installation in rainy weather or when rain is expected within one hour of installation.

Ensure the surface is completely dry before applying adhesive or primer.

The ambient temperature must not be less than 55 ºF (13 ºC) during installation of the epoxy concrete material and

preformed elastomeric neoprene profile seal.

Ensure the ambient temperature is between 45 ºF (7 ºC) and 100 ºF (38 ºC) while installing the elastomeric

concrete material.

Ensure the ambient and surface temperatures are between 45 ºF (7 ºC) and 75 ºF (24 ºC) while installing the

low-density, closed cell, cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen blown seal.

Handle, place, finish, and cure elastomeric concrete joint systems according to the manufacturer’s instructions

and the following:

Mix and place the epoxy mortar according to the manufacturer’s recommendations and the following:

plus hardener in the required proportions) with three volumes of aggregate meeting the requirements of

this specification.

the epoxy concrete.

588588588588588588588

The cure time of epoxy mortar is directly related to temperature. Use the following table as a general guideline for

cure time at various temperatures.

Air and Deck Temperature o

F ( o

C) Approximate Cure Time (hours)

40 (4) 5

50(10) 4

60(16) 3

70(21) 2.5

80(27) 1.5

90(32) 1

100(38) 0.75

Postpone the installation process if the ambient temperature is not 55 ºF (13 ºC) and rising. If you cannot

postpone the operation, use supplemental heat to complete the operation and reopen the lane in a reasonable

time. If using supplemental heat, ensure that the cure has progressed throughout the mass of the header.

Handle, place, finish, and cure the elastomeric concrete material according to the manufacturer’s instructions.

Allow the elastomeric concrete to cool and solidify for at least one hour before opening to traffic.

temporary joint filler (when called for) and thoroughly clean the joint faces of all joint filler.

below the riding surface.

Application

remove the temporary joint filler (when called for) and thoroughly clean the joint faces of all joint filler.

iron of 350 °F (177 °C) for 7-10 seconds and pressing the ends together tightly.

pushing it down into the joint opening until it has recessed approximately 1/4 in. (6 mm) below the deck

surface. Do not push the joint seal material into the joint at an angle that will stretch the seal material.

to clean the top surface of the joint seal material 589589589589589589589

Do not permit traffic to drive over sealed joints until the epoxy or elastomeric concrete has hardened enough to

resist displacement of the seal due to deck movement or other causes. Allow the elastomeric concrete to cool and

solidify for at least one hour before opening to traffic. Allow the epoxy concrete to cure for at least two hours

before opening to traffic.

449.3.06 Quality Acceptance

Provide evidence from the manufacture that the joint system has been used successfully in installations

with similar environmental and project conditions. Failure to perform adequately in actual use shall be cause

for rejection.

At the Contractor’s expense, repair, or remove and replace, joint seals that are complete and have leaks, have

adhesive or cohesive failure, or that are damaged during construction or by traffic before final acceptance.

449.3.07 Contractor Warranty and Maintenance

To comply with Subsection 106.05, Materials Certification, provide certification from the manufacturer that shows that

the bridge deck joint sealing system materials conform to the requirements stated in Subsection 449.2. Transfer to the

Department the manufacturer’s standard five-year performance warranty on each installation. A warranty claim may be

filed for cohesive or adhesive failure of the materials supplied or material failure due to weathering.

449.4Measurement

When listed as a pay item in the Proposal, bridge deck joint seal will be measured and paid for at the Contract price

linear foot (meter) complete in-place joint at the location specified on the Plans. Payment is full compensation for the

removal of any old sealant, cleaning the joint, and furnishing and installing the new seal and header if required and

all incidentals.

No separate measurement and payment will be made unless a pay item for the work is included in the Proposal. If no

pay item is included in the proposal, the cost of the joint seal shall be included in the overall bid price submitted.

No separate measurement or payment will be made for any saw-cutting required to install the joint.

449.4.01 Limits

General Provisions 101 through 150. 590590590590590590590

449.5Payment

When shown in the schedule of Items in the Proposal, the following items will be paid for separately:

Item No. 449 Performed Elastomeric Neoprene Profile Joint Seal with Epoxy Concrete

Headers Bridge No.______Bent No._____

Per linear foot (meter)

Item No. 449 Performed Elastomeric Neoprene Profile Joint Seal with Elastomeric

Concrete Headers Bridge No.______Bent No._____

Per linear foot (meter)

Item No. 449 Low-Density, Closed Cell, Cross-linked, Ethylene Vinyl Acetate,

Polyethylene Copolymer, Nitrogen-Blown Seal with Epoxy Concrete

Headers Bridge No.______Bent No._____

Per linear foot (meter)

Item No. 449 Low-Density, Closed Cell, Cross-linked, Ethylene Vinyl Acetate,

Polyethylene Copolymer, Nitrogen-Blown Seal with Elastomeric Concrete

Headers Bridge No.______Bent No._____

Per linear foot (meter)

Item No. 449 Low-Density, Closed Cell, Cross-linked, Ethylene Vinyl Acetate,

Polyethylene Copolymer, Nitrogen-Blown Seal Bridge No.______Bent

No._____

Per linear foot (meter)

Item No. 449 Elastomeric Profile Bridge Joint Seals, Bridge No.______Bent No._____ Per linear foot (meter)

449.5.01 Adjustments

General Provisions 101 through 150.. 591 591 591 591 591 591 591