129460 — Expansion Joints in Structures

460.01 Description

Furnish, fabricate and install pourable joint seals, joint fillers, preformed joint seals, structural steel components, metal plates, bridge roadway finger joints including structural steel components, and foam seals to be utilized in providing expansion and contraction capabilities in structures. Furnish, fabricate, and install drainage troughs, catch basins, and downspouts and appurtenances. This work also includes the replacement of joint seals and the repair or modification of existing joints. Refer to Sections 435 and 436 for painting requirements.

460.02 Materials

460.02.01 Pourable Joint Sealant.

Pourable Silicone Sealant for Structures 911.01.03 Non-Sag Silicone Sealant for Vertical Joints in Structures 911.01.06 Use a backer rod that is made of closed cell polyethylene foam. Ensure the backer rod used is flexible, compressible and non-shrinking with a surface that will not bond with the joint seal, and that is capable of uniformly containing the sealer within the desired shape factor. Do not use hard rubber or materials that swell when wet or deform at seal application temperatures.

460.02.02 Preformed Joint Seals.

Preformed Silicone Joint Seal 911.01.04 Silicone Adhesive 911.01.05 Preformed Joint Filler 911.02 Performed Polychloroprene Elastomeric Compression Seal 911.04.02 Lubricant Adhesive 911.04.03 Use a joint seal primer conforming to the manufacturer’s recommendations. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS

460.02.04 Drainage Troughs.

Structural Steel 909, A 709, Grade 36 or Grade 50 Drainage Trough 911.11 Fiberglass Catch Basins 921.10 Polyvinyl Chloride Downspouts 905.01, Schedule 80 Non-Shrink Grout 902.11(c) All structural steel for drainage troughs shall be hot-dip galvanized to meet A123. All hardware for drainage troughs shall be stainless steel meeting F593, Type 304 with stainless steel nuts meeting F594 and SS304 washers. Ensure that drainage trough fabric meets the thickness requirements for the type of material supplied. Place joints and splices for drainage troughs only where specified.

460.02.05 Paint. Refer to 435.01.01(c), 435.02.01, and 436.01.01(e). Unless otherwise specified,

finish coat on all exposed steel portions shall match AMS-STD-595A, Color No. 26440. 460.02.06 Concrete Repair Materials. Refer to Section 423. 460.02.07 Finger Joints. Anchor Studs High Strength Bolts Traffic Plates, Support Plates and Angles, and Parapet Plates Closed Cell Foam Joint Seal Adhesive 909.05 F3125, Grade A325, Type 1 A 709, Grade 36 or 50 with supplementary toughness requirements per M-270, Zone 2 for Traffic Plates

911.13 01

911.13 02

Use a foam seal capable of handling 50 percent compression, 25 percent tension, 200 percent elongation. Ensure the preformed joint material be the size shown on the Plans within a tolerance of plus 10 percent to minus 3 percent. Use a foam seal capable of sealing the deck surface and curbs through the total range of joint movement as shown on the Plans. Install the joint seal in one continuous length for each joint to be sealed unless otherwise specified. Use the heat welding method to make splices in joint seal material in accordance with the manufacturer’s recommendations at direction changes such as vertical placement at the intersection of the deck and parapet or at the limits of staged construction. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS

460.03 Construction

Store expansion joint materials delivered to the bridge site under cover, on platforms at least 4 inches above all types of surfaces and vegetation. Protect materials from damage and keep clean of dirt, oil, grease and other foreign substances. All materials and standard installation methods from catalog cuts shall be approved by the Engineer before any materials may be ordered or fabricated. Meet AWS D1.1 or D1.5 for all welding, unless otherwise specified. 460.03.01 Preconstruction Meeting. A preconstruction meeting shall be conducted prior to beginning work on the replacement of joint seals in existing bridges. The meeting shall be attended by a minimum of the Contractor’s installation crew, a manufacturer’s representative knowledgeable in field installation of the product(s) specified, and the Engineer. Topics discussed shall include surface preparation, primers, temperature restrictions, pot life, cure time, access, maintenance of traffic, tools, equipment and installation techniques.

460.03.02 Joint Modification. Where the Contract Documents specify modification or repair of

existing expansion joints in bridges on which traffic must be maintained, secure a supply of steel roadway plates available at least 4 ft x 8 ft and 1 in. thick to be placed over the joints if traffic must be restored before new concrete has cured or anytime work cannot be completed within one traffic closure period. Remove concrete as specified in Section 423. Cut all existing steel armor with a saw and drill all holes and slots. Torch cutting is not permitted. Thoroughly clean existing drainage troughs and remove all debris. 460.03.03 Surface Preparation. Remove the existing seal materials and debris, if applicable, and clean both sides of the joint opening as specified below:

460.03.04 Joint Seal Primer. Apply VOC compliant joint seal primer in accordance with the

manufacturer’s recommendations. Uniformly coat the entire surface to which joint seal materials will be affixed. Over application may cause premature failure of joint seal materials.

460.03.05 Pourable Silicon Joint Sealant Installation. Unless otherwise specified, do not use

pourable joints when the expected movement due to thermal expansion from 0 F to 120 F is more than 1/2 inch. For horizontal applications, furnish the two components of pourable joint sealant material from the manufacturer in premeasured units. Use only full units of each component for mixing the pourable joint sealant. For vertical applications, furnish the non-sag pourable joint sealant material from the manufacturer. The manufacturer’s technical representative must be present during the initial installation of pourable joint sealant. Provide equipment approved by the seal manufacturer’s representative. Install a circular backer rod, sized approximately 25 percent larger than the joint opening, into the joint opening to provide 1 in. clearance below the roadway surface. If two pieces of backer rod must be used, tape the ends together to prevent any pourable joint sealant from leaking between them. Install silicone sealant as soon after cleaning and backer rod placement as reasonably possible to ensure the joints remain clean and dry. In the event the joint becomes contaminated or wet prior to installing the sealant, remove the backer rod, clean and dry the joint, and install a new backer rod. Install pourable joint sealant as per manufacturer’s recommendations and to the shape and dimensions specified as shown on the Plans. If site conditions justify a change to the manufacturer’s recommendations, proceed as directed by the Engineer. Use the multiple pass technique with the initial passes along the joint edges. Make all passes in the same direction to minimize air entrapment. The pourable joint sealant must be recessed a minimum 1/2 in. below the pavement surface to prevent traffic abrasion or snowplow damage. Provide a smooth and even finished surface of the joint seal across the joint opening. When vertical joint openings are to be sealed at curbs, parapets, and outside edges the bottom and outside edges of the joint opening must be dammed to prevent pourable joint sealant from leaking out. Position the damming material so that the installed pourable joint sealant is sandwiched between the backer rod and the damming material. Allow the pourable joint sealant to cure prior to removal of damming material. The damming procedure shall be as recommended by the manufacturer. In lieu of damming, use a non-sag pourable silicone sealant or preformed silicone joint seal at these locations.

460.03.06 Preformed Silicone Joint Seal Installation. Install the preformed Silicone Joint Seal

in accordance with the manufacturer’s recommendations, as shown on the Plans. If site conditions justify a change to the manufacturer’s recommendations, proceed as directed by the Engineer. The manufacturer’s technical representative must be present during the initial installation of the preformed silicone joint seal. Provide equipment approved by the seal manufacturer’s representative. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS Furnish the preformed silicone joint seal material in the longest possible lengths to minimize field splices. Shop splices are prohibited. Use the longest seal pieces as practicable when installing the bridge joints. When field splicing is necessary, obtain the Engineer’s approval of the location and number of splices prior to installing any lengths of the joint. Do not use lengths less than 4 ft long. Make field cuts and splices along straight lines and flush edges. Clean the preformed Silicone Joint Seal immediately prior to installation by wiping with a solvent saturated cloth. Install preformed silicone joint seal in accordance with the manufacturer’s recommendations, to the depth and dimensions shown in the plans, and as directed by the Engineer. Apply a bead of silicone adhesive to each side of the joint opening, position the preformed silicone joint seal in the joint opening and press down to the indicated depth. The preformed silicone joint seal must be recessed a minimum 1/2 in. below the pavement surface to prevent traffic abrasion or snowplow damage. When the preformed silicone joint seal is in position, apply silicone adhesive along each side of the preformed silicone joint seal to the top of the serrations. Tool the silicone adhesive twice to ensure complete contact between the joint opening and the preformed silicone joint seal.

460.03.07 Preformed Polychloroprene Elastomeric Compression Seal Installation. Install

preformed polychloroprene elastomeric (neoprene) compression seals at the locations specified in the Contract Document. The neoprene compression seals shall be sized in accordance with the manufacturer’s recommendations, as shown on the Plans. If site conditions justify a change to the manufacturer’s recommendations, proceed as directed by the Engineer. Furnish the preformed polychloroprene elastomeric (neoprene) compression seal material in the longest possible lengths to minimize field splices. Shop splices are prohibited. Use the longest seal pieces as practicable when installing the bridge joints. When it becomes necessary to field splices, obtain the Engineer’s approval of the location and number of splices prior to installing any lengths of the joint. Do not use lengths less than 4 ft long. Make field cuts and splices along straight lines and flush edges. Splice joint elements using the heat fusion method. Clean the neoprene compression seals prior to installation by wiping with a solvent saturated cloth. Apply lubricant adhesive in accordance with the manufacturer’s recommendations. If the seal is stretched more than 5 percent, remove it and reinstall it with a new segment of joint material.

460.03.08 Finger Joint Installation. Refer to the Plans. Ensure that all surfaces to receive application of the adhesive are completely dry, clean, free of

sharp edges, and free of laitance. Immediately prior to application of the adhesive, blast clean the faces of the steel that will receive the adhesive to meet SSPC-SP 10, Near White. Protect adjacent painted and concrete surfaces from the blasting operations by masking or other appropriate measures. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS Apply the adhesive and the foam joint seal in accordance with the manufacturer’s recommendations and as directed by their technical representative. Use hand operated equipment as recommended by the seal manufacturer for applying the adhesive and installing the foam joint seal. The foam seal manufacturer shall have a technical representative present during surface preparation and installation and furnish a written certification that each was properly installed. Do not use any equipment that will puncture or damage the foam seal material in any manner. Placement of the foam joint seal is prohibited when the surface or ambient temperatures are 35 F or below, or when the temperatures are expected to fall below 35 F at any time during the 12 hour period following the placement. Placement will be permitted if the entire expansion device is heated in an enclosure and maintained to at least 35 F for the installation and the following 12 hour period.

460.03.09 Clean and Paint. Clean and paint steel armor in new and existing roadway joints as

specified in Section 435 and Section 436. 460.03.10 In-Place Testing. When requested by the Engineer, subject completed joints to a water test to detect any leakage. Conduct test at least five days after completing the joint. Provide all facilities required for the Engineer’s inspections of the underdeck areas. Cover the roadway section of the joint from curb to curb, or parapet to parapet, with at least 1 in. of water. If this is not possible, perform the water test in part section along the joint. When testing subsequent part sections, overlap at least 1 ft of the joint previously tested. Maintain the ponding for a period of five hours for the entire roadway or each section of joint being tested. During and at the conclusion of the test, examine the underside of the joint for leakage. The expansion joint seal will be considered watertight if no obvious wetness is visible. If the joint system exhibits evidence of water leakage at any point, locate and repair any leaks. When repairs are required, perform a subsequent water test. If the joint leaks after the second test, replace and retest the seal.

460.03.11 Joint Seal Warranty. Any failure of joint seals due to lack of adhesion, improper or

unsatisfactory workmanship by the Contractor, or damage by the Contractor’s operations will be cause for rejection, and the joint seal shall be repaired to the satisfaction of the Engineer at no additional cost to the Administration.

460.03.12 Drainage Troughs, Catch Basins, and Downspouts. Furnish and install new drainage

troughs, catch basins and downspouts at the locations shown on the plans, as specified in the Contract Documents or as directed by the Engineer. When specified in the Contract Documents, or directed by the Engineer, damaged portions of existing drainage troughs, catch basins and downspouts shall be removed and replaced to the limits specified. This work shall include unfastening trough fabric, cleaning and disposing of debris from the existing drainage troughs, catch basins and downspouts. Also, replace any damaged or 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS corroded hardware as needed to reattach drainage troughs, catch basins and downspouts as required. Slope drainage troughs at 1 minimum under finger joints, and 1/4 in./ft minimum under all other roadway joints. Repair deteriorated concrete end diaphragms as specified in Section 423. Set threaded rods for hangers in cored holes at least 4 in. deep and 1/2 in. larger than the diameter of the hanger using non-shrink grout. Repair areas of the existing coatings damaged during drainage trough installation as specified in

436.03 25.

460.04 Measurement and Payment

The payment will be full compensation for furnishing, fabricating, placing, cleaning, and painting all joint materials including the structural steel, roadway seals, backer rods, adhesive, closed cell foam joint seals for finger joints, drainage troughs, catch basins, downspouts, hangers, and all hardware. Payment will also include the preconstruction meeting, arrangements to have all manufacturer’s representatives on the project site, temporary roadway plates, testing, and all material, labor, equipment, tools, and incidentals necessary to complete the work.

460.04.01 Unless otherwise noted and no other pertinent items appear in the contract documents,

joints including finger joints, drainage troughs, catch basins, and downspouts in structures will not be measured but the cost will be incidental to the pertinent Superstructure Concrete item.

460.04.02 Modifying or repairing existing roadway joints, to include finger joint repairs, will be

measured and paid for at the Contract unit price per linear foot for the pertinent Joint Modification item. In addition to the first paragraph in 460.04, payment will be full compensation for modifying or repairing the existing joint openings in bridges including saw cutting, removal of existing steel and seal material, cutting, drilling, welding, and otherwise modifying existing steel, and furnishing and installing replacement anchor studs or rivets. The measurement for modified transverse joints will be the horizontal distance along the roadway joint from the inside face to inside face of parapets plus the vertical distance of the curb faces and parapets.

460.04.03 Pourable joint sealant will be measured and paid for at the Contract unit price per linear

foot for the pertinent Pourable Joint Sealant item, for replacement seal items of work. In addition to the first paragraph in 460.04, payment will be full compensation for the removal of existing seal materials, cleaning the existing joint surfaces, surface preparation, primer, furnishing and placing new pourable silicone joint seals, damming, and coating repair. The measurement for pourable transverse joints will be the horizontal distance along the roadway joint from the inside face to inside face of parapets plus the vertical distance of the curb faces and parapets.

460.04.04 Preformed silicone joint seal will be measured and paid for at the Contract unit price

per linear foot for the pertinent Preformed Silicone Joint Seal item, for replacement seal items of work. In addition to the first paragraph in 460.04, payment will be full compensation for the removal of existing seal materials, cleaning the existing joint surfaces, surface preparation, primer, furnishing and installing new preformed silicone joint seal, and coating repair. The measurement for preformed silicone transverse joints will be the horizontal distance along the roadway joint from the inside face to inside face of parapets plus the vertical distance of the curb faces and parapets.

460.04.05 Preformed polychloroprene elastomeric (neoprene) compression seals will be measured

and paid for at the Contract unit price per linear foot for the pertinent Neoprene Compression Seal item, for replacement seal items of work. In addition to the first paragraph in 460.04, payment will be full compensation for the removal of existing seal materials, cleaning the existing joint surfaces, surface preparation, lubricant adhesive, furnishing and installing new neoprene compression seal and coating repair. The measurement for preformed polychloroprene elastomeric transverse seals will be the horizontal distance along the roadway joint from the inside face to inside face of parapets plus the vertical distance of the curb faces and parapets.

460.04.06 When an item for Drainage Trough for Bridge appears in the Contract, installation of

new drainage troughs will be measured and paid for at the Contract unit price per linear foot for the pertinent Drainage Trough Item. Payment will be full compensation for removing existing drainage troughs including fabric, structural steel, hardware, hangers, catch basins, and downspouts; capping the bottom of the existing downspout pipes in pier columns and filling existing trough drain holes in piers with non-shrink grout. The payment will also include fabricating, furnishing and installing new drainage troughs including galvanized structural steel, stainless steel hardware, fabric, PVC downspouts, catch basins, welding, drilling and coring holes in existing steel and concrete, and attaching to existing structure. The measurement of drainage trough will be the centerline distance from end to end of the installed drainage trough fabric.

460.04.07 Repair of existing drainage troughs will be measured and paid for at the Contract unit

price per linear foot for the pertinent Drainage Trough Repair item. Payment will be full compensation for removing portions of existing drainage troughs including fabric, structural steel, hardware, hangers, catch basins, and downspouts. The payment will also include fabricating, furnishing and installing portions of new drainage trough including galvanized structural steel, stainless steel hardware, fabric, PVC downspouts, catch basins, welding, drilling and coring holes in existing steel and concrete, and attaching to existing structure. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS The measurement of repairs will be the centerline distance from end to end of the installed drainage trough fabric.

460.04.08 When a Testing Expansion Joints in Structures item is included in the Contract

Documents, it will be measured and paid per each joint included in a successful test. The payment will include furnishing and applying all water, providing full access to all areas tested, and all material, labor, equipment, tools, and incidentals necessary to complete the work. There will be no payment for a tested joint that failed its test.

460.04.09 Repair of deteriorated concrete in abutments, piers, and deck end diaphragms will be

measured and paid as specified in 423.04. 461 — METAL RAILING CATEGORY 400 STRUCTURES SECTION 461 — METAL RAILING

461.01 Description

Furnish, fabricate, coat, and install metal or polyester coated steel railings.

461.02 Materials

Refer to Contract Documents. Square Structural Tubing for Rail Elements 909, A500, Grade B, or A618 or A501 Steel Posts and Plates 909, A36 Anchor bolts 909.08 Fusion Bonded Polyester Powder Coating 917.03, Color shall match AMS-STD - 595A, Color No. 20040 or as specified Hot Dip Galvanized Zinc A123, A153 Galvanizing Repair 465.03.05(c)

461.02.01 Structural Steel. Grind all welds of the railing system smooth, and remove all weld

spatter. Ensure that all components are free of oil and any mill coating, burrs, pits, rust, or other foreign matter or surface blemishes. Galvanize all structural steel including fasteners and anchor bolts. Oversize the threads of the nuts according to A563. When specified, after fabrication and galvanizing, coat all structural steel for the railing with the polyester coating system as specified in 465.03.01 and 465.03.02, except as noted. Completely fabricate each component of the railing system including drilling of all holes prior to galvanizing and/or applying the polyester coating system.

461.02.02 Bolts, Nuts, and Washers. When specified, coat bolts, nuts, and washers with the

polyester coating system. Tap the nuts with oversize threads according to A563. The coating manufacturer shall ensure that the polyester coated bolts, nuts, and washers fit together without damaging their respective coatings. 2025 STANDARD SPECIFICATIONS FOR CONSTRUCTION AND MATERIALS