2473Expansion Joint Devices

2473.1DESCRIPTION

This Work consists of providing and installing a watertight expansion joint device consisting of a preformed non-reinforced strip seal that is mechanically locked into a structural steel rail anchored into a Bridge or other Structure.

2473.2MATERIALS

A Single Joint Device Provide a watertight expansion joint device for movement up to 4 inches. A.1 Joint Seal Furnish a single diaphragm unreinforced neoprene gland whose physical and chemical properties conform to ASTM D5973, Standard Specification for Elastomeric Strip Seals with Steel Locking Edge Rails Used in Expansion Joint Sealing. Department Special Requirements:

certified test results from the manufacturer attesting to the physical and chemical properties of the expansion joint devices in accordance with 1603, “Materials: Specifications, Samples, Tests, and Acceptance”

Laboratory for the Engineer including the lot number of the seal provided A.2 Steel Extrusion Provide only one of the devices shown on the APL, Bridge, “Expansion Joint System.” The Fabricator will install a filler Material in the seal groove in the steel rail which will prevent any unwanted Material from entering. A.3 Lubricant-Adhesive Provide only one of the approved lubricant adhesives shown on the APL , Bridge, “Expansion Joint Lubricant Adhesive.”

A.4 Cover Plates Provide expansion joint cover plates on pedestrian Bridges and Sidewalk areas that are raised pattern plate. B Modular Bridge Joint Systems Provide a watertight expansion joint device for movement greater than 4 inches. Provide only one of the devices shown on the APL, Bridge, “Modular Bridge Joint System.” For products not on the Department's prequalified list, provide information as required on the website so it can be evaluated and potentially qualified.

2473.3CONSTRUCTION REQUIREMENTS

A General Perform the Work in accordance with the applicable requirements of 1703, “Patented Devices, Materials, and Processes,” 2401, “Concrete Bridge Construction, “ 2402, “Steel Bridge Construction,” 2471, “Structural Metals,” the Plans, and the following: The Department will invoke its Corrective Action Process if the routine inspections or audits indicate non-conformance. Corrective actions deemed appropriate by the Engineer, are effective immediately and apply to any work remaining on a current project a nd all future projects. If the Engineer determines that work does not comply with the QM or that fabrication does not follow approved fabrication procedures, the Engineer will deem the materials as non -conforming in accordance with 1503, “Conformity with Contract Documents,” and 1512, “Unacceptable and Unauthorized Work.” If the Engineer finds non-conforming work, direct the Supplier to immediately correct the procedure and submit a written non-conformance report, containing data required by the Engineer to ensure compliance with the QM, specifications, and drawings. Perform additional testing as required by the Engineer at no additional cost to the Department. For repeat offences or negligence, the Department will require corrective action of hiring a third party Quality Control Inspector at no additional cost to the Department. A copy of the Department’s Corrective Action Process may be obtained from the Engineer. B Single Joint Device B.1 Joint Seal Extend seals beyond the ends of the edge and center beams by at least 2 inches. Remove filler Material and clean joint seal to steel contact areas of dirt, oil, grease, or other contaminants before installing the seal. Lightly sandblast the contact areas so as to roughen but not damage the galvanized surface just before applying the lubricant-adhesive. Apply lubricant-adhesive on both seal and galvanized steel contact areas when installing the seal. Install the seal only with tools recommended by the manufacturer. B.2 Field Welding A certified welder will be permitted to weld galvanized sections of expansion device steel rail at the crown breaks if the following is met:

welding must be done by an individual certified in accordance with AWS D1.1 using an approved weld procedure for the application

require inclusion of additional anchorages

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gland seal groove

encasing in concrete. Repair the welded surface as per 3394, “Galvanized Structural Shapes” B.3 Steel Extrusion Provide only one of the devices shown on the APL, Bridge, “Expansion Joint System.” B.4 Lubricant-Adhesive Apply as recommended by the manufacturer. C Modular Bridge Joint Systems (MBJS) Install the MBJS in a manor acceptable to the manufacturer and the Engineer. C.1 Submittals Furnish Certificates of Compliance to: Structural Metals Engineer MnDOT Bridge Office 3485 Hadley Ave. N. Oakdale, MN 55128-3307 C.1.a Material Certifications, Calculations, Installation and Maintenance Plan, and Acceptance Include the following information in the Certificates of Compliance submittal: Certification that the control springs are produced by the same manufacturer with the same process and in the same configuration as those used in the Opening Movement and Vibration (OMV) Test. Certification that the same lubricant -adhesive used for the Seal Push Out Test was also used to assemble the MBJS. Include the manufacturer’s name and contact information as well as production date and lot identifiers. Certification that MBJS sub-assemblies with similar center beam and support bar cross-sections and joints have passed pre-qualification testing requirements described in this Specification. Design calculations sealed by a Professional Engineer licensed in Minnesota. Method of installation including, but not limited to, sequence, installation gap setting for various temperatures, support during placement of the concrete, and installation at curbs. Any required changes to the blockout reinforcement in order to accommodate the MBJS. A temporary bridging Plan for any MBJS for which construction and public traffic is anticipated following installation.

Submit a 12 inch section of elastomeric seal Material from each lot of Material furnished, and samples of the PTFE sheet, size 2 inches by 3 inches by 1/8 inch from the production Material to the Engineer for testing, if requested in writing. A written maintenance and part replacement plan prepared by the MBJS manufacturer, including a list of parts and instructions for maintenance inspection, acceptable wear tolerances, methods for determining wear, and procedures for replacing worn parts. C.1.b Shop Drawings Submit shop drawings for the MBJS in accordance with the requirements of 2473.3C.1.b, “Shop Drawings,” and include, but not limited to, the following additional items: Plans and section views of the MBJS for each movement rating and Roadway width showing dimensions and tolerances. Show welded center beam-to-support bar joints. Show welded shop splices and welded field splices. Complete details of components and sections showing Material incorporated into the MBJS. All appropriate Material designations (MnDOT, ASTM, AASHTO etc.). Corrosion protection system. Lifting locations and lifting mechanisms for installation. Opening adjustment devices for temperature variations and opening dimensions relative to temperature. C.2 Fabrication Requirements The same manufacturer is required to fabricate all MBJS components. Hot-dip galvanize all structural steel surfaces, except those made of stainless steel, after fabrication per 3394, “Galvanized Structural Shapes.” Weld stainless steel sheet at each end to the steel substrate with an accepted welding procedure. Clamp down the stainless steel sheet to have full contact with the substrate during welding. Do not allow welds to protrude beyond the sliding surface of the stainless steel. Intermittent fillet welds are not allowed. Ensure tops of the edge and center beams are in the same plane with a maximum tolerance of 1/8 inch difference in elevation among the tops of the center beams or edge beams. Ensure the support box flatness at bearing and compression spring locations is not out of flat in excess of 1/32 inch. Ultrasonically inspect the full-penetration weld that connects the center beam to the support bar in accordance with 2471, “Structural Metals,” and AWS D1.1, Structural Welding - Steel. Test 25 percent of the center beam-to-support bar welds, or as directed otherwise by the Engineer. If ultrasonic inspection reveals a rejectable weld defect, the Fabricator shall then ultrasonically inspect an additional 25 percent of the center beam-to-support bar welds

(25 percent of the original total of welds). If a rejectable defect is found in the second 25 percent set of welds (50 percent of total), all remaining non-inspected welds shall then be inspected. Repair each weld that is rejected by ultrasonic inspection using a welding proce dure approved by the Engineer. Retest the repaired welds by ultrasonic inspection in accordance with the original requirements. CJP welds will be tested to cyclically loaded criteria. The Fabricator will be permitted to shop-weld galvanized sections of the edge and center beams if the following requirements are met:

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seal groove. Completely remove galvanizing from the weld area. Grind smooth the weld across the top of the beams. Repair areas of galvanizing damaged by welding operations in accordance with 2471.3L.1, “Galvanizing”

galvanizing. Provide an anchorage within 9 inches of each end of each pre-galvanized section If field splices will be used, stagger the ends of the edge and center beams so that they are not at the same point on each beam. Assemble each MBJS at the fabrication shop. Install elastomeric seals at the shop. Use continuous seals for the full length of each MBJS. Apply lubricant adhesive to elastomer-to-steel contact areas for seal installation. When a staged longitudinal joint is required in the Plan fabricate each MBJS for shipment in separate sections sized in accordance with the slab construction joints required for the construction stages as shown in the Plans. Installation of elastomeric seals is not required during fabrication since they must be continuous without splices for the full length of the device. Ship elastomeric seals as directed by the Engineer. C.3 Lifting and Preset Opening Devices Provide lifting devices for the MBJS. Provide other devices to maintain the preset openings at a uniform spacing not greater than 15 feet along its length. Use at least 3 such devices per fabricated segment. C.4 Joint Seal Extend seals beyond the ends of the edge and center beams by at least 2 inches. C.5 Field Splice Welds in Edge and Center Beams Fabricate and ship each MBJS to the Project Site as a single unit unless any of the following conditions apply:

shipping impractical

Only field splice details that have been designed in accordance with AASHTO LRFD Bridge Design Specifications can be used for the MBJS. Locate splices away from wheel tracks and

in areas of least live load stress. Edge beams may be field-welded with fillet welds covering only part of the beam profile. Ensure center beam splices are welded connections. The span – between support beams – in which the field splices are located, cannot exceed the maximum length of 3 feet. If the MBJS contains only a single center beam, a complete joint penetration (CJP) field weld will be used. Design the MBJS, taking into account any different installation procedures required under conditions that require field splices. Clearly indicate such procedures on the shop drawings. C.6 Field Installation Requirements To aid in assuring proper installation of the MBJS, the manufacturer shall furnish technical assistance to the Contractor and Engineer through a technical representative who is a full-time employee of the manufacturer. The representative shall be accessible to the Engineer and at the site during the Work that involves the setting of all parts of each device. Inform the representative of the date of installation. Immediately prior to installation, the Engineer will inspect the MBJS and the blockout for:

kinks, disconnected seals, and other deficiencies, per the judgment of the Engineer, before installation at no expense to the Department. Perform an audio hammer test on the welded stud anchors. Replace studs that do not emit a ringing sound when struck lightly with a hammer as ordered by the Engineer. Maintain the clearance shown in the Plans and/or shop drawings between the bottoms of the support boxes and the tops of the beams. Reposition reinforcement bars that are cast into the deck and abutment, if possible, in lieu of cutting to provide a minimum of 2 inches of clearance to the support boxes, anchorage devices, and edge beams. Also, maintain a minimum of 2 inches of clearance for reinforcement bars placed during installation of the MBJS. Alter bar spacing shown in the P lans to clear the MBJS. If welded field splices are used for the edge and center beams, prevent weld metal from entering the seal retainer grooves. Install each MBJS at the joint opening given on the shop drawings for a specific ambient temperature, or as adjusted by the manufacturer's installation technician for the tempe rature at time of installation. Ensure tops of the edge and center beams are in the same plane with a maximum tolerance of 1/8 inch difference in elevation among the tops of the center beams or edge beams. Measure this variation vertically from a straight line connecting the top of the deck profile on each side of the MBJS. Ensure there is no more than 1/2 inch longitudinal difference among gap widths at either end of a seal or among multiple gaps. Ensure formwork for the blockout concrete prevents entry of concrete into the support boxes, and do not allow concrete to impede free movement of the MBJS.

Fully support the MBJS during placement of the concrete in the blockout. Grout pads under the support boxes are not recommended, but if used, shall terminate beyond the sides of the support boxes. Do not pour concrete until the MBJS installation and joint opening(s) – at the time of the pour – have been inspected and accepted by the Engineer in writing. If there is a vertical grade on the Bridge, place concrete on the down-grade side of the block out first. Thoroughly vibrate the concrete so as to adequately consolidate the concrete underneath the support boxes and against the backside of the edge beams. Construction loads will not be allowed on the MBJS for at least 72 hours after installation, including concreting, is complete. If necessary to cross the joint during that 72-hour period, bridge over the MBJS in a manner approved by the Engineer. Ensure the complete MBJS installation is watertight at all points and test it by filling the joint opening or portions thereof, as designated by the Engineer, with water and observe the results over a period of not less than one hour.

2473.4METHOD OF MEASUREMENT

A Expansion Joint Devices The Engineer will measure Expansion joint devices of each type by length based on the horizontal distance between the outside edges of the deck measured along the centerline of the joint. B Modular Bridge Joint System The Engineer will measure Modular Bridge joint system of each type by length based on the horizontal distance between the outside edges of the deck measured along the centerline of the joint.

2473.5BASIS OF PAYMENT

The Contract Unit Price for Expansion joint devices Type ___ includes the cost of providing and installing the devices complete in-place, including curb, Sidewalk, median, barrier sections, cover plates, and waterproof glands. The Contract Unit Price for Modular Bridge joint system, Type ___ includes the cost of providing and installing the devices complete in-place, including curb, Sidewalk, median, barrier sections, cover plates, and waterproof glands. The Department will pay for Expansion joint devices on the basis of the following schedule: Item No. Item Unit

2473.503 Expansion Joint Devices Type _____ linear foot

3 Modular Bridge Joint System Type ___ linear foot