561PREFABRICATED EXPANSION JOINT

New Hampshire Department of Transportation Standard Specifications – 2016 Description

1.1This work shall consist of fabricating, furnishing and installing a watertight prefabricated expansion joint system utilizing

one of the following: (a) single preformed elastomeric strip seal with steel locking extrusions (edge rails), (b) single preformed elastomeric strip seal with steel locking extrusions (edge rails) and plow plates, (c) prefabricated finger joint, (d) modular bridge joint system (MBJS) in accordance with the contract plans, specifications and the manufacture’s recommendations. Materials

2.1Preformed Elastomeric Strip Seal Expansion Joint System. The single preformed elastomeric strip seal joint systems

with steel locking extrusions (edge rails) shall conform to the requirements of ASTM D5973, meet the configuration as shown on the plans, and be a product as included on the Qualified Products List. Each seal shall be furnished full length. Splices in the length of an individual seal will not be permitted unless the splices are made at the plant by the manufacturer of the seal with the approval of the Department. The seal material shall be identified with the production date, manufacturer’s name or trademark, and lot number. 2.1.1 Steel members. Steel members for the preformed elastomeric strip seal expansion joint system and plow plates sha ll conform to specifications ASTM A 572 Grade 50. Minor steel plates and extrusions may conform to specifications ASTM A 36. 2.1.1.1 Studs shall meet the requirements of AASHTO M 169 (ASTM A 108). 2.1.1.2 All steel members shall be galvanized confo rming to 550.2.9 and Section 708 - Appendix A, 3.2.3, 3.2.4 and 3.2.5. If distortion becomes an issue, an approved zinc rich coating shall be used as approved by the Engineer. 2.1.1.3 Anchorage of the preformed elastomeric strip seal expansion joint to the backwall and deck, between the curb lines, shall be made using a loop rebar attached to a joint support plate and shall be spaced at 1’ -0” maximum, as shown on the plans. Brush curb and sidewalk anchorage shall be made of stud anchors and shall be spaced at 1’ -6” maximum, as shown on the plans. The anchorage reinforcement shall extend into the backwall or curb reinforcement cage for proper anchorage. 2.1.2 Lubricant adhesive. Lubricant adhesive shall be a one-part moisture curing polyurethane and aromatic hydrocarbon solvent mixture meeting the requirements of ASTM D4070 for use in lubricating preformed bridge seals for insertion and adhesion to metal and concrete surfaces. 2.1.2.1 Each lot of adhesive shall be delivered in containers plainly marked with the manufacturer’s name or trademark and shall be accompanied by the manufacturer’s affidavit attesting conformance with the specification. 2.1.3 Bolts for Plow Plates and Anchor Rods. 2.1.3.1 Bolts for the plow plates in roadway shall be 3/4” diameter high-strength hexhead bolts conforming to ASTM A325, galvanized. 2.1.3.2 Anchor rods shall conform to ASTM 307, galvanized.

2.2Prefabricated Finger Joint System. The prefabricated finger joint system shall meet the configuration and details as shown

on the plans. 2.2.1 Steel members. Steel members for the prefabricated finger joint system shall conform to specifications ASTM A 572 Grade 50. Minor steel plates may conform to specifications ASTM A 36. 2.2.1.1 Studs shall meet the requirements of AASHTO M 169 (ASTM A 108). 2.2.1.2 All steel members shall be galvanized conforming to 550.2.9. If distortion becomes an issue, an approved zinc rich coating shall be used as approved by the Engineer. 2.2.1.3 Anchorage of the prefabricated finger joint to the backwall and deck, between the curb lines, shall be made using a loop rebar attached to a joint support plate and shall be spaced at 1’-0” maximum, as shown on the plans. Brush curb and sidewalk anchorage shall be made of stud anchors and shall be spaced at 1’ -6” maximum, as shown on the plans. The anchorage reinforcement shall extend into the backwall or curb reinforcement cage for proper anchorage. 2.2.2 Fabric trough. The preformed fabric trough shall be a product as included on the Qualified Products List and shall be a multi-layer sheet composed of multi -plies of 15 oz. per square yard (5%) polyester laminated with butadiene acrylonitrile and vulcanized to form an integral laminate, meeting the following requirements:

New Hampshire Department of Transportation Standard Specifications – 2016 Physical Properties Number of Plies 3 Minimum Weight of Laminate (lbs/sq. ft.) 0.85 Minimum Thickness (inches) 5/32 Minimum Ultimate Tensile Strength of Laminate ((lbs/in) of width) 1,200 Maximum Elongation at Ultimate Tensile Strength 30% Maximum Elongation at 1/10 Ultimate Tensile Strength 3% 2.2.3 Bolts and Anchor Rods. 2.2.3.1 Bolts in roadway plates shall be 3/4” diameter high-strength hexhead bolts conforming to ASTM A325, galvanized. 2.2.3.2 Bolts in curb or sidewalk plates shall be 3/4 ” diameter countersunk head bolts with socket head and conforming to ASTM A276, Type 304 - stainless steel. 2.2.3.3 Anchor rods shall conform to ASTM 307, galvanized.

2.3Modular Bridge Joint System (MBJS). The modular bridge joint system shall be designed in accordance the current

AASHTO LRFD Bridge Design Specifications, Article 14.5, “ Bridge Joints ”, and meet the current AASHTO LRF D Bridge Construction Specifications, Section 19, “ Bridge Deck Joint Seal ”. The MBJS shall be prequalified by satisfying all testing requirements detailed in the current AASHTO LRFD Bridge Construction Specifications, Appendix A19. MBJS shall meet the configuration as shown on the plans and shall be a product as included on the Qualified Products List. 2.3.1 Steel members. Steel members for the modular bridge joint system shall conform to s pecifications ASTM A 572 Grade 50. Minor steel plates may conform to specifications ASTM A 36. 2.3.1.1 Studs shall meet the requirements of AASHTO M 169 (ASTM A 108). 2.3.1.2 All steel members shall be galvanized conforming to 550.2.9. If distortion becomes an issue, an approved zinc rich coating shall be used as approved by the Engineer. 2.3.1.3 Anchorage of the modular bridge joint system to the backwall and deck, between the curb lines, shall be made using a loop re bar attached to a joint support plate and shall be spaced at 1’ -0” maximum, as shown on the plans. Brush curb and sidewalk anchorage shall be made of stud anchors and shall be spaced at 1’ -6” maximum, as shown on the plans. The anchorage reinforcement shall extend into the backwall or curb reinforcement cage for proper anchorage. 2.3.2 Lubricant adhesive. Lubricant adhesive shall be a one- part moisture curing polyurethane and aromatic hydrocarbon solvent mixture meeting the requirements of ASTM D4070 for use in lubricating preformed bridge seals for insertion and adhesion to metal and concrete surfaces. 2.3.2.1 Each lot of adhesive shall be delivered in containers plainly marked with the manufacturer’s name or trademark and shall be accompanied by the manufacturer’s affidavit attesting conformance with the specification. 2.3.3 Preformed elastomeric strip seal. Preformed elastomeric strip seal joint system with steel locking extrusions (edge rails) shall conform to the requirements of ASTM D5973, meet the configuration as shown on the plans, and be a product as included on the Qualified Products List. Each seal shall be furnished full length. Splices in the length of an individual seal will not be permitted unless the splices are made at the plant by the manufacturer of the seal with the approval of the Department. The seal material shall be identified with the production date, manufacturer’s name or trademark, and lot number. 2.3.4 Urethane foam shall conform to ASTM D3574. 2.3.5 Polytetrafluorethylene (PTFE) shall be 100% Virgin Teflon, woven PTFE fabric, or dimpled PTFE conforming to the requirements of the current AASHTO LRFD Bridge Construction Specifications, Section 18.8 and shall be pro vided on every sliding surface. 2.3.6 Stainless steel sheets shall conform to ASTM A240, Type 304, and shall be provided on every sliding surface. ASTM A240, Type 316 shall be used for a severe environment. 2.3.7 Springs, bearings, and equidistance devices (control springs) shall be the same material composition and formulation, manufacturer, fabrication procedure, and configuration as the ones used in the prequalification test.

New Hampshire Department of Transportation Standard Specifications – 2016 Construction Requirements

3.1General. The expansion joint assembly shall be fabricated at an AISC certified plant with a certification in accordance to

Section 550.3.2. 3.1.1 For a MBJS, the manufacturer shall have a minimum of three years’ experience in designing and fabricating modular bridge expansion joint systems. The Contractor shall provide written certification of the manufacturer’s experience.

3.2Fabrication.

3.2.1 Submittals. Shop fabrication drawings showing all details of the complete expansion joint assembly such as dimensions, anchorages, and welding procedures shall be submitted for approval in accordance with 105.02. Approval of the shop fabrication drawings shall be required prior to the manufacture of the assembly. Detailed welding procedures shall be considered an integral part of shop fabrication drawings and shall be submitted for approval along with the shop fabrication drawings. The shop fabrication drawings shall indicate the welding procedure to be used for each weld shown. The name of the manufacturer of the preformed elastomeric strip seal shall be shown on the shop fabrication drawings. Original shop fabrication drawings, corrected, shall be delivered to the Department before the final payment is made. 3.2.1.1 The manufacturer inst ructions for the proper installation of the joint system shall be shown on the shop drawings. Shop drawings that lack the manufacturer installation instruction, may be returned without approval. 3.2.1.2 For modular bridge joint systems, the Contractor shall submit details of the MBJS to be used together with installation and waterproofing plans for approval in accordance with 105.02 prior to fabrication. The shop fabrication drawings shal l be in accordance with 3.2.1 and the current AASHTO LRFD Bridge Construction Specifications, Section 19. 3.2.1.3 For modular bridge joint systems, the Contractor shall submit test reports and certificates of the MBJS in accordance with the current AASHTO LRFD Bridge Construction Specif ications, Section 19, for review and approval in accordance with

105.02prior to fabrications. The Contractor shall also submit documentation of a Quality Assurance Inspection program performed

by an independent inspection agency provided by the manufacturer. The name of the independent inspection agency , details of the proposed quality assurance inspection program including inspection frequen cy, and all applicable reporting forms shall be submitted prior to the start of fabrications. 3.2.2 Fabrication and workmanship shall be performed in accordance with the applicable provisions of 550.3. 3.2.3 Preblast. All steel elements shall be blast cleaned before fabrication in conformance with the requirements of SSPC - SP 10, Near White Blast Cleaning. At the fabricators option, surfaces to be welded may be ground to bare metal. If the product is to be galvanized, blasting is not required before galvanizing. 3.2.4 Welding of steel shall be performed in accordance with 550.3.6. Welding shall be performed by prequalified welders and welding operators. 3.2.5 Stud Welding. 3.2.5.1 Studs shall be welded using automatically -timed stud welding equipment in accordance with AASHTO Welding Specifications, Section 7 (see 550.3.6.10). Welding by SMAW is an option only if approved by the Department. 3.2.5.2 Automatic equipment. Studs shall be welded with automatically timed stud welding equipment connected to a suitable source of direct current straight polarity power. Welding voltage, current, time, and gun settings for lift and plunge should be set at optimum settings, based on past practice, recommendations of stud and equipment manufacturer, or both. AWS C5.4, Recommended Practices for Stud Welding, should also be used for technique guidance. 3.2.5.3 Testing. The first two welded studs installed and ten percent (10%) of the remaining studs shall be tested. The test shall consist of bending the studs, after they a re allowed to cool, to an angle of approximately 15 degrees from their original axes by either striking the studs on the head with a hammer or placing a pipe or other suitable hollow device over the stud and manually or mechanically bending the stud. If any studs fail the test, then all studs shall be tested. Acceptable bent studs shall be left in the bent position. 3.2.6 Shipping and adjusting devices required to ship, install, and adjust the joint assembly on the bridge shall be provided at approximately 4 ft. spacing and shall be furnished and installed by the fabricator. 3.2.7 The joint system shall be fabricated by the manufacturer and delivered to the bridge site completely assembled, unless otherwise specified in the contract documents. For single preformed elastomeric strip seal expansion joint systems, the preformed elastomeric strip seal will be shipped concurrent with the joint system and will be clearly identified as the joint location corresponding to the strip seal.

New Hampshire Department of Transportation Standard Specifications – 2016

3.3Inspection.

3.3.1 Notice. The fabricator shall give ample notice (two weeks minimum) of the beginning of work so that arrangements can be made for inspection. No materials shall be fabricated before the Engineer has been so notified. 3.3.2 The Department will inspect the fabrication of expansion joints. This inspection will include the examination of materials, welding, testing, work procedures, painting, and the final fabricated product. 3.3.3 The Engineer may waive shop inspection and make a complete inspection at a later stage in the construction sequence. 3.3.4 The Engineer shall visually inspect the seal material to confirm size, configuration, and identify possible defects in seal due to manufacturing or shipment. Any seal with defects shall be replaced at the Contr actor’s costs. 3.3.5 When the materials are delivered to the job site, the manufacturer shall provide a certification to the Engineer that all materials meet the specification requirements. 3.3.6 Pre-installation inspection. Immediately prior to installation, the Engineer shall inspect the MBJS and the blockout for the following:

and the surface of the blockout should be verified.

3.4Installation. The joint assembly shall be installed in the bridge as shown on the plans, in strict accordance with the

manufacturer’s written instructions along with the advice of their qualified representative. Installation of MBJS shall also be installed be in accordance with the current AASHTO LRFD Bridge Construction Specifications, Section 19.5. 3.4.1 For the installation of MBJS, a qualified installation technician shall be present at the job site to assur e a proper installation of each expansion joint system. This technician shall be a full time employee of the manufacturer of the specif ic expansion joint system being installed. The Contractor shall comply with all recommendations made by the expansion j oint manufacturer’s installation technician as approved by the Engineer. Each expansion joint system manufacturer’s installation technician shall certify to the Engineer that the Contractor properly followed the approved installation procedures. All certifications to the Engineer shall be in writing and shall be signed and dated by the manufacturer’s installation technician. 3.4.2 Class AA concrete shall be placed as blockout filler as directed. 3.4.3 The joint system shall be set to line and grade, with vertical offset as detailed on the plans, ensuring that the system’s uppermost plane parallels the finished roadway profile. 3.4.4 In order for the expansion joint to be installed properly, it must be set at a width that is directly dependent upon the ambient temperature at the start of installation under the direction of the Engineer, as shown on the contract plans. The width setting shall be accomplished through the use of mechanical devices supplied by the fabricator. 3.4.5 Cleaning the mating surfaces of the steel elements shall be performed just prior to installing the seal. The steel and seal surfaces shall be cleaned in accordance with the manufacturer’s recommendations. 3.4.6 Immediately after the joint has been secured to the structural steel and the abutment, the shipping and adjustment devices shall be removed and any bolt holes plug welded. Any welds on exposed surfaces shall be ground smooth. Repair any damaged galvanized surfaces according to 550.2.9.1. 3.4.7 For a finger expansion joint system, a water collection and drainage system shall be located as shown on the plans. The drainage system shall catch and channel all water to a point where it can be discharged away from the superstructure and substructure. 3.4.7.1 The hopper and downspout shall be secured to the concrete substructure at 10-foot intervals (maximum) or as shown on the plans or as directed by the Engineer. 3.4.8 Watertight Integrity Test for the Strip Seal Expansion Joint System. After the joint system has been fully installed, the Contractor shall test the entire (full length) joint system for watertight integrity employing a method satisfactory to the Engineer. The entire joint system shall be covered with water, either ponded or flowing, for a minimum duration of 15 minutes. The concrete surfaces under the joint shall be inspected, during this 15 minute period and also for a minimum of 45 minutes after the supply of water has stopped, for any evidence of dripping water or moisture. Water tightness shall be interpreted to be no free dripping water on any surface on the underside of the joint. Patches of moisture shall not be cause for non -acceptance.

New Hampshire Department of Transportation Standard Specifications – 2016 Should the joint system exhibit evidence of water leakage at any place whatsoever, th e Contractor shall locate the place(s) of leakage and take all measures necessary to stop the leakage. The repair procedure shall be recommended by the manufacturer an d approved by the Engineer. This work shall be done at the Contractor's expense. A subsequent water integrity test shall be performed subject to the same conditions and consequences as the original test. 3.4.9 Watertight Integrity Test for the Fabric Trough of the Finger Expansion Joint . After the joint system has been fully installed, the Contractor shall test the entire length of the fabric trough for watertight integrity employing a method satisfactory to the Engineer. The entire joint system shall be covered with flowing water for a minimum duration of 15 minutes. The fabr ic trough, during this 15 minute period, shall be inspected for any evidence of dripping or splashing water. Water tightness shall be interpreted as all free dripping water is collected into the fabric trough and flows down the trough into the downspout. No free dripping water shall be outside the trough or splashing occurring at the entrance to the downspout. Should the expansion joint exhibit evidence of water not being collected in the trough at any place whatsoever, the Contractor shall locate the problem place(s) and take all measures necessary to ensure that the fabric trough will collect all the water. The repair procedure shall be approved by the Engineer. This work shall be done at the Contractor's expense. A subsequent water integrity test shall be performed subject to the same conditions and consequences as the original test. 3.4.10 Watertight Integrity Test for the MBJS. After the joint system is installed and completed, the MBJS shall be flooded for a minimum of 1 hour t o a minimum depth of 3.0”, in acco rdance with the current AASHTO LRFD Bridge Construction Specifications, Section 19.5. For phase construction, the MBJS shall be flooded as noted above, for each completed phase. I f leakage is observed, the MJBS shall be repaired to the Engineer’s satisfaction and retested at the Contractor’s expense. The repair procedure shall be recommended by the manufacturer and approved by the Engineer. Method of Measurement

4.1Prefabricated expansion joints, of the type specified, will not be measured, but shall b e the linear foot final pay quantities in

accordance with 109.11 for prefabricated expansion joints required as shown on the plans. Basis of Payment

5.1Prefabricated expansion joints, of the type specified, are final pay quantity items and will be paid for at the Contract unit

price per linear foot complete in place in accordance with 109.11 Pay items and units:

561.10XX

561.12XX

561.13XX

Prefabricated Strip Seal Expansion Joint (F) Prefabricated Strip Seal Expansion Joint w/ Plow Plates (F) Prefabricated Strip Seal Expansion Joint Rehabilitation (F) Linear Foot

Linear Foot

Linear Foot

561.20XX

561.23XX

Prefabricated Modular Bridge Joint System (F) Prefabricated Modular Bridge Joint System - Rehabilitation (F) Linear Foot Linear Foot

561.30XX

561.33XX

Prefabricated Finger Expansion Joint (F) Prefabricated Finger Expansion Joint - Rehabilitation (F) Linear Foot Linear Foot

New Hampshire Department of Transportation Standard Specifications – 2016

Description

This work shall consist of all work required to furnish and install silicone joint sealant as shown on the plans. The joint

sealant shall consist of a cured-in-place silicone rubber material forming a flexible watertight seal. Materials

Silicone joint sealant shall meet the requirements of ASTM D 5893 and shall be a product listed on the Qualified Products

List. Silicone joint sealant for horizontal joints shall be either Type NS (Non-Sag) or Type SL (Self-Leveling). Silicone joint sealant for vertical joints shall be Type NS (Non-Sag).

Backer rod, when required, shall be expanded closed cell polyethylene, meeting the requ irements of ASTM 5249.

Primer shall be a product recommended by the silicone joint sealer manufacturer.

Construction Requirements

General. The treatment of the steel, concrete, and stone surfaces and the preparation and installation of material sh all be as

recommended by the manufacturer. 3.1.1 Concrete shall have cured a minimum of 14 days prior to application of the primer and/or sealant. 3.1.2 The joint area shall be abrasive blast cleaned to achieve an anchor profile that is clean, and free of laitance, oil and foreign materials. Steel substrates shall receive an SSPC SP10 near -white metal blast cleaning or other treatment as directed by the Engineer prior to application of the primer. After blasting, all abrasives, dust and dirt shall be blo wn out of and away from the joint using a high-pressure air blast. All equipment used for preparing and cleaning the joint shall be equipped with traps capable of providing moisture-free and oil-free air. All surfaces shall be dry and frost- free. 3.1.3 Primer shall be applied to all substrates to be sealed unless otherwise directed by the Engineer. The prime coat shall be applied in a thin, uniform layer over the entire contact surface area in accordance with the sealant manufacturer’s recommendations. 3.1.3.1 The primer shall cure in accordance with the manufacturer’s recommendations before application of the sealant. In all cases, the prime coat shall be allowed to dry for a minimum period of 60 minutes prior to the application of the sealant. The priming operation shall not be performed more than 3 hours ahead of the sealing operation at any given time. 3.1.4 The backer rod, when required, shall be installed at the appropriate distance below the finish grade surface. The width of the backer rod shall be approximately 25% wider than the joint opening. 3.1.5 Silicone sealant installation method and application tools shall be as recommended by the manufacturer. Non -sag sealants shall be tooled in place in accordance with the manufacturer’s recommendations. 3.1.5.1 The silicone bead shall be no thicker than 1/2” and no thinner than 1/4” The top of the silicone bead shall be recessed 3/8” below finish grade except below paved surfaces, where sealant shall be at top of concrete. For non -joint applications on the plans where sealant is specified to fill a void, the sealant shall be pressed into place to completely seal the void and tooled to shed moisture. Method of Measurement

Silicone joint sealant will not be measured, but shall be the linear fo ot final pay quantities in accordance with 109.11 for

silicone joint sealant required as shown on the plans. Material removed because of faulty workmanship will not be measured. Basis of Payment

Silicone joint sealant is a final pay quantity item and will be paid for at the Contract unit price per linear foot complete in

place in accordance with 109.11. No additional payment will be made for the primer or backer material. Pay item and unit:

562.1Silicone Joint Sealant (F) Linear Foot