CONSTRUCTION JOINTS AND EXPANSION DEVICES 518.04 507 Friction control lubricants; Flushing lubricants or contaminants from the ducts; and Endoscope inspection of duct work and grouting. CONSTRUCTION JOINTS AND EX PANSION DEVICES
518.01 Description
This work consists of fabricating, furnishing, and installing construction joints, water stops, and expansion devices. Provide joints in accordance with the details shown on the Plans, Specifications, Standard Drawings, and recommendations of the manufacturer as directed by the Engineer. Seal the joints as indicated on the Plans to prevent water from seeping through the openings. Design expansion joint systems in accordance with the most recent edition of the AASHTO LRFD Specification, using HL93 truck loading plus Impact, and appropriate load and distribution factors.
518.02 Materials
Provide materials in accordance with the following section and/or subsections: Material: Section or Subsection: Low Modulus Silicone Joint 701.08.F Sealant (Self –Leveling) Rapid Cure Joint Sealant and 701.08.G Elastomeric Mortar Construction Joint and Expansion Joint Sealers 701.08.H Waterstops 733. 08
518.03 Equipment - Vacant
518.04 Construction Methods
A.Construction Joints Place construction joints in accordance with the plans and as directed by the Resident Engineer.
1.Forming and Sealing
a.Saw Cutting Construction Joints Saw-cut the top of the joint after concrete placed on both sides of the joint hardens 1 in [25 mm] deep and ¼ in [6 mm] wide after concrete hardens on both sides of the joint. Seal sawed joints in accordance with Section 415 “Concrete Joint Sealing.” Use a sealant meeting the properties of Subsection 701.08.F, “Low Modulus Silicone Joint Sealant (Self -Leveling).”
518.04 Construction Joints and Expansion Devices
508 (2) Formed Joints Where the reinforcing steel does not go through the existing formed construction joints, seal joints in accordance with the Subsection 518.04.C.(5)(b), “Joints Made of Elastomeric Mortar and Rapid Cure Joint Sealant ,” or the Contractor may seal construction joints ½ in [12 mm] and wider with a preformed silicone foam seal in accordance w ith Subsection 518.04.C (5)(f), “Preformed Silicone Foam Joints .” Accept formed construction joints in accordance with Subsection
518.04 C.(6) , “Acceptance Test Procedures f or All Expansion Devices.” Alternately, seal
construction joints ½ in [12 mm] to 4” [100 mm] wide , including pressure relief joints between roadway pavement approach slab , with a preformed silicone foam seal in accordance with Subsection 518.04.C( 5f), “Preforme d Silicone Foam Joints.”
B.Water Stops Seal vertical joints in retaining walls and other members with rubber or plastic waterstops as required by the Contract meeting the Material requirements of subsection 733.08 , "Waterstops ." Use waterstops that allow the required movement.
1.Rubber Waterstops Before installation, submit the following for approval: Performance test data, A 1 yd [1 m] sample of Contract required types of waterstop, and If using splices, at least one preliminary field splice. Form waterstops with a cross -section that is uniform in width and web thickness. The Department will not allow splicing straight strips. Full -mold all junctions in the special con nection pieces. Provide cured, dense, nonporous, homogeneous special connection pieces. Fabricate dense, homogenous splices made watertight by vulcanizing or mechanical means. Make splices with a minimum tensile strength of 50 percent of the unspliced ru bber waterstop. Before installation, submit the following for approval:
2.Plastic Waterstops Submit at least one preliminary field splice sample before installation. Heat splices in accordance with the manufacturer’s instructions to make watertight. Fabr icate splices with a minimum tensile strength of 80 percent of the unspliced plastic waterstop.
3.Placing Waterstops Protect waterstops from displacement or damage. Keep waterstop surfaces free of deleterious material until embedded in the concrete. Encl ose embedded waterstops in dense concrete.
C.Expansion Devices
1.Shop Drawings for Metallic Expansion Devices. Submit complete working drawings for fabrication, installation, and approval showing the following for any expansion device that uses metallic components (primarily SEJ, aluminum finger, and Modular joints): CONSTRUCTION JOINTS AND EXPANSION DEVICES 518.04 509 Plans, details, elevations, and sections of the joint system for each movement rating and roadway width showing dimensions and tolerances. Designation of each material to be used in fabricat ion of the expansion device including all ASTM, AASHTO, or other material designations as required. Method of installation including but not limited to sequence, setting relative to temperature, anchorage during setting, and installation at curbs. Show the joint dimension opening on shop drawings for an ambient temperature of 60 °F [15 °C] and adjustments to that dimension due to temperature variations. Conform expansion joints to deck geometry matching cross slopes, and break points. Assemble expansion joi nts with metal headers in the shop, check for fit, and match mark for shipment. Use welding procedures in accordance with AASHTO/AWS D1.5 Bridge Welding Code and interim supplements. Describe the corrosion protection system. Show details of temporary supp orts for shipping and handling. For modular joints, provide design calculations for all structural elements. Include in the design calculations for a fatigue design and a strength design for all structural elements, connections, and splices. Illustrate all welded centerbeam splices on the shop plans. Provide manufacturer’s certificate of compliance with the AISC Quality Certification Program. Certify that shop welding inspection personnel are qualified and certified as welding inspectors under AWS QC1, Sta ndard for Qualification and Certification of Welding Inspectors. Show modular joint temperature setti ngs on the shop drawings. Obtain approval for joint shop drawings and materials before instal lation of the expansion device.
2.Fabrication of Metallic Expansion Devices
a.General Fabricate the expansion joint system in accordance with the dimensions, shapes, designs, and details shown in the approved shop plans and in conformance with the Standard Specifications and the Special Provisions. Fabricate m odular expansion joint assemblies by the same AISC Certified manufacturer. Provide structural steel in accordance with subsection
701.08 H(4) , "Armored Steel Receptors."
b.Polytetrafluoroethylene (PTFE) Sliding Surface Typically for Modular Joints Bond the PTFE under controlled conditions and in accordance with the written instructions of the manufacturer of the PTFE. After completion of the bonding operation, ensure that the PTFE surface is smooth and without bubbles.
518.04 Construction Joints and Expansion Devices
510 (c) Corrosion Protection (doe s not apply to aluminum plates) Hot-dip galvanize all structural steel components of the expansion joint and overlapping parapet and median barrier plates in accordance with AASHTO M111. Portions of the expansion joint may be masked as required by the joi nt manufacturer.
3.Shipping and Handling Design, fabricate, and deliver each assembly to the job site as a continuous unit to the greatest extent possible to minimize field splices in the expansion joint system. The maximum length of completed expansion joint assemblies will be determined by practical shipping limitations as approved by the Engineer. At the site, store the expansion joint system in accordance with the manufacturer’s written recommendations and as approved by the Eng ineer. For modular joi nts, start lifting locations and lifting mechanisms on the shop plans. Damage to the joint system during shipping or handling will be cause for rejection of the joint system. Repair damage to the corrosion protection system to the satisfaction of the Eng ineer. Do not cut seals except as recommended by the manufacturer and approved by the Engineer. To the greatest extent possible, seal splices in the shop using methods approved by the manufacturer. The Department does not allow splices in the field to Se aled Expansion Joints or Modular Joints unless otherwise approved by the manufacturer and specified on the shop drawings.
4.Installation Install the device in accordance with the manufacturer’s recommendations, and to the lines, elevations, and opening s hown on the Plans. Install expansion joint devices so the joint surface matches the plane of the adjacent concrete along the length of the assembly. Adequately brace the expansion device in a manner approved by the Engineer to fit conditions existing at ti me of installation. Secure headers in place during concrete placement. Place expansion joint devices within ± 1/8" [3 mm] of plan dimensions. Perform all joint installation work under the supervision of the manufacturer’s representative, or use experience d installers that are certified by the manufacturer’s representative. Notify the sealant manufacturer at least two (2) weeks before starting work on the joint installation. Provide an opening in the curbs, sidewalks, traffic rail, and concrete parapets sp ecified on the plans but at least the expansion device opening. Adjust the joint opening for an ambient temperature as specified i n the plans and specifications. Adjust the joint opening for an ambient temperature as specified in the plans and specificatio ns at the time of setting. Measure the structure temperature by recording the surface temperature of the concrete and steel using a surface thermometer. Record the temperature of the underside of the concrete slab at each side of the superstructure element adjacent to the expansion joint. In addition, record the surface temperature of the shaded portion of the girder web at each location. Use the average of the readings of the concrete and steel temperatures to determine the required opening. Ensure the dev ice is free to move with temperature variations as soon as the concrete has set. Ensure that the expansion device will accommodate the anticipated temperature movements while maintaining a smooth riding surface. Test and accept all expansion joints for le akage in accordance with Subsection 518.04.C.(6), “Acceptance Procedures for All Expansion Devices.” For Special requirements for the Installation of Modular Joints, provide the services of a qualified installation technician who is employed full -time by the manufacturer of the expansion CONSTRUCTION JOINTS AND EXPANSION DEVICES 518.04 511 system to aid in assuring proper installation of each modular expansion joint system in the field. Adhere to the recommendations made by the expansion joint manufacturer’s installat ion technician, on or off the job site, and approved by the Engineer. The expansion joint manufacturer’s installation technician shall advise the contractor and certify to the Engineer that the proper installation procedures are being followed. Provide c ertifications to the Engineer in writing, signed and dated by the manufacturer’s installation technician. Install the modular expansion joint system in strict accordance with the manufacturer’s instructions, and the advice of the manufacturer’s installati on technician. Provide to the Engineer, two weeks before the intended installation, with two copies of the written instructions. Ensure that the permanently installed expansion joint system matches the finished roadway profile and grades. Take precautions to protect the expansion joint system from damage. Exercise special care at all times to ensure protection of the expansion joint system. Protect the blockout and supporting system from damage and construction traffic until installation of the expansion j oint assembly. After installation of the joint system, do not permit construction loads on the expansion joint device. Provide a temporary bridge over the expansion joint assembly in a manner approved by the Engineer. Set the modular expansion joint syst em to the proper width for the ambient temperature at the time of setting. Remove all forms and debris that tend to interfere with the free action of the expansion joint system and open to traffic as approved by the Engineer. Test and accept all joints an d expansion devices for leakage in accordance with subsection
518.04 C(6) ,"Acceptance Procedures for All Expansion Devices."
5.Different Types of Expansion Joints
a.Sealed Expansion Joints (SEJ) Provide neopren e gland and receptors in accordance with Subsection 701.08.H(3) ,"Joint Sealants for SEJ and Modular Joints ." Fabricate the steel receptors to be continuous for the length of the joint. Minimize the number of splices in the steel receptor. To splice steel receptors, use a partial penetration weld, ground smooth. The Department will not allow welding in the areas in contact with the neoprene. Before installing the neoprene gland in sealed expansion joints, clean steel surfaces that will contact the neoprene. Continuously provide and install a neoprene gland the length of the joint. Where the Contract requires jo ints to be mitered for skew of at least 35°, splice the neoprene by vulcanizing or other Engineer approved method. Ensure spliced neoprene has strength and durability equal to unspliced neoprene. Make splices watertight. Cut any rigid connections between opposite halves of an expansion joint assembly after initial concrete set to prevent damage from joint movement from thermal changes in the superstructure.
b.Joints Made of Elastomeric Mortar and Rapid Cure Joint Sealant Install the joint in accordance w ith the manufacturer’s recommendations. Provide elastomeric mortar and rapid cure joint sealant in accordance with Subsection 701.08.G, “Rapid Cure Joint Sealant and Elastomeric Mortar.” Strip forms and clean the con crete surfaces to ensure proper bond of the elastomeric mortar. For existing concrete surfaces, saw, flush, and clean joints in accordance with the manufacturer’s recommendations. Blast -clean steel surfaces in accordance with SSPC -SP10, “Near -White Blast C leaning.” After preparing the surface, notify
518.04 Construction Joints and Expansion Devices
512 the Engineer for inspection of the joint before installing the elastomeric mortar. Install the elastomeric mortar when the joint surface temperature reaches at least 45°F [7°C]. If recommended by the manufact urer, apply heat to improve the elastomeric mortar curing time. Before exposing joint to traffic, allow the mortar to cure for at least 2 hr, or if joint surface temperatures fall below 70°F [21°C], cure for 4 hr. After installing the elastomeric mortar, install the rapid cure joint sealant when the joint surface temperature is at least 60° F [15° C] or the manufacturer’s recommendation. Install the sealant in expansion joints when the joint openings are from 3/8 in to 2½ in [10 mm to 65 mm]. Place backe r rod to the depths specified in Table 518:1, “Backer Rod Depth,” (exception: in the shoulder, taper the recess from the specified depth to zero at the curb, parapet, or rail). Before placing silicone sealant in the driving l anes, verify backer rod depth using a wooden block shaped in the form of a ‘T.’ Table 518:1 *Backer Rod Depth Width of Opening Backer Rod Depth ⅜⅜ in [10 mm] 9/16 in [14 mm] ½½ in [13 mm] ⅝ in [16 mm] ¾ in [19 mm] ¾ in [19 mm] 1 in [25 mm] ⅞ in [22 mm] 1 ½ in [38 mm] 1 ¼ in [32 mm] For openings greater than 1 ½” [38 mm], use backer rod depths as specified by the Manufacturer.
c.Inverted “V” Joints Bonded with Adhesive Use preformed elastomeric compression joint sealant in accordance with Table 701:16A "Physical Properties of Joint Sealants ." Provide all components from a single manufacturer. Install in joints having an opening with a width in a range of 1 to 4 in [25 mm 200 mm]. Install the sealant when the minimu m temperature is 40°F [4°C] and the temperature is rising. Ensure that the joint surface is completely dry and there will not be any chance of precipitation during the installation. Install the joint sealant the same day as the surface preparation. Blast -clean steel surfaces in accordance with SSPC -SP10, “Near -White Blast Cleaning.” Blast clean concrete surfaces to remove all fines, laitance, and unsound concrete as determined by the Engineer. Clean and apply alcohol rub and primer adhesive to vertical surf aces in accordance with the manufacturer’s recommendations. Splice joints as directed by the Manufacturer’s representative. Place the joint sealant in an inverted “V” shape in accordance with the manufacturer’s directions. Place the top of the inverted “ V” a minimum 3/4" -0" / +1/4" [19 mm -0 mm / +6 mm] below the roadway surface. Verify installation depth using a wooden block shaped in the form of a ‘T ’ with the depth of the 'T' equal to 3/4" and the stem wider than the joint opening. Any rips, tears, or bond failure will be cause for rejection. Use adhesives meeting the requirements of Table 701:16B "Physical Properties for the Silicone Locking Adhesive ." Replace rejected seals or portions of seals in accordance with the Manufacturer’s recommendation s and as directed by the Engineer. CONSTRUCTION JOINTS AND EXPANSION DEVICES 518.04 513 (d) Aluminum Finger Expansion Device Provide manufactured finger type expansion device system and all its component parts, including the elastomeric membrane, anchorages, and aluminum alloy triangular teeth. Certify that all components comply with the manufacturer’s current literature. Furnish two (2) copies of the current published literature containing pertinent materials and installation data for the finger type expansion device supplied to the Bridge Engineer for app roval at the same time shop drawings are sent for review. Place the aluminum alloy elements end to end and strongly fixed to the structure by means of prestressed anchorages placed under controlled tension. Insert an elastomeric membrane, continuous on t he width of the roadway, without splices, between two metallic elements that are anchored to the slab.
e.Modular Bridge Joint Systems (MBJS)
1.General Requirements: Provide a modular sealed joint with two or more elastomeric seals held in place by edgebeams that are anchored to the bridge deck or approach slab and one or more transverse centerbeams that are parallel to the edgebeams. Provide neoprene strip seals mec hanically held in place by steel edge and separation beams in accordance with Subsection 701.08.H, "Construction Joint and Expansion Joint Sealers." Support each separation beam with an independent support bar which is welded to the separation beam. Suspend the support bars over the joint opening using sliding elastomeric bearings. Incorporate an equidistant control system which develops its maximum co mpressive force when the joint is at its maximum opening. Avoid using any bolted connections between the separator beams and support bars. Fabricate the modular expansion joints at facilities owned and operated by the manufacturer, the manufacturer being the single entity that designs, fabricates, and installs (or supervises the installation of) the joint assemblies. Ensure that the fabrication shop is certified by the American Institute of Steel Construction as a Quality Certified Fabricator in the catego ry of Simple Steel Bridge Structures. Use a manufacturer with at least three years of experience in designing and fabricating modular bridge expansion joint systems of the type and size required by this project. Provide written certification of the manufa cturer’s experience and provide a list of at least five expansion joint systems that have been installed with an owner and contact person for each system indicated. Ensure that the shop drawings and calculations are prepared, reviewed, signed, and sealed by an Oklahoma registered Professional Engineer. Ensure that the registered Professional Engineer is either a full -time employee of the manufacturer or has designed modular joint systems for three years. Provide a record of previous completed projects including contact persons. Ensure that the expansion joint assembly seals do not protrude above the top of the joint into the level of the roadway. Use elastomeric springs and bearings so that they are removable and replaceable. Ensure that the removal and reinstallation of the strip seal can be easily accomplished from above the joint with a 1¼ inch [32 mm] minimum gap width during a partial closure of the roadway. Use a maximum movement range on the expansion joint strip seals of 3.15 inches [80 mm]. " Box" seals or seals utilizing double webs will not be acceptable.
2.Design and Testing Requirements for Modular Bridge Joint Systems (MBJS): Design MBJS for strength and fatigue in accordance with Article 14.5 “Bridge Joints,” of the
518.04 Construction Joints and Expansion Devices
514 AASHTO LRFD Bridge D esign Specifications. Provide computations signed and sealed as noted above for acceptance to the Bridge Engineer demonstrating that the MBJS will meet minimum requirements for strength and fatigue. Using an independent laboratory, do specimen testing on typical components of the MBJS. All testing is to be in accordance with the most recent edition including interim revisions to the AASHTO LRFD BRIDGE CONSTRUCTION SPECIFICATIONS – Section 19: Bridge Deck Joint Seals, Appendix A19. Provide test data for ac ceptance indicating that the MBJS meets the minimum requirements for the following test procedures as described in AASHTO LRFD BRIDGE CONSTRUCTION SPECIFICATIONS - Section 19, Appendix A19: 2.1) Opening Movement and Vibration (OMV) Test 2.2) Seal Push -Out (SPO) Test 2.3) Fatigue Test Provide MBJS with the same components and from the same suppliers as used for the specimen testing. Any variations in components or suppliers must be tested as noted above for acceptance.
f.Preformed Silicone Foam Joints Furnish a foam joint seal topped with fuel resistant silicone. Provide cellular polyurethane foam impregnated with a wax free 100% hydrophobic acrylic polymer, factory coated with highway -grade, low modulus, fuel resistant silicone. Provide a width greater than the mean measured opening which when compressed will form bellows as recommended by the manufacturer. Provide a foam depth appropriate for the joint opening as recommended by the manufacturer. Provide field -applied epoxy adhesive primer and field -injected silicone sealant bands in accordance with Tables 701:16C "Physical Properties for Preformed Silicone Foam Joints" and 701:16D "Physical Properties for Preformed Silicone Foam Joints – Silicone ." Prepare surfaces to receive sealant by repairing spalls, chips, irregular or unsound joint surfaces in a manner approved by the Engineer. Blast -steel surfaces when attaching to existing metal headers in accordance with SSPC -SP10, "Near -White Blast Cleaning." After preparing surfaces, notify the Engineer for inspection prior to sealant installation. Install the joint when the temperature is in the range of 40oF [4oC] to 95oF [35oC]. Ensure joint sides are dry of solvents or other cleaning agen ts before installation. Place prefabricated 90's at start of installation when these members are specified. Provide a minimum recess of 3/4" -0" / +1/4" [19 mm -0 mm / +6 mm]. Verify depth using a wooden block shaped like a 'T' with the stem having a dept h of 3/4" [19 mm] and top having a width wider than the joint opening. Mix and place epoxy adhesive when the temperature is in the specified range noted above. Apply epoxy adhesive to the sides of the joint header as directed by the Engineer. Unwrap prec ompressed foam sealant with silicone topping and place in joint as directed by the Engineer. Before the epoxy adhesive cures, force a bead of silicone sealant between the foam and silicone topping.
6.Acceptance Test Procedures for All Expansion Devices A watertight integrity test will be performed for acceptance as directed by the Engineer. Correct any seepage of water through the joint to the satisfaction of the Engineer at no cost to the CONSTRUCTION JOINTS AND EXPANSION DEVICES 518.06 515 Department. Wait at least 72 hours after the joint was placed. Flo od the joint with water. Visually verify that there are not any leaks on the underside of the joint as determined by the Engineer. Reject joints that leak. Repair leaky joints in accordance with the manufacturer’s recommendations. For modular joint system s, flood for at least one hour to a minimum depth of 3 inches [75 mm]. If leakage is observed, repair the expansion joint system at the contractor's expense. Use the repair procedure that is recommended by the manufacturer and approved by the Engineer.
518.05 Method of Measuremen T
Measure in general, expansion joints will be measured by the linear foot from end to end along the joint centerline of the joint at the roadway surface from end to end except as follows: The aluminum finger type expansion device will be measured by the linear foot between the edges of the deck along the centerline of the joint, completely installed and accepted. Rapid cure joint sealant will be measured by the linear foot along the joint centerline at the roadway surface. The m odular expansion joints will be measured by the linear foot along the centerline of joint (at the top of the joint cross -section) from end to end of the joint. Parapet and median barrier plates, as well as deck haunch plates, will not be measured for payme nt. Water stops wi ll not be measured for payment .
518.06 Basis of Payment
Accepted quantities of the construction joint or expansion device, measured as provided above, will be paid for at the contract unit price for: Pay Items: PAY UNIT:
A.ALUMINUM FINGER TYPE EXPANSION DEVICE Linear Foot [Meter]
B.SEALED EXPANSION JOINTS Linear Foot [Meter]
C.RAPID CURE JOINT SEALANT Linear Foot [Meter]
D.ELASTOMERIC MORTAR Cubic Foot [Meter]
E.PREFORMED SILICONE EXPANSION JOINTS Linear Foot [Meter]
I.MODULAR EXPANSION JOINT Linear Foot [Meter]
J.PREFORMED SILICONE FOAM JOINTS Linear Foot [Meter] Payment is considered full payment for all work necessary to complete the specified items including furnishing all materials, installing the device and hardware, and furnishing all tools, equipment, labor, and incidentals necessary to complete the work in accordance with the Plans and specifications. The detailing and fabrication of any miscellaneous steel components (i.e., parapet plates and median barrier plates, and deck haunch forming plates) are included in this pay item. The Department will consider the cost of other joint fillers, other joint sealers, and water stops to be included in the contract unit price for other bid items.
520.04 Structural Concrete Repair By Sealing and Injection
516 SECTION 520 STRUCTURAL CONCRETE REPAIR BY SEALING AND INJECTION
520.01 Description
This work consists of restoring the structural integrity of portland cement concrete (PCC) structures by injecting and sealing cracks, delaminations, and hollow planes with an epoxy resin system.
520.02 Materials
A.Injection Ports Provide injection ports such as tubes, fittings, or pressure plates for the epoxy resin system under injection pressures of 60 psi [0.4 MPa]. Provide a seal for each injection port.
B.Crack Sealer Provide a sealing compound specified by th e epoxy resin manufacturer to seal cracks in concrete and to anchor the injection ports.
C.Pressure Plates The Department will allow the use of pressure plates instead of sealing compound, as approved by the Engineer. Provide clear plastic pressure plate s that cover the entire crack.
D.Epoxy Resin System Provide an epoxy resin system in accordance with Subsection 701.13.A, “General” Type D.
520.03 Equipment
Provide a pressure pot, hand pump, caulking device, injection machine, or other device to inject the epoxy resin. Provide a special pressure fitting on the injector to prevent leaks when injecting the epoxy resin through the ¼ in [6 mm] holes in the pressure plates. Drill the injection ports using equipment with a vacuum system to prevent dust from compacting into the cracks and laminations.
520.04 Construction Methods
A.Preparation Clean the surfaces adjacent to cracks of efflorescence, deteriorated concrete, and other surface debris detrimental to the adh esion of the surface sealing epoxy compound. Clean the interior surfaces of the cracks with air under sufficient pressure to remove loose materials entrapped within the crack including efflorescence. When sealing cracks underwater, use appropriate cleani ng methods as approved by the Engineer. After cleaning, drill injection port holes using a swivel drill chuck and hollow drill bits including a vacuum attachment which will remove dust and debris generated during drilling.
Source: Oklahoma Standard Specifications for Highway Construction, 2019 Edition. Pages 521–529 of 935.