705JOINT MATERIAL

705.1PREMOLDED EXPANSION JOINT FILLER—From a manufacturer listed in Bulletin 15, provide one

of the following cork, sponge rubber, fiber joint fillers , or polypropylene foam conforming to the following requirements:

If used for transverse joints in reinforced or plain cement concrete pavement, furnish lengths equal to the width of the traffic lane, ramp, or taper with a minimum thickness of 1 inch. P rovide a smooth top surface and holes punched for dowel bars to provide a snug fit without loss in thickness of the material. If used for longitudinal joints in concrete base courses, furnish pieces at least 8 feet in length and join securely. If used for joints in structures, furnish pieces at least 8 feet in length, or as otherwise indicated, and join securely.

Joint filler modified to include polyurethane bonded recycled rubber, consisting of preformed strips of a durable composite of ground recycled rubber from automobile tires bonded together with polyurethane adhesive, is allowed.

with a minimum area of 16 square inches. For glass fiber tested for compression, the applied force may be less than the minimum 100 pounds per square inch.

of a semi-rigid, non-extruding, resilient type, closed-cell polypropylene foam, preformed joint filler.

705.2LONGITUDINAL JOINT MATERIAL—From a manufacturer listed in Bulletin 15 and as shown on the

Standard Drawings or as indicated. Use tie bars, tiebolts, and key formers conforming to the following requirements:

Section 709.1(c).

in Section 709.1(c).

• Manufactured from mild steel.

• A 9/16-inch diameter bar with rolled threads or a 5/8-inch diameter bar with cut threads, with a threaded sleeve nut.

• For the nut, steel pipe or hexagonal steel bar (1 1/16 inches diameter by 1 7/8 inches long), or a high strength steel bar (27/32-inch diameter by 2 inches long).

• For the assembled tiebolt, a minimum yielding load of 15,000 pounds is necessary.

• Epoxy coated or galvanized, excluding threads, as specified in Section 709.1(c) or 1105.02(s).

705.3LOAD-TRANSFER UNITS FOR REINFORCED AND PLAIN CEMENT CONCRETE PAVEMENTS—

T 253 Section 5, or Structural adequacy testing according to PTM No. 642 showing a maximum Linear Variable Differential Transformers (LVDT) differential deflection for dynamic and static loading, for both the approach and leave sides of the joint of not more than 7.5 mils at 1 million cycles and not greater than a 2.5-mil increase in the LVDT differential deflection at 10 million cycles from the corresponding 1 million cycle LVDT deflection. The differential deflection is the absolute difference in deflection bet ween the loaded and unloaded sides of the joint. Provide bars with their free end a true circle and without burrs.

steel-coated dowel bars may be used if documentation of conformance to applicable requirements of Section 705.3 are accepted by LTS.

3.a Type A. Coating material develops sufficiently low bond strength with concrete, so a shop applied bond breaker or bond breaker lubricant is not necessary.

3.b Type B. Coating material develops bond strength with concrete, so a shop applied bond breaker or bond breaker lubricant is necessary. Shop- applied bond breakers are to conform to the pull -out load requirements of AASHTO M 254.

Provide fusion-bonded epoxy coating as a Type B coating with a minimum non-abraded thickness of 8 mils. No more than 2 holidays per linear foot average, as detected with a 67.5 V holiday detector, are allowed. Repair areas damaged during shipment, handling, fabrication, or placement. The sum of all damaged areas to be repaired per linear foot may not exceed 2% of the bar surface area per linear foot. Repair all visible signs of rust and all visible defects. Repair is accomplished by means of a mechanical wire brush cleaning, or another acceptable procedure, followed by application of an approved epoxy paint utilizing the paint manufacturer's recommended procedure. Do not cover more than 5% of the total bar surface area with patching material.

(ASTM B695 and B696). Coating thickness to be not less than 3.4 mils (2.0 ounces per square foot).

baskets conforming to ASTM A955/A955M as specified in Section 709.1(f) for stainless steel reinforcement.

AASHTO M 334 categorized as Level 3 by AASHTO T 374 for uncoated, corrosion-resistant steel reinforcement.

requirements of Table A and as follows:

• Diameter of 1.5 inches or 1.25 inches (+ 0.25 inch, - 0.001 inch) as shown on the Standard Drawing RC-20M or as indicated.

• Length of 18 inches (+/- 1/2 inch)

• For tubular dowels, provide nonmetallic or epoxy coated metallic caps on the ends of the tube that do not exceed the outside diameter of the tube, and prevent intrusion of concrete or other materials.

• Submit structural adequacy testing according to PTM No. 642 showing a maximum Linear Variable Differential Transformers (LVDT) differential deflection for dynamic and static loading, for both the approach and leave sides of the joint of not more than 7.5 mils at 1 million cycles and not greater than a 2.5-mil increase in the LVDT differential deflection at 10 million cycles from the corresponding 1 million cycle LVDT deflection. The differential deflection is the absolute difference in deflection between the loaded and unloaded sides of the joint.

Table A – High Performance Dowel Bar Requirements Dowel Surface Material Configuration Solid Bar or Tube Material Cladding or Coating Material Material Minimum Wall Thickness (in.) Material Minimum Wall/Coating Thickness (in.) Stainless Steel Solid Bar Stainless Steel(1) ― ― ― Clad Bar Steel(2) ― Stainless Steel(1)(4) 0.04 Clad Tube Steel(2) 0.12 Stainless Steel(1)(4) 0.04 Solid Tube Stainless Steel(1) 0.12 ― ― Zinc Clad Clad Bar Steel(2) ― Rolled Zinc Alloy(5) 0.04 Clad Tube Steel(2) 0.12 Rolled Zinc Alloy(5) 0.04 Glass Fiber- Reinforced Polymer Coated (GFRP) Coated Bar or Tube Steel(2) ― GRFP(3) 0.125 Multi-Layer Epoxy Coated Coated Bar or Tube Steel(2) ― Minimum 2 Coats of Epoxy(6) 0.02 Notes:

dowels, and ASTM A249 for clad tubular dowels meeting one of the following UNS Designations: S31603, S31653, S31803.

of 60 kips per square inch or higher for tubular dowels.

Specification for GFRP Reinforced Concrete Bridge Decks and Traffic Railings. Provide clips that firmly hold the GFRP dowel bars in the Load Transfer Unit. Provide clips to positively secure the GFRP dowels to the Load Transfer Unit. Do not weld GFRP dowel bars to Load Transfer Unit.

to ASTM A934 for the first epoxy coating layer and an abrasion resistant second epoxy layer passing NACE TM0215 using 110 pound weight, and the Smooth Cut Carbide Bit gouge tool with a maximum gouge depth of 17.3 mils. Provide a total non-abraded epoxy coating thickness of 20 mils to 60 mils. Zero holidays are allowed. Weld areas used for dowel basket attachments must be ground for welding, and cleaned, and recoated after welding. Remove and replace dowel bars that have epoxy coating damaged (including the ends of the dowels) during shipment, handling, fabrication, or placement, before paving.

steel-coated dowel bars, may be used, if documentation of conformance to applicable requirements of Section 705.3(f) are accepted by LTS.

3.a. Type A. Coating material develops sufficiently low bond strength with concrete so that a bond breaker is not necessary.

3.b. Type B. Coating material develops bond strength with concrete so that a bond breaker is necessary. Shop-applied bond breakers are to conform to the pull-out load requirements of AASHTO M 254.

705.4JOINT SEALING MATERIAL—

one-part formulation, which requires tooling, from a manufacturer listed in Bulletin 15. Furnish silicone joint sealing material conforming to the following physical requirements:

• Tensile Stress at 150% elongation, pounds per square inch, maximum (ASTM D412, Die C) 7-day cure at 77F ± 3F and 45% to 55 % relative humidity

• Elongation at maximum tensile strength, %, minimum (ASTM D412, Die C)

• Extrusion rate, grams/minute, min. 0F to 100F (Test for extrusion using an air-powered caulking gun, having a 1/8-inch orifice, at 90 pounds per square inch)

• Specific gravity (ASTM D792, Method A)

1.010 to 1.515 • Durometer hardness, shore “A” (ASTM D2240) 7-day cure at 77F ± 3F and 45 to 55% relative humidity.

10 to 25 @ 0F • Shelf life, days, minimum, from date of manufacture.

• Ozone and ultraviolet resistance (ASTM C793) No chalking, cracking, or bond loss after 5000 hours. • Flow (ASTM C639-Type II)

Nil • Bond to cement mortar, pounds per square inch, minimum, primed if required. (Mold three cement mortar briquets according to AASHTO T 132 and moisture cure for at least 28 days. Saw briquets in half, clean, and oven dry to a constant weight in an oven at 110 °C ± 5 °C. After cooling, bond halves together with approximately 10 mils of silicone sealant, cure 7 days at 77F ± 3F and 45 to 55% relative humidity, and test using clips conforming to AASHTO T 132. Test specimens in tension at loading rate of 0.3 inch/minute.

• Tack free time, minutes, maximum (ASTM C679)

• Movement capability and adhesion (ASTM C719) Cyclic movement: +100% / -50% (extension/compression), no adhesive or cohesive failure after 10 cycles @ 0F

Type II or Type IV for sealing asphalt pavement joints . Use only ASTM D6690-Type IV for all other joint sealing applications.

ASTM D3542 for bridge seals, and as follows:

1.a Seals.

• Free of pin holes and uncured areas and uniform in all dimensions.

• Function properly at temperatures between -20F and +140F.

• Misalign the walls by not more than 1/8 inch if the pavement seal is in a compressed condition.

• Exceed nominal width by not more than 1/16 inch for seals up to 1 1/2 inches; 3/16 inch for seals greater than 1 1/2 inches up to 2 1/2 inches; 1/4 inch for seals greater than 2 1/2 inches up to 4 inches; and 5/16 inch for seals greater than 4 inches. Allow no negative tolerance from nominal width.

• Vary from nominal height by not more than 1/8 inch if pavement seals are used and 1/4 inch if bridge seals are used.

• Allow no tolerance in the movement range for initial qualification samples. Allow up to a - 5% tolerance in the movement range for routine production samples.

• Allow no negative tolerance on the movement classification for bridge seals. The movement classification for each bridge seal configuration is determined by rounding the movement range criterion down to the nearest 1/2-inch increment.

• Pavement seals have a minimum seal recovery as follows:

Temperature Percent Recovery* Plant Verification Samples (PV) Field Samples (QA, DQA, FV, etc.)

-20F 88 83 14F 95 88 212F 90 85

* Based on nominal width

Seal Size Minimum Movement

1 inch 0.365 inch 1 1/4 inches 0.540 inch

• Pavement seals have a minimum side wall bearing pressure of 4 pounds per square inch at 85% nominal width.

1.b Lubricant Adhesive. ASTM D4070 and as follows: Of suitable viscosity at installation temperature and compatible with application equipment. Do not use lubricant adhesive more than nine months after date of manufacture.

with the automated statement of approval or rejection. A seal lot is a continuous production not exceeding 10,000 linear feet for pavement seals, and not exceeding 3,000 linear feet for bridge seals.

3.a Seals. Clearly and permanently mark the top of each seal with appropriate line characters of not less than 0.0625 inch in height, in increments not exceeding 4 feet. The line characters must designate the lot or batch number, the cure date code, and the type of seal designation. Mark the top of each pavement seal at 1 foot ±1/8 inch intervals in a manner clear and durable to enable stretch/compression determinations of the seal.

3.b Lubricant Adhesive. Label each container with the code or type designation, plant place, lot number, and manufacture date.

Compressive Strength:

• Minimum—Load required to compress test specimen by 25% (to 75% of original thickness) must not be less than 5 psi.

• Maximum—Load required to compress test specimen by 85% (to 15% of original thickness) must not be greater than 30 psi.

to a cross-sectional shape and easily installed in a pavement joint with parallel sides and is sufficiently self- locking to prevent the material from floating out of the joint. Furnish joint filler from a manufacturer listed in Bulletin 15 and as follows:

• Length—minimum 8-foot lengths

• Width—4 7/16 inches to 4 3/4 inches

• Depth—7 3/4 inches to 13 inches

• Density, pounds per cubic inch

6.0-10.0 • Compressive deflection (ASTM D7174)

• Pressure (Load) necessary to compress the test specimen 25%

minimum 5 pounds per square inch • Pressure (Load) necessary to compress the test specimen 65%

maximum 30 pounds per square inch • Recover, % of original, minimum 65% deflection, calculated after 60 seconds of relaxation form deflection return

95% • Water absorption, maximum 30% volume

705.5GASKETS AND WATERSTOPS—From a manufacturer listed in Bulletin 15 and conforming to the

following requirements:

place, and manufacture date. Certify materials, as specified in Section 106.03(b)3.

• Flash Point, Cleveland Open Cup (C.O.C.) minimum, F 350

• Fire Point, C.O.C. minimum, F 375

• Storm Water Systems. ASTM C1478

• Sanitary Sewer Systems. ASTM C923

minimum copper mass of 99.5%.

2.a Physical Requirements.

• Manufactured from virgin polyvinyl chloride resin with the addition of only those plasticizers, stabilizers, and other materials necessary to ensure aging stability and in-place durability

• Not factory scrap or reclaimed polyvinyl chloride.

• Brittleness temperature, ASTM D746

-20F maximum • Modulus of flexure, ASTM D747, pounds per square inch.

400 minimum • Tensile strength, ASTM D412, Die C original, pounds per square inch. Across job splice, pounds per square inch.

1,000 minimum 1,150 minimum • Elongation Original, percent Across job splice, percent

280 minimum 200 minimum • Tear strength, ASTM D624, Die B Original, pounds per inch.

260 minimum • Oven aging, ASTM D573, 70 hours at 212F Change in tensile strength, percent change Change in elongation, percent change

20 maximum 20 maximum

• 14-Day extraction, 140F/150F Change in tensile strength, percent change Change in elongation, percent change

40 maximum 40 maximum

2.b Marking. Permanently label with the manufacturer's name and style or code number, at intervals not exceeding 3 feet.

2.c Acceptance. Material shipped is subject to inspection at the delivery point. If directed, provide samples, selected at random from the shipment, consisting of one portion 4 feet long and another portion from a job splice consisting of a minimum of 12 inches of splice, within 6 inches of unspliced material on each side. Submit samples to the LTS for material confirmation and compliance.

705.6MORTAR—Mix mortar in an acceptable type of mixer, unless otherwise allowed. Do not use retempered

mortar or mortar mixed for more than 1/2 hour, unless otherwise specified. Certify as specified in Section

106.03(b)3

plastic composition. Use materials conforming to the following requirements:

• Cement. Section 701

• Fine Aggregate. Section 703.1, Type C

• Water. Section 720.1

Inlets. ASTM C270, Type N

705.7CAULKING COMPOUND—Certify as specified in Section 106.03(b)3. From a manufacturer listed

in Bulletin 15 and conforming to the following requirements:

and Inlets. ASTM D4586

705.8JOINT BACKING MATERIAL—Expanded, low-density, polyethylene foam from a manufacturer listed

in Bulletin 15 and conforming to ASTM D5249. Certify each shipment as specified in Section 106.03(b)3. If indicated, the foam may be used as a bond breaker between joint filler material and joint sealer.

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