The present invention relates generally to expansion joint systems configured for use in concrete and other building systems, bridges, and roadways and, more particularly, to expansion joints configured to accommodate thermal and/or seismic movements in such systems while also assisting in alleviating deterioration of structural features due to environmental effects.
Concrete structures and other building systems often incorporate joints that accommodate movements due to thermal and/or seismic conditions. These joint systems may be positioned to extend through both interior and exterior surfaces (e.g., walls, floors, and roofs) of a building or other structure.
In the case of an exterior joint in an exterior wall, roof, floor, and so forth, exposed to external environmental conditions, the expansion joint system should also resist the effects of the external environment conditions. In vertical joints, such conditions will likely be in the form of rain, snow, or ice that is driven by wind. In horizontal joints, the conditions will likely be in the form of rain, standing water, snow, ice, and in some circumstances all of these at the same time. Additionally, some horizontal systems may be subjected to pedestrian and/or vehicular traffic.
With particular regard to bridge expansion joints, a major cause of structural deterioration of piers, columns and beams on bridges is leaking and/or deterioration of joints. Water laced with de-icing salts and atmospheric contaminants directed through expansion joints can shed directly onto critical structural elements of the bridges. Potential corrosion and subsequent spalling may occur thereby necessitating expensive reconstruction of beams, piers, columns, wing walls, and so forth.
Moreover, expansion joint products do not fully consider the irregular nature of some expansion joints. It is common for an expansion joint to have several transition areas along the length thereof. These may be walls, parapets, columns, or other obstructions. As such, the expansion joint product follows the joint as it traverses these obstructions. In many products, this is a point of weakness, as the homogeneous nature of the product is interrupted. Methods of handling these transitions include stitching, gluing, and welding. In many situations, it is difficult or impossible to prefabricate these expansion joint transitions, as the exact details of the expansion joint and any transitions and/or dimensions may not be known at the time of manufacturing.
Additionally, in many products, the afore-referenced transitions present weak spots from both a water proofing aspect and a fire resistant aspect. Both expansion joints and fire resistive expansion joints typically address either water tightness aspects or the fire resistive nature, but not both. This has typically resulted in the installation of two systems for each expansion joint where both a fire rating and water resistance is required. In many cases, however, there simply is not sufficient room in the physical space occupied by the expansion joint to accommodate both a fire rated system and a waterproofing system.
Accordingly, there exists a need for improved expansion joint systems, which can not only accommodate thermal and/or seismic movements, but also assist in alleviating and/or preventing deterioration of structural features due to environmental factors. There is a further need for such expansion joint systems that can also address fire and water resistance in one system.
Embodiments disclosed herein address the above needs, as well as others.
According to an aspect, an expansion joint system comprises: a core; and a layer of elastomer disposed on the core. The core and the layer of elastomer disposed thereon form an elongated section, wherein the elongated section is configured to be oriented vertically between substantially coplanar substrates. The expansion joint system further comprises a termination section located at one end of the elongated section and comprising a flared end forming an angle with the elongated section and configured to direct fluid and/or particles and/or solvents away from the expansion joint system.
According to another aspect, an expansion joint system comprises: a core; and a layer of an elastomer disposed on the core. The core and the layer of elastomer disposed thereon form an elongated section, the elongated section configured to be oriented horizontally between substantially coplanar substrates and having an end portion configured to angle around a corner, the end portion being vertically oriented. The expansion joint system further comprises a termination section located at the end portion configured to angle around the corner. The termination section comprises a flared end forming an angle with the vertically oriented end portion and configured to direct fluid and/or particles and/or solvent away from the expansion joint system.
According to a further aspect, a fire and water resistant expansion joint system comprises: a first substrate; and a second substrate arranged substantially coplanar with the first substrate; and an expansion joint system located in compression between the first substrate and the second substrate. The expansion joint system comprises: an open celled foam having a fire retardant material infused therein, wherein the ratio of fire retardant material infused in the open celled foam is in a range of about 3.5:1 to about 4:1 by weight; and a layer of an elastomer disposed on the open celled foam. The open celled foam and the layer of elastomer disposed thereon form an elongated section, the elongated section being configured to be oriented vertically between the first substrate and the second substrate. The expansion joint system further comprises a termination section located at one end of the elongated section and comprising a flared end forming an angle with the elongated section and configured to direct fluid and/or particles and/or solvent away from the expansion joint system.
According to another aspect, a fire and water resistant expansion joint system comprises: a first substrate; a second substrate arranged substantially coplanar with the first substrate; and an expansion joint system located in compression between the first substrate and the second substrate. The expansion joint system comprises: open celled foam having a fire retardant material infused therein, wherein the ratio of fire retardant material infused in the open celled foam is in a range of about 3.5:1 to about 4:1 by weight; and a layer of an elastomer disposed on the open celled foam. The open celled foam and the layer of elastomer disposed thereon form an elongated section, the elongated section configured to be oriented horizontally between the substantially coplanar first substrate and the second substrate, and having an end portion configured to angle around a corner, the end portion being vertically oriented. The expansion joint system further comprises a termination section located at the vertically oriented end portion configured to angle around the corner, the termination section comprising a flared end forming an angle with the vertically oriented end portion and configured to direct fluid and/or particles and/or solvent away from the expansion joint system.
According to a further aspect, a termination section comprises: a core; and a layer of elastomer disposed on the core; wherein the termination section is configured for an expansion joint system comprising an elongated section configured to be oriented vertically between substantially coplanar substrates. The termination section is configured to be located at one end of the elongated section and comprises a flared end configured to form an angle with the elongated section and direct fluid and/or particles and/or solvents away from the expansion joint system.
According to a further aspect, a termination section comprises: a core; and a layer of elastomer disposed on the core, wherein the termination section is configured for an expansion joint system comprising an elongated section configured to be oriented horizontally between substantially coplanar substrates and having an end portion configured to angle around a corner, the end portion being vertically oriented. The termination section is configured to be located at the end portion to angle around the corner and comprises a flared end configured to form an angle with the vertically oriented end portion and direct fluid and/or particles and/or solvents away from the expansion joint system.
According to a still further aspect, a kit comprises: a termination section configured to attach to an elongated section of an expansion joint system. The termination section comprises: a core; and a layer of elastomer disposed on the core, wherein the termination section comprises a flared end configured to form an angle with a portion of the elongated section, and direct fluid and/or particles and/or solvents away from the expansion joint system.
Embodiments of the invention provide a resilient water resistant and/or fire resistant expansion joint system able to accommodate thermal, seismic, and other movements while maintaining water resistance characteristics, as well as able to direct, e.g., fluid, and/or particles and/or solvents away from the structure employing the expansion joint system. Thus, embodiments are particularly effective in providing protection from deterioration to the expansion joint system and surrounding structures due to environmental effects, such as water, snow, ice, oil, solvents, contaminants, debris, and so forth.
Accordingly, embodiments are suited for use in concrete buildings and other structures including, but not limited to, parking garages, stadiums, tunnels, bridges, roadways, airport runways, waste water treatment systems and plants, potable water treatment systems and plants, and the like. Moreover, it is noted that embodiments are particularly suitable for use as bridge expansion joint systems (BEJS).
Embodiments of the expansion joint systems disclosed herein are described, for example, as being installed between concrete substrates. However, it is noted that the expansion joint systems may be installed between substrates or surfaces other than concrete. Materials for such substrates or surfaces include, but are not limited to, glass, asphalt, stone (granite, marble, etc.), metal, and so forth. Particular structures for the substrates include, but are not limited to, a first deck and a second deck of a bridge, parking garage, and so forth.
Referring now to
It is noted that the elongated section 26 can be oriented in non-vertical orientations. The orientation depends on the particular need for the system 20, and the substrates employed. For instance,
The expansion joint system 20 shown in each of
The core 22 can be infused with a suitable material including, but not limited to, waterproofing material such as an acrylic, such as a water-based acrylic chemistry, a wax, a fire retardant material, ultraviolet (UV) stabilizers, and/or polymeric materials, and so forth. A particularly suitable embodiment is a core 22 comprising an open celled foam infused with a water-based acrylic chemistry, and/or a fire retardant material.
One type of fire retardant material that may be used is a water-based aluminum tri-hydrate (also known as aluminum tri-hydroxide (ATH)). However, the present invention is not limited in this regard, as other fire retardant materials may be used. Such materials include, but are not limited to, metal oxides and other metal hydroxides, aluminum oxides, antimony oxides and hydroxides, iron compounds, such as ferrocene, molybdenum trioxide, nitrogen-based compounds, combinations of the foregoing materials, and other compounds capable of suppressing combustion and smoke formation.
As is best seen in
As a non-limiting example, the amount of fire retardant material infused into the core 22, such as an open celled foam, is between 3.5:1 and 4:1 by weight in a ratio with the un-infused core itself. The resultant uncompressed core whether comprising a solid block or laminates, has a density of about 130 kg/m3 to about 150 kg/m3, specifically 140 kg/m3, according to embodiments.
The infused core 22, such as infused foam laminate, can be constructed in a manner which insures that substantially the same density of fire retardant is present in the product regardless of the final size of the product. For example, the starting density of the infused foam is approximately 140 kg/m3, according to embodiments. After compression, the infused foam density is in the range of 200-700 kg/m3. After installation, the laminate can cycle between densities of approximately 750 kg/m3 at the smallest size of the expansion joint to approximately 400-450 kg/m3 or less at the maximum size of the joint. This density of 400-450 kg/m3 is based upon experiments as a reasonable minimum which still affords adequate fire retardant capacity, such that the resultant composite can pass the UL 2079 test program. The present invention is not limited to cycling in the foregoing ranges, however, as the material may attain densities outside of the herein described ranges. It is further noted that UL 2079, developed by Underwriters Laboratories, is a further refinement of ASTM E-119 by adding a cycling regimen to the test. Additionally, UL 2079 stipulates that the design be tested at a maximum joint size. This test is more reflective of real world conditions, and as such, architects and engineers have begun requesting expansion joint products that meet it. Many designs which pass ASTME-119 without the cycling regime do not pass UL 2079. This may be adequate for non-moving building joints; however, most building expansion joint systems are designed to accommodate some movements as a result of thermal effects (e.g., expansion into the joint and contraction away from the joint) or as a result of seismic movement. Advantageously, embodiments of the expansion joint system 20 disclosed herein meet and can pass UL 2079 testing.
As best seen in
In any embodiment, for example when individual laminations 34 are used, several laminations, the number depending on the expansion joint size (e.g., the width, which depends on the distance between opposing substrates 36 into which the expansion joint system 20 is to be installed), can be compiled and then compressed and held at such compression in a suitable fixture. The fixture, referred to as a coating fixture, is typically at a width slightly greater than that which the expansion joint will experience at the greatest possible movement thereof.
It is noted that in the fixture, the laminations 34 can be configured in any desired shape and size depending upon the desired application and end use location of resultant expansion joint system 20. For example, the laminations 34 thus can be configured and factory fabricated, with use of a fixture, as a substantially straight portion of the elongated section 26, shown in
According to embodiments, in the fixture, the assembled infused or un-infused core 22 is typically coated with a waterproof elastomer 24 on, for example, one or more surface. The elastomer 24 may comprise, for example, at least one polysulfide, silicone, acrylic, polyurethane, poly-epoxide, silyl-terminated polyether, combinations and formulations thereof, and so forth, with or with or without other elastomeric components, coatings, liquid sealant materials, and so forth. A particularly suitable elastomer 24 for coating, e.g., laminations 34 for applications where vehicular traffic is expected is PECORA 301 (available from Pecora Corporation, Harleysville, Pa.) or DOW 888 (available from Dow Corning Corporation, Midland, Mich.), both of which are traffic grade rated silicone pavement sealants. For vertical wall applications, an especially suitable elastomer 24 for coating the laminations 34 is DOW 790 (available from Dow Corning Corporation, Midland, Mich.), DOW 795 (also available from Dow Corning Corporation), or PECORA 890 (available from Pecora Corporation, Harleysville, Pa.). A primer may be used depending on the nature of the adhesive characteristics of the elastomer 24.
During or after application of the elastomer 24 to, e.g., laminations 34 of the termination section 28 and the elongated section 26, shown in
It is noted that the layer of elastomer 24 located on the termination section 28 and the elongated section 26 can be the same or different. The layer of elastomer 24 also can be continuous or non-continuous over the elongated section 26 and termination section 28. It is further noted that while, e.g.,
Additionally, typically the termination section 28 comprises the elastomer 24 on all external surfaces of the termination end, although this is not required. For example, an additional coating layer, such as an intumescent layer 38 further described below, could be located over the layer of elastomer 24 on one or more surfaces of the termination section 28, and/or located directly on one or more surfaces of the termination section 28.
As shown in the embodiments of
According to embodiments, the surface of, e.g., the infused laminate opposite the surface coated with the waterproofing elastomer 24 could be coated with an optional intumescent material 38, as shown in
It is noted that various combinations of elastomer 24 and intumescent material 38 can be employed, according to embodiments. For example, either or both of the elongated section 26 and termination end 28 can be coated with a first layer of elastomer 24 followed by a second layer of intumescent material 38. Also, the side of the elongated section 26 and termination section 28 shown opposite the layer of elastomer 24 in
After tooling or otherwise configuring to have, e.g., a bellows-type profile, the coating of elastomer 24 and any intumescent material 38, if applicable, can be cured in place on the core 22 of the elongated section 26 and/or termination end 28 while the lamination is held at the prescribed compressed width, thereby effecting a secure bond to the, e.g., infused laminations 34. After curing, the entire composite can then be removed from the fixture, optionally compressed to less than the nominal size of the material and packaged for shipment. In the packaging operation, a hydraulic or mechanical press (or the like) can be employed to compress the material to, e.g., a size below the nominal size of the expansion joint at the job site. For example, the material can be held at that the desired size by using a heat shrinkable poly film. The present invention is not limited in this regard, however, as other devices (ties and so forth) may be used to hold the material to the desired size.
As noted above, such construction with the use of individual laminations 34 is not required as a solid block construction, and so forth, could be employed. Accordingly, the descriptions herein regarding fabrication with use of a coating fixture and application of elastomer 24 and/or intumescent 38 layers also can apply to such non-laminations constructions.
Referring to
It is further noted that the adhesive may be pre-applied to the core 22, such as pre-applied to the foam laminations thereof. In this case, for installation, the lamination can be removed from the packaging and simply inserted into the expansion joint where it is allowed to expand to meet the concrete or other substrate. Once this is completed, the adhesive in combination with the back pressure of the core 22 can hold the core 22 in position.
Additionally, as best seen in
To fill an entire expansion joint, it is noted that the installation as described above could be repeated, if needed, using, e.g, the elongated section 26 without the termination section 28. For example, after inserting the system 20 as shown in
Additionally, regarding, e.g., bridge expansion joint system (BEJS) applications, the system 20, which also may be referred to as a “kick out termination” can be installed at the edge of a bridge deck(s) with its downturn over the side of the bridge and the termination section 28 or “drip edge” protruding out beyond the face of the slab. Thus, the “kick out termination” can be a factory fabricated piece, as described above, with a built in “drip edge” or termination section 28 that directs environmental effects, such as water runoff, and so forth, advantageously away from the bridge structure thereby assisting in increasing the life span of the BEJS and surrounding structures by preventing some deterioration of those surfaces from such adverse effects. For example, water that runs off of the joint is advantageously directed away from the bridge and its bearing pads, columns, and so forth, by, e.g., a silicone coated flared end 30 of the termination section 28. The “kick out termination” can be installed first, followed by connecting the afore-described straight length sections.
It is noted that in any embodiment, the construction or assembly of the systems 20 described herein is often carried out off-site, but elements thereof may be trimmed to appropriate length on-site. It is noted that such off-site assembly is not required. However, by constructing or assembling the systems 20 disclosed herein in a factory setting, on-site operations typically carried out by an installer, who may not have the appropriate tools or training for complex installation procedures, can be minimized. Accordingly, the opportunity for an installer to effect a modification such that the product does not perform as designed or such that a transition does not meet performance expectations also is minimized.
In furtherance to the above, it is noted that there may be instances where just the herein described termination section 28 is desired to be fitted onto an existing portion of an expansion joint system at, e.g., the job site. Such installation can be carried out with use of, e.g., a kit comprising the termination section 28 configured to attach to a section of an existing expansion joint system, such as attachment to elongated section 26 or even another portion/section depending upon the configuration of the system. This also can improve existing expansion joint systems in terms of, e.g., protecting the system and surrounding structures from deterioration due to exposure to environmental effects including fluid, and/or particles and/or solvents. During such an installment, the termination section 28 can be attached or secured using any suitable securing mechanism including, but not limited to adhesive, such as epoxy.
It is noted that the terms “a” and “an” and “the” herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Any use of the suffix “(s)” herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term. Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments. Moreover, regarding the Drawings, it is noted that the Drawings herein are merely representative of examples of embodiments and features thereof, and are thus not intended to be limiting or be of exact scale.
Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of the appended claims.
This application is a Continuation application of U.S. patent application Ser. No. 14/080,960 (1269-0006-1), filed on Nov. 15, 2013, now U.S. patent No., which claims the benefit of U.S. Provisional Patent Application No. 61/727,351 (1269-0006), filed on Nov. 16, 2012, the contents of each of which are incorporated herein by reference in their entireties and the benefits of which are fully claimed herein.
Number | Date | Country | |
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61727351 | Nov 2012 | US |
Number | Date | Country | |
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Parent | 14080960 | Nov 2013 | US |
Child | 14730896 | US |