02762_en.pdf

Section 02762 1

SECTION 02762

JOINTS, REINFORCEMENT, AND MOORING EYES IN CONCRETE PAVEMENTS

PART 1 - GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A 615/A 615M (1995; Rev. C) Deformed and Plain Billet-

Steel Bars for Concrete Reinforcement

ASTM D 1752 (1984; R 1992) Preformed Sponge Rubber and

Cork Expansion Joint Fillers for Concrete

Paving and Structural Construction

AMERICAN WELDING SOCIETY (AWS)

AWS D1.4 (1992) Structural Welding Code -

Reinforcing Steel

FEDERAL SPECIFICATIONS (FS)

FS L-C-530 (Rev. C) Coating, Pipe, Thermoplastic

Resin

1.2 SUBMITTALS

Shop Drawings:

Load-transfer devices

Mooring eyes

Preformed Compression seals

Manufacturer's catalog data in the form of catalog cuts may be submitted in lieu of drawings for the listed items.

Test Reports:

Joint sealer

Certificates:

Equipment list

Submit a list and description of equipment to be used. Equipment for heating, mixing and installing joint seals shall be in accordance with instructions provided by joint seal manufacturer.

Blocking media

Separating tape

Dowel

Reinforcement

Joint seal

2 Section 02762

Manufacturer's Instructions:

Joint sealants

Preformed compression seals

Dowel Assemblies

Instructions for joint sealants shall include, but not be limited to:

storage requirements, ambient temperature and humidity ranges, and moisture condition of joints for successful installation; requirements for preparation of joints; safe heating temperature; mixing instructions;

installation equipment and procedures; application and disposal requirements; compatibility of sealant with filler material; curing requirements; and restrictions to be adhered to in order to reduce hazards to personnel or to the environment. Submit instructions at least

30 days prior to use.

Closeout Submittals:

Joint sealer

Joint filler

A record of joint sealant and filler materials used shall be furnished, in duplicate, to the Contracting Officer’s Technical Representative in the following format:

MILITARY MATERIAL SPECIFICATION MANUFACTURER

BASE/AREA DESIGNATION/TYPE

MATERIAL USED EXACT ON-SITE QUANTITY OF DATE

(MFR DESIG) LOCATION SEALANT APPLIED

1.3 DELIVERY, STORAGE, AND HANDLING

Inspect for damage, unload, and store materials delivered to site in accordance with manufacturer's instructions.

1.3.1 Joint Seal Materials

Deliver liquid joint sealants and lubricants in original sealed containers and protect from freezing and high temperatures. Store preformed joint fillers in a manner to maintain straightness and avoid damage.

1.3.2 Coated Dowel Bars

Coated dowel bars shall be stored in a manner to avoid cracking or perforations in coating. Cover stored dowel bars with tarpaulin or black colored polyethylene film.

1.3.3 Reinforcement

Store reinforcement on pallets or wooden sleepers in a manner to avoid excessive rusting or contamination with soil, grease, oil, or other objectionable material. Store reinforcement in separate piles or racks to

Section 02762 3 avoid loss of identification after bundles of reinforcing bars or mats are broken.

1.4 ENVIRONMENTAL REQUIREMENTS

Forming of joints or applying joint sealants shall not proceed when the underlying layer or surface is frozen, or when, in the opinion of the

Contracting Officer’s Technical Representative, weather conditions will prevent the proper installation of the joint sealants. During installation, surfaces shall be dry and sealant and bond breakers shall be protected from moisture.

1.5 TRAFFIC CONTROL

Do not permit vehicular or heavy equipment traffic on the pavement in area of the joints being sealed during the protection and curing period of joint sealant. At end of curing period, traffic may be permitted on pavement when approved.

1.6 EQUIPMENT

Maintain machines, tools, and other equipment used in performance of work in proper working conditions at all times. Furnish necessary equipment and accessories to install preformed joint filler, preformed compression seal, and liquid sealant in hardened concrete in accordance with equipment list. Concrete saws shall be adequate to remove filler and saw grooves for all joints.

1.6.1 Joint and Pavement Cleaning Equipment

1.6.1.1 Sandblasting Equipment

Sandblasting equipment for cleaning joints shall include an air compressor, hose, and nozzles of proper size, shape and opening to produce a clean joint. Equip compressor with traps that will maintain compressed air free of oil and water.

1.6.1.2 Power Saws

Concrete saws shall be self-propelled and capable of sawing joints in concrete to indicated width, depth and alignment without spalling or ravelling of concrete and at a production rate to avoid uncontrolled cracking.

1.6.1.3 Vacuum Sweeper

Self-propelled, vacuum pickup sweeper capable of removing saw cuttings, loose sand, water, joint material, and debris from pavement surface.

1.6.2 Joint Sealing Equipment

Joint sealing equipment shall be of a type required by joint seal manufacturer's installation instructions. Equipment shall be capable of installing sealant to depths, widths and tolerances indicated. Inspect equipment periodically during installation of sealant as required but not less than once each work day, to ensure the equipment is functioning properly. If malfunctions are noted, joint sealing shall not proceed until they are corrected.

4 Section 02762

1.6.2.2 Two Component Cold-Applied Liquid Sealants

For two component cold-applied machine mixed sealants equipment shall be capable of delivering each component within an accuracy of 5 percent.

Equip reservoirs for each component with mechanical agitation devices.

Equip equipment with thermostatically controlled indirect heating of components when required. Equipment shall include screens over each reservoir to eliminate foreign particles or partially polymerized material which may clog lines. Equipment shall be capable of intimately mixing the two components through a range of application rates from 0.01 to 0.06 liter per second and through a range of pressures from 345 to

1034 kPa. Hand-mixing of cold-applied two component sealant may be done at the option of the Contractor for sealants conforming to FS SS-S-200, Type H.

1.6.2.3 Preformed Joint Seal

Install seals with equipment recommended in writing by sealant manufacturer. Equipment shall be capable of installing joint seal to indicated depth without damaging, distorting, or stretching seal material.

1.6.2.4 Equipment for Silicone Sealant

Equipment for silicone sealant shall be air-powered pump, components, and hoses as recommended by the sealant manufacturer. Hoses and seals shall be lined to prevent moisture penetration and withstand pumping pressures.

Equipment shall be free of contamination from previously used to other type sealant.

PART 2 - PRODUCTS

2.1 MATERIALS

2.1.1 Joint Filler

2.1.1.1 For Expansion Joints

Preformed joint filler, ASTM D 1752, Type II or Type III.

Filler must be compatible with joint sealer material.

2.1.2 Bond Breakers

2.1.2.1 Blocking Media

Compressible, non-shrinkable, non-reactive with joint sealant and non-absorption type such as plastic rod, free of oils or bitumens.

Blocking media shall have a water absorption of not more than 5 percent by weight when tested in accordance with ASTM C 509. Blocking media shall be consistent with joint seal manufacturer's installation instructions and be at least 25 percent larger in diameter than width of joints as shown.

2.1.2.2 Separating Tape

Polyethylene or polyester tape, 0.08 mm minimum thickness, or masking

Section 02762 5 tape, nonreactive, nonabsorptive, adhesive back tape, width equal to width of joints as indicated. Separating tape shall be consistent with joint seal manufacturer's installation instructions.

2.1.3 Joint Sealants

2.1.3.1 Two Component Cold-Applied Sealing Compound

FS SS-S-200, Type M or Type H.

2.1.3.2 Single Component Cold-Applied Silicone

Silicone sealant shall be self-leveling, non-acid curing, and meet the following requirements:

TEST TEST METHOD REQUIREMENTS

Weight Loss ASTM C 792

Modified(See Note 1)

10 percent max

Flow ASTM C 639 (Type I) Smooth and level

Extrusion Rate ASTM C 603 30 seconds max

Tack Free Time ASTM C 679 5 hours max

Hardness (Shore 00)

(See Note 2)

ASTM C 661 30 – 80

Tensile Stress at 150

Percent

Elongation(See Note

2)

ASTM D 412 (Die C) 207 kPa

Percent Elongation(See

Note 2)

ASTM D 412 (Die C) 700 minimum

Accelerated Weathering ASTM C 793 Pass 5000 hours

Bond and Movement

Capability

ASTM C 719 Pass 10 cycles at +50 percent movement (no adhesion or cohesion failure)

Flame Resistant FS SS-S-200 Pass

NOTES:

1. Percent weight loss of wet (uncured) sample after placing in forced-draft oven maintained at 70 degrees at + 2 degrees C for two hours.

2. Specimen cured 21 days at 23 degrees + 2 degrees C and 50 percent.

ACCELERATED WEATHERING FACTORY TEST REPORT. For Accelerated Weathering test, in lieu of testing of actual joint sealant to be used on the project, a report of a factory test, performed within two years of contract award, may be submitted.

2.1.3.3 Primers

Select concrete primer recommended by manufacturer of proposed liquid joint sealant.

2.1.3.4 Preformed Compression Seals

ASTM D 2628. ASTM D 2835, for lubricant.

2.1.4 Mooring Eyes

6 Section 02762

Plain bars conforming to ASTM A 615/A 615M, Grade 400 Grade 60, as indicated. Welding shall conform to AWS D1.4.

2.1.5 Coated Dowel Bars

Bars shall conform to ASTM A 615/A 615M, Grade 300 for plain billet-steel bars of size and length indicated.

Remove burrs and projections from dowel bars. Coating system shall conform to FS L-C-530, Type 2. Coat bars with a double coat system or an epoxy coating system for resistance to penetration of oil and salt solutions. System shall be in accordance with manufacturer’s recommendation for coating which are not bondable to concrete. Bond coating to dowel bar to resist laps or folds during movement of joint.

Coating thickness shall be 0.18 mm minimum and 0.50 mm maximum. For doweled expansion joints, fit the outer end of sliding portion of each dowel with a tight fitting metal sleeve which conforms to manufacturer's recommendation for dowel bars.

2.1.6 Dowel Assemblies

Support dowels with steel baskets or dowel assemblies. Supports shall conform to manufacturers recommendations for rigid welded dowel assemblies, heavy duty type. Weld spacer wires parallel to dowels and weld alternate ends of dowels to sides of assembly. Sliding surfaces shall be parallel with longitudinal axis of pavement within a tolerance of 3 mm per 3 m.

2.1.7 Reinforcement for Slabs

Welded steel wire fabric shall be electro-welded netting for concrete reinforcement, conforming to D.M. 9 January 1996 and shall have the following minimum properties:

Yield stress, fyk or f(0.2)k 390 MPa

Breaking stress, ftk 440 MPa

Ration of diameters of intersecting wires

0.6 min

Elongation 8 %

Minimum ratio for ftk/fyk 1.10

PART 3 - EXECUTION

3.1 PREPARATION OF SEALANTS

3.1.1 Liquid Sealants

Prior to use, inspect liquid joint seal to ensure product has not become damaged during shipping and storage, material is of proper lot number and has not reached its shelf life retest date.

3.1.2 Preformed Joint Fillers

Prior to installing inspect preformed joint fillers to ensure they are straight, without damage, and resilient.

3.1.3 Cold-Applied Two Component Type Liquid Sealants

Section 02762 7

Inspect sealant components and containers prior to use, and reject materials that contain water, hard caking of separated constituents, nonreversible gel, or that are otherwise unsatisfactory. Settlement of constituents in a soft mass that can be readily and uniformly remixed in field with simple tools will not be cause for rejection. Prior to transfer of components from shipping containers to reservoirs of application equipment, mix materials in shipping containers to ensure homogeneity of components and incorporation of all constituents at time of transfer. When necessary warm components of the sealer to a temperature not exceeding 32 degrees C by placing components in heated storage, but in no case shall components be heated by direct flame or in single-walled, non-oil-bath heating kettles.

3.2 JOINTS

Joints shall be type shown and shall form a regular rectangular pattern.

Joints shall conform to details shown. Seal joints by procedures indicated. Preformed joint filler installed for expansion joints shall be securely held in position during concreting operations. Wherever curved pavement edges occur, make joints to intersect tangents to curve at right angles. Joints shall be in a continuous straight line extending from edge to edge of pavement. Do not stagger joints in abutting pavements except where shown. Protect joints from curing compounds by covering with tape or rope. Take necessary precautions to ensure proper curing at joints.

3.2.1 Sawing of Joints

Sawing will be conducted when concrete has hardened sufficiently to prevent raveling or flaking along edges of saw cut and before uncontrolled shrinkage cracking of pavement occurs. Mark alignment of joints by chalk line or other suitable guide. Saw cuts shall not vary from required alignment by more than 13 mm in 3 m. Saw cutting shall be carried on both during the day and at night as required. A supply of saw blades and at least one stand-by sawing unit in working condition will be readily available during sawing operations. Discontinue sawing if a crack develops ahead of a saw cut. If uncontrolled cracking has occurred do not saw cut along the cracks but notify the Contracting Officer’s Technical

Representative immediately.

3.2.2 Protection of Joints

Immediately after each joint is sawed, thoroughly clean saw cut and adjacent concrete surface by flushing with water and blowing with compressed air to remove waste. Respray curing compound on surfaces affected by sawing and cleaning operations but do not permit curing compound into joints. Protect joints from intrusion of foreign materials by installation of blocking media or separating tape as indicated. Do not seal joints until concrete has cured sufficiently as required by joint sealant manufacturer's instructions.

3.2.3 Preformed Compression Seals

Install preformed compression seals in a straight line and plumbed vertically in accordance with manufacturer’s requirements.

3.2.4 Expansion Joints

Expansion joints shall have dimensions and spacing shown, and be filled with preformed joint filler and sealant. Hold filler in place accurately

8 Section 02762 and securely during the placing and finishing of concrete. Use metal supports to support filler and protect material from damage during concrete operations. A bulkhead, when used, shall have sufficient strength to remain straight from edge to edge of slab when concrete is placed against it. Stake bulkhead in place securely at right angles to longitudinal or transverse axis and surfaces of concrete slab. Space and drive flat metal stakes to hold filler firmly in position. Deposit concrete and compact and strike off before bulkhead is removed. Do not remove stakes until the concrete has been finished. Under no circumstances shall concrete be left above expansion material or across joint at any point. Cut away carefully concrete spanning ends of the joint next to forms after forms are removed.

Fit abutting sections of joint filler material tightly together to prevent concrete from entering expansion joint space.

3.2.5 Contraction Joints

Saw joints to dimensions indicated. Joint lines shall be within specified tolerance, straight, and extend for width of transverse joint, and for entire length of longitudinal joint.

3.2.6 Construction Joints

3.2.6.1 Butt Type Joints

Provide butt type joints as indicated by placing fresh concrete against hardened concrete. Clean vertical surface of hardened concrete and then coat with curing compound or asphalt emulsion bond breaker before concrete is placed. After concrete has cured, saw joint line in accordance with procedures specified for sawing joints and to dimensions

3.2.6.2 Emergency Stops

If an emergency stop occurs remove the concrete back to indicated location of transverse joint and install a dowelled construction joint as

3.2.6.3 Keyed Joints

Locate keyways as indicated. When concrete is placed using side or stationary forms, use plastic or metal forms securely fastened to concrete form to form keyway in plastic concrete. When concrete is placed using slip-form pavers, form the keyway by metal forms permanently attached to side forms or during slip-form operation by inserting preformed metal or plastic keyway liners which may be left in place.

3.2.7 Preparation of Joints

Seal joints unless otherwise indicated. Immediately before installation of sealant, thoroughly clean joints until laitance, curing compound, preformed joint filler, and protrusions of hardened concrete are removed from sides and upper edges of joint space.

3.2.7.1 Cleaning of Sawed Joints

Use a power-driven concrete saw to saw through preformed joint filler and to widen joint to indicated dimensions. Blow loosened materials from joint with compressed air. Clean exposed concrete joint faces and

Section 02762 9 pavement surfaces extending at least 25 mm from edges of joints by thoroughly sandblasting and air blowing until surfaces are free of dust, dirt, curing compound, preformed joint filler, and other material that might prevent bonding of sealer to concrete.

3.2.8 Disposal of Debris

Remove from joints and pavement surface saw cuttings, excess joint material, dirt, water, sand, and other debris. Dispose of the debris immediately in accordance with Section 02220, "Site Demolition."

3.3 INSTALLATION

Joint preparation, primer and sealant shall be in accordance with joint seal manufacturer's instructions.

3.3.1 Bond Breakers

Immediately after joints receive final cleaning, install specified bond breaker in the bottom of joint reservoir.

3.3.2 Bonding Agents and Primer

Apply joint seal bonding agents and primer in accordance with joint seal manufacturer's instructions. When primed joint becomes dusty or otherwise contaminated prior to sealing, re-sandblast, air blow, and re-prime joint.

3.3.3 Installation of Liquid Sealants

Do not install liquid joint seals until test section has been inspected and approved by the Contracting Officer’s Technical Representative.

Joints shall be dry and free of debris and contaminants prior to placement of sealant. Fill joints to depths and tolerances indicated without formation of voids or entrapped air. Remove excess or spilled sealant from pavement and discard.

3.3.4 Installation of Preformed Compression Seal

Install preformed compression seals in accordance with manufacturer's instructions to dimensions and tolerances indicated. Seal shall be plumb and shall not be stretched or twisted during installation.

3.3.5 Setting Mooring Eyes

Set mooring eyes accurately, plumb, square, and flush, within a tolerance of 13 mm below top of slab. Depressions may be formed or troweled to required shape. Finish depressions to neat true uniform surfaces.

3.3.6 Coated Dowel Bars

Install bars, accurately aligned vertically and horizontally, at indicated locations and to dimensions and tolerances indicated. Reject coatings which are perforated, cracked or otherwise damaged. While handling avoid scuffing or gouging of coatings.

3.3.7 Dowel Assemblies

10 Section 02762

Dowels for transverse contraction joints shall be installed in unreinforced concrete by presetting in steel baskets. At transverse expansion joints set dowels with dowel assemblies. Dowels in longitudinal construction joints must be drilled and grouted with an approved grout.

Before construction commences method for installing dowel bars shall be approved.

3.3.8 Tie Bars

Install bars, accurately aligned horizontally and vertically, at indicated locations.

3.3.9 Setting Slab Reinforcement

Type and amount of steel reinforcement shall be as shown. For pavement thickness of 300 mm or more, install reinforcement steel by strike-off method wherein concrete is deposited on underlying material, consolidated and struck to indicated elevation of steel reinforcement.

Place reinforcement on pre-struck surface, then place remaining concrete and finish in required manner. If second lift causes steel to be displaced horizontally from its original position, increase thickness of first lift and depress reinforcement into plastic concrete to required elevation.

Increase in thickness shall be only as necessary to permit correct horizontal alignment to be maintained. Remove and replace portions of bottom layer of concrete that have been placed more than 30 minutes without being covered with top layer. Wire mesh reinforcement may be placed with mechanical mesh placers and vibrated into place. For pavements less than 300 mm thick, reinforcement may be positioned on suitable chairs prior to concrete placement or reinforcement steel may be depressed into plastic concrete to the required elevation after concrete has been spread.

At expansion, contraction and construction joints, place reinforcement as indicated. Reinforcement, when placed in concrete, shall be free of mud, oil, scale or other foreign materials. Place reinforcement accurately and wire securely. Laps at splices shall be 300 mm minimum and distances from ends and sides of slabs and joints shall be as indicated.

3.4 FIELD QUALITY CONTROL

3.4.1 Joints

Joints which have been cleaned are ready to be primed for adhesive shall be inspected and approved prior to installing compression seal or silicone or bi-component sealant or joints which have backer rods or bond breaking tape installed shall be inspected and approved prior to sealing.

3.4.2 Reinforcement

Inspect reinforcement prior to installation to assure it is free of loose flaky rust, loose scale, oil, mud, or other objectionable material.

3.4.3 Dowels

Inspect dowel placement prior to placing concrete to assure that dowels are of size indicated, and are spaced, aligned and painted and oiled as specified. Dowels shall not deviate from vertical or horizontal alignment after concrete has been placed by more than 3 mm per 300 mm.

Section 02762 11

3.5 ACCEPTANCE

Joint sealer that fails to cure properly, or fails to bond to joint walls, or reverts to uncured state or fails in cohesion, or shows excessive air voids, blisters, surface defects, swelling, or other deficiencies, or is not recessed within indicated tolerances shall be rejected. Remove rejected sealer and re-clean and reseal joints in accordance with the specifications.

-- End of Section --