U.S. patent application number 14/229463 was filed with the patent office on 2015-09-17 for factory fabricated precompressed water and/or fire resistant tunnel expansion joint systems, and transitions.
This patent application is currently assigned to EMSEAL JOINT SYSTEMS LTD.. The applicant listed for this patent is Emseal Joint Systems Ltd.. Invention is credited to Lester Hensley, William Witherspoon.
Application Number | 20150259905 14/229463 |
Document ID | / |
Family ID | 52004223 |
Filed Date | 2015-09-17 |
United States Patent
Application |
20150259905 |
Kind Code |
A9 |
Hensley; Lester ; et
al. |
September 17, 2015 |
FACTORY FABRICATED PRECOMPRESSED WATER AND/OR FIRE RESISTANT TUNNEL
EXPANSION JOINT SYSTEMS, AND TRANSITIONS
Abstract
A fire and/or water resistant expansion joint system for
installation between substrates of a tunnel. The system includes a
coating applied at a predetermined thickness to the substrates and
a fire and water resistant expansion joint. The expansion joint
includes a core and a fire retardant infused into the core. The
core is configured to define a profile to facilitate the
compression of the expansion joint system when installed between
the substrates. The coating and the fire and water resistant
expansion joint are each capable of withstanding exposure to a
temperature of at least about 540.degree. C. or greater for about
five minutes.
Inventors: |
Hensley; Lester;
(Westborough, MA) ; Witherspoon; William; (Guelph,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Emseal Joint Systems Ltd. |
Westborough |
MA |
US |
|
|
Assignee: |
EMSEAL JOINT SYSTEMS LTD.
Westborough
MA
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20140360118 A1 |
December 11, 2014 |
|
|
Family ID: |
52004223 |
Appl. No.: |
14/229463 |
Filed: |
March 28, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13731327 |
Dec 31, 2012 |
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14229463 |
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13729500 |
Dec 28, 2012 |
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13731327 |
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12635062 |
Dec 10, 2009 |
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13731327 |
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12622574 |
Nov 20, 2009 |
8365495 |
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13729500 |
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61806194 |
Mar 28, 2013 |
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61121590 |
Dec 11, 2008 |
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61116453 |
Nov 20, 2008 |
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Current U.S.
Class: |
52/309.6 ;
52/309.4; 52/396.01 |
Current CPC
Class: |
E04B 2001/6818 20130101;
E02D 29/045 20130101; E04B 1/6815 20130101; E04B 1/948 20130101;
E21D 11/385 20130101; E04B 1/6812 20130101 |
International
Class: |
E04B 1/94 20060101
E04B001/94 |
Claims
1. A fire and water resistant expansion joint system, comprising: a
coating applied at a predetermined thickness to substrates of a
tunnel; and a fire and water resistant expansion joint including: a
core; and a fire retardant infused into the core, the core
configured to define a profile to facilitate the compression of the
expansion joint system when installed between the substrates;
wherein the coating and the fire and water resistant expansion
joint are capable of withstanding exposure to a temperature of
about 540.degree. C. or greater for about five minutes.
2. The fire and water resistant expansion joint system of claim 1,
wherein the coating and the fire and water resistant expansion
joint are capable of withstanding exposure to a temperature of
about 930.degree. C. or greater for about one hour.
3. The fire and water resistant expansion joint system of claim 1,
wherein the coating and the fire and water resistant expansion
joint are capable of withstanding exposure to a temperature of
about 1010.degree. C. or greater for about two hours.
4. The fire and water resistant expansion joint system of claim 1,
wherein the coating and the fire and water resistant expansion
joint are capable of withstanding exposure to a temperature of
about 1260.degree. C. or greater for about eight hours.
5. The expansion joint system of claim 1, wherein the core
comprises a plurality of individual laminations assembled to
construct a laminate, one or more of the laminations being infused
with at least one of the fire retardant and a water-based acrylic
chemistry.
6. The expansion joint system of claim 1, wherein the core
comprises foam.
7. The expansion joint system of claim 1, wherein the core
comprises open celled polyurethane foam.
8. The expansion joint system of claim 1, wherein a first layer of
elastomer is disposed on the core, the elastomer comprising a
silicone.
9. The expansion joint system of claim 8, wherein the elastomer
disposed on the core is selected from the group consisting of
polysulfides, acrylics, polyurethanes, poly-epoxides,
silyl-terminated polyethers, and combinations of one or more of the
foregoing.
10. The expansion joint system of claim 8, further comprising a
second layer disposed on the first layer of the elastomer, wherein
the second layer is selected from the group consisting of another
elastomer, a fire barrier layer and combinations thereof.
11. The expansion joint system of claim 1, wherein the core is
tooled to define at least one of a bellows profile and a bullet
profile.
12. The expansion joint system of claim 1, wherein the ratio of the
fire retardant infused into the core is in a range of about 3.5:1
to about 4:1 by weight.
13. The expansion joint system of claim 1, wherein a layer
comprising the fire retardant is sandwiched between the material of
the core.
14. The expansion joint system of claim 1, wherein the fire
retardant infused into the core is selected from the group
consisting of water-based alumina tri-hydrate, metal oxides, metal
hydroxides, aluminum oxides, antimony oxides and hydroxides, iron
compounds, ferrocene, molybdenum trioxide, nitrogen-based
compounds, phosphorus based compounds, halogen based compounds,
halogens, and combinations of the foregoing materials.
15. The expansion joint system of claim 1, wherein the core
uncompressed has a density of about 100 kg/m.sup.3 to about 180
kg/m.sup.3.
16. The expansion joint system of claim 1, wherein the coating is
applied at the predetermined thickness to achieve a substantially
uniform layer on the substrates of the tunnel.
17. The expansion joint system of claim 16, wherein the fire and
water resistant expansion joint is positioned in a gap between the
substrates of the tunnel, an edge of the gap is chamfered as the
edge abuts the expansion joint and the coating is applied to fill
the chamfer.
18. The expansion joint system of claim 1, wherein the coating is
applied at the predetermined thickness to achieve a substantially
uniform layer on the substrates of the tunnel to a predetermined
distance away from a gap between the substrates, and at a second
predetermined thickness from the predetermined distance until an
edge of the gap.
19. The expansion joint system of claim 18, wherein the coating is
applied in an increasingly tapered manner from the predetermined
thickness at the predetermined distance away from the gap until
reaching the second predetermined thickness at the edge of the gap.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This patent application claims priority benefit under 35
U.S.C. .sctn.119(e) of copending, U.S. Provisional Patent
Application Ser. No. 61/806,194, filed Mar. 28, 2013, the
disclosure of which is incorporated by reference herein in its
entirety. This application also claims priority benefit under 35
U.S.C. .sctn.120 of copending, U.S. Non-provisional patent
application Ser. No. 13/731,327, filed on Dec. 31, 2012 (attorney
docket no. 1269-0002-1CIP), which is a Continuation-in-Part
Application of U.S. patent application Ser. No. 12/635,062, filed
on Dec. 10, 2009 (attorney docket no. 1269-0002-1), which claims
the benefit of U.S. Provisional Patent Application No. 61/121,590,
filed on Dec. 11, 2008, the contents of each of which are
incorporated herein by reference in their entireties and the
benefits of each are fully claimed. This application also claims
priority benefit under 35 U.S.C. .sctn.120 of copending, U.S.
Non-provisional patent application Ser. No. 13/729,500, filed on
Dec. 28, 2012 (attorney docket no. 1269-0001-1CIP), which is a
Continuation-in-Part Application of U.S. patent application Ser.
No. 12/622,574, filed on Nov. 20, 2009, (attorney docket no.
1269-0001-1) now U.S. Pat. No. 8,365,495, which claims the benefit
of U.S. Provisional Patent Application No. 61/116,453, filed on
Nov. 20, 2008, the contents of each of which are incorporated
herein by reference in their entireties and the benefits of each
are fully claimed.
TECHNICAL FIELD
[0002] The present invention relates generally to joint systems for
use in concrete and other building systems and, more particularly,
to expansion joints for accommodating thermal and/or seismic
movements in such systems.
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] In the case of a joint in an exterior wall, roof, or floor
exposed to external environmental conditions, the expansion joint
system should also, to some degree, resist the effects of the
external environment conditions. As such, most external expansion
joints systems are designed to resist the effects of such
conditions (particularly water). 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.
[0005] Many expansion joint products do not fully consider the
irregular nature of building 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, in some fashion
or other, 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.
[0006] In cases of this type, job site modifications are frequently
made to facilitate the function of the product with regard to the
actual conditions encountered. Normally, one of two situations
occurs. In the first, the product is modified to suit the actual
expansion joint conditions. In the second, the manufacturer is made
aware of issues pertaining to jobsite modifications, and requests
to modify the product are presented to the manufacturer in an
effort to better accommodate the expansion joint conditions. In the
first situation, there is a chance that a person installing the
product does not possess the adequate tools or knowledge of the
product to modify it in a way such that the product still performs
as designed or such that a transition that is commensurate with the
performance expected thereof can be effectively carried out. This
can lead to a premature failure at the point of modification, which
may result in subsequent damage to the property. In the second
case, product is oftentimes returned to the manufacturer for
rework, or it is simply scrapped and re-manufactured. Both return
to the manufacturer and scrapping and re-manufacture are costly,
and both result in delays with regard to the building construction,
which can in itself be extremely costly.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a fire and/or water
resistant expansion joint system for installation between
substrates of a tunnel. The system includes a coating applied at a
predetermined thickness to the substrates and a fire and water
resistant expansion joint. The expansion joint includes a core and
a fire retardant infused into the core. The core is configured to
define a profile to facilitate the compression of the expansion
joint system when installed between the substrates. The coating and
the fire and water resistant expansion joint are each capable of
withstanding exposure to a temperature of about 540.degree. C. or
greater for about five minutes.
[0008] In another aspect of the invention, the coating and the fire
and water resistant expansion joint of the fire and water resistant
expansion joint system are each capable of withstanding exposure to
a temperature of about 930.degree. C. or greater for about one
hour, a temperature of about 1010.degree. C. or greater for about
two hours, or a temperature of about 1260.degree. C. or greater for
about eight hours.
[0009] In one embodiment, the core of the fire and water resistant
expansion joint system includes a plurality of individual
laminations assembled to construct a laminate, one or more of the
laminations being infused with at least one of the fire retardant
and a water-based acrylic chemistry.
[0010] In another aspect of the invention, the coating of the
expansion joint system is applied at the predetermined thickness to
achieve a substantially uniform layer on the substrates of the
tunnel. In one embodiment, the fire and water resistant expansion
joint is positioned in a gap between the substrates of the tunnel,
an edge of the gap is chamfered as the edge abuts the expansion
joint and the coating is applied to fill the chamfer.
[0011] In another aspect of the invention, the coating of the
expansion joint system is applied at the predetermined thickness to
achieve a substantially uniform layer on the substrates of the
tunnel to a predetermined distance away from a gap between the
substrates, and at a second predetermined thickness from the
predetermined distance until an edge of the gap. In one embodiment,
the coating is applied in an increasingly tapered manner from the
predetermined thickness at the predetermined distance away from the
gap until reaching the second predetermined thickness at the edge
of the gap.
[0012] In another aspect, the present invention resides in a fire
and water resistant vertical expansion joint system comprising a
first section of core extending in a horizontal plane and a second
section of core extending in a vertical plane. An insert piece of
core is located between the first and second sections, the insert
piece being configured to transition the first section from the
horizontal plane to the vertical plane of the second section. The
core is infused with a fire retardant. A layer of an elastomer is
disposed on the core to impart a substantially waterproof property
thereto. The vertical expansion joint system is pre-compressed and
is installable between horizontal coplanar substrates and vertical
coplanar substrates. Although the vertical expansion joint system
is described as having an angle of transition from horizontal to
vertical, it should be understood that the transition of the angles
is not limited to right angles as the vertical expansion joint
system may be used to accommodate any angle.
[0013] In another aspect, the present invention resides in a fire
and water resistant expansion joint system, comprising a core; and
a fire retardant infused into the core. The core infused with the
fire retardant is configured to define a profile to facilitate the
compression of the expansion joint system when installed between
substantially coplanar substrates, and the expansion joint system
is angled around a corner.
[0014] In any embodiment, the construction or assembly of the
systems described herein is generally carried out off-site, but
elements of the system may be trimmed to appropriate length
on-site. By constructing or assembling the systems of the present
invention 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 is
also minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a vertical expansion joint
system of the present invention.
[0016] FIG. 2 is an end view of the vertical expansion joint system
taken along line 2-2 of FIG. 1.
[0017] FIG. 2A is a detailed view of a portion of FIG. 2.
[0018] FIG. 3 is an end view of the vertical expansion joint system
installed between two substrates.
[0019] FIG. 4 is a perspective view of an assembly of laminations
being prepared to produce the vertical expansion joint system of
FIG. 1.
[0020] FIG. 5 is a perspective view of the assembly of laminations
being further prepared to produce the vertical expansion joint
system of FIG. 1.
[0021] FIG. 6 is a perspective view of four sections of the
vertical expansion joint system used in a building structure.
[0022] FIG. 7 is a perspective view of a horizontal expansion joint
system of the present invention.
[0023] FIG. 8 is an end view of a vertical and/or horizontal
expansion joint system installed between two substrates, depicting
an elastomer on one surface of the core and an intumescent material
on another surface of the core.
[0024] FIG. 9 is an end view of a vertical and/or horizontal
expansion joint system installed between two substrates, depicting
alternative layering on the core.
[0025] FIG. 10 is an end view of a vertical and/or horizontal
expansion joint system installed between two substrates, depicting
further layering on the core.
[0026] FIG. 11 is an end view of a vertical and/or horizontal
expansion joint system installed between two substrates, depicting
a fire retardant layer in the core and no coatings located on two
outer surfaces of the core.
[0027] FIG. 12 is an end view of a vertical and/or horizontal
expansion joint system installed between two substrates, depicting
a fire retardant material in the core and layering on two outer
surfaces of the core.
[0028] FIG. 13 illustrates a schematic view of a tunnel expansion
joint system, according to the embodiments.
[0029] FIG. 14A illustrates a schematic view of a tunnel 200 with a
fire therein.
[0030] FIG. 14B illustrates a schematic view of a tunnel 200
showing loss of portions of concrete therein.
[0031] FIG. 15 illustrates a schematic view of a tunnel expansion
joint system, according to the embodiments.
[0032] FIG. 16 illustrates a schematic view of a tunnel expansion
joint system showing chamfered edges 204, according to the
embodiments.
DETAILED DESCRIPTION
[0033] Embodiments of the present invention provide a resilient
water resistant and/or fire resistant expansion joint system able
to accommodate thermal, seismic, and other building movements while
maintaining water resistance and/or fire resistance
characteristics. Embodiments of present invention are especially
suited for use in concrete buildings and other concrete structures
including, but not limited to, parking garages, stadiums, tunnels
including tunnel walls, floors and tunnel roofs, bridges, waste
water treatment systems and plants, potable water treatment systems
and plants, and the like.
[0034] Referring now to FIGS. 1-3, embodiments of the present
invention include an expansion joint system oriented in a vertical
plane and configured to transition corners at right angles. This
system is designated generally by the reference number 10 and is
hereinafter referred to as "vertical expansion joint system 10." It
should be noted, however, that the vertical expansion joint system
10 is not limited to being configured at right angles, as the
products and systems of the present invention can be configured to
accommodate any desired angle. Moreover, as further explained
below, embodiments herein are not limited to transition corners at
right angles or other angles. For example, embodiments of the
expansion joint systems and materials described herein for such
systems can be configured in any suitable shape and configuration
including, e.g., the use of straight sections, curved sections,
coiled sections provided as, e.g., fixed length members or coiled
on a roll, and so forth.
[0035] The vertical expansion joint system 10 comprises sections of
a core 12', e.g., open or closed celled polyurethane foam 12
(hereinafter "foam 12" for ease of reference which is not meant to
limit the core 12' to a foam material, but merely illustrate on
exemplary material therefore) that may be infused with a material,
such as a water-based acrylic chemistry, and/or other suitable
material for imparting a hydrophobic characteristic. As shown in
Detail FIG. 2A, for example, the core 12' can be infused with a
fire retardant material 60 such that the resultant composite fire
and/or water resistant vertical expansion joint system 10 is
capable of passing UL 2079 test program, as described in detail
below. Moreover, it should be understood, however, that the present
invention is not limited to the use of polyurethane foam, as other
foams are within the scope of the present invention, and other
non-foam materials also can be used for the core 12', as explained
below.
[0036] As is shown in FIG. 2, the core 12' and/or foam 12 can
comprise individual laminations 14 of material, e.g., foam, one or
more of which are infused with a suitable amount of material, e.g.,
such as the acrylic chemistry and/or fire retardant material 60.
The individual laminations 14 can extend substantially
perpendicular to the direction in which the joint extends and be
constructed by infusing at least one, e.g., an inner lamination
with an amount of fire retardant 60. It should be noted that the
present invention is not so limited as other manners of
constructing the core 12' and/or foam 12 are also possible. For
example, the core 12' and/or foam 12 of the present invention is
not limited to individual laminations 14 assembled to construct the
laminate, as the core 12' and/or foam 12 may comprise a solid block
of non-laminated foam or other material of fixed size depending
upon the desired joint size, laminates comprising laminations
oriented horizontally to adjacent laminations, e.g., parallel to
the direction which the joint extends, or combinations of the
foregoing.
[0037] Thus, foam 12 merely illustrates one suitable material for
the core 12'. Accordingly, examples of materials for the core 12'
include, but are not limited to, foam, e.g., polyurethane foam
and/or polyether foam, and can be of an open cell or dense, closed
cell construction. Further examples of materials for the core 12'
include paper based products, cardboard, metal, plastics,
thermoplastics, dense closed cell foam including polyurethane and
polyether open or closed cell foam, cross-linked foam, neoprene
foam rubber, urethane, ethyl vinyl acetate (EVA), silicone, a core
chemistry (e.g., foam chemistry) which inherently imparts
hydrophobic and/or fire resistant characteristics to the core;
and/or composites. Combinations of any of the foregoing materials
or other suitable material also can be employed. It is further
noted that while foam 12 is primarily referred to herein as a
material for the core 12', the descriptions for foam 12 also can
apply to other materials for the core 12', as explained above.
[0038] The core 12' can be infused with a suitable material
including, but not limited to, an acrylic, such as a water-based
acrylic chemistry, a wax, a fire retardant material, ultraviolet
(UV) stabilizers, and/or polymeric materials, combinations thereof,
and so forth. A particularly suitable embodiment is a core 12'
comprising open celled foam infused with a water-based acrylic
chemistry and/or a fire retardant material 60.
[0039] The amount of fire retardant material 60 that is infused
into the core 12' is such that the resultant composite can pass
Underwriters Laboratories' UL 2079 test program, which provides for
fire exposure testing of building components. For example, in
accordance with various embodiments, the amount of fire retardant
material 60 that is infused into the core 12' is such that the
resultant composite of the fire and water resistant expansion joint
system 10 is capable of withstanding exposure to a temperature of
at least about 540.degree. C. for about five minutes, a temperature
of about 930.degree. C. for about one hour, a temperature of about
1010.degree. C. for about two hours, or a temperature of about
1260.degree. C. for about eight hours, without significant
deformation in the integrity of the expansion joint system 10.
According to embodiments, including the open celled foam
embodiment, the amount of fire retardant material that is infused
into the core 12' is between 3.5:1 and 4:1 by weight in ratio with
the un-infused foam/core itself. The resultant uncompressed
foam/core, whether comprising a solid block or laminates, has a
density of about 130 kg/m.sup.3 to about 150 kg/m.sup.3 and
preferably about 140 kg/m.sup.3. Other suitable densities for the
resultant core 12' include between about 50 kg/m.sup.3 and about
250 kg/m.sup.3, e.g., between about 100 kg/m.sup.3 and about 180
kg/m.sup.3, and which are capable of providing desired water
resistance and/or waterproofing and/or fire resistant
characteristics to the structure. One type of fire retardant
material 60 that may be used is water-based aluminum tri-hydrate
(also known as aluminum tri-hydroxide (ATH)). The present invention
is not limited in this regard, however, 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, phosphorus based
compounds, halogen based compounds, halogens, e.g., fluorine,
chlorine, bromine, iodine, astatine, combinations of any of the
foregoing materials, and other compounds capable of suppressing
combustion and smoke formation. Also as is shown in FIG. 3, the
vertical expansion joint system 10 is positionable between opposing
substrates 18 (which may comprise concrete, glass, wood, stone,
metal, or the like) to accommodate the movement thereof. In
particular, opposing vertical surfaces of the core 12' and/or foam
12 can be retained between the edges of the substrates 18. The
compression of the core 12' and/or foam 12 during the installation
thereof between the substrates 18 and expansion thereafter enables
the vertical expansion system 10 to be held in place between the
substrates 18.
[0040] In any embodiment, when individual laminations 14 are used,
several laminations, the number depending on the expansion joint
size (e.g., the width, which depends on the distance between
opposing substrates 18 into which the vertical expansion system 10
is to be installed), can be compiled and then compressed and held
at such compression in a fixture. The fixture, referred to as a
coating fixture, is at a width slightly greater than that which the
expansion joint will experience at the greatest possible movement
thereof. Similarly, a core 12' comprising laminations of non-foam
material or comprising a solid block of desired material may be
compiled and then compressed and held at such compression in a
suitable fixture.
[0041] In one embodiment in the fixture, the assembled infused
laminations 14 or core 12' are coated with a coating, such as a
waterproof elastomer 20 at one surface. The elastomer 20 may
comprise, for example, at least one polysulfide, silicone, acrylic,
polyurethane, poly-epoxide, silyl-terminated polyether,
combinations and formulations thereof, and the like, with or
without other elastomeric components or similar suitable
elastomeric coating or liquid sealant materials, or a mixture,
blend, or other formulation of one or more the foregoing. One
preferred elastomer 20 for coating core 12', e.g., for coating
laminations 14 for a horizontal deck or floor application 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, a preferred elastomer 20 for coating, e.g., the
laminations 14 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 20. For example, a
primer may be applied to the outer surfaces of the laminations 14
of foam 12 and/or core 12' prior to coating with the elastomer 20.
Applying such a primer may facilitate the adhesion of the elastomer
20 to the foam 12 and/or core 12'.
[0042] During or after application of the elastomer 20 to the
laminations 14 and/or core 12', the elastomer is tooled or
otherwise configured to create a "bellows," "bullet," or other
suitable profile such that the vertical expansion joint system 10
can be compressed in a uniform and aesthetic fashion while being
maintained in a virtually tensionless environment. The elastomer 20
is then allowed to cure while being maintained in this position,
securely bonding it to the infused foam lamination 14 and/or core
12'.
[0043] Referring now to FIGS. 4 and 5, in one embodiment when the
elastomer 20 has cured in place, the infused foam lamination 14
and/or core 12' is cut in a location at which a bend in the
vertical expansion system 10 is desired to accommodate a corner or
other change in orientation of the expansion system 10, e.g., a
change in orientation from a horizontal plane to a vertical plane,
as described below. The cut, which is designated by the reference
number 24 and as shown in FIG. 4, is made from one side of the
expansion system 10, referred to for clarity and not limitation, as
an outside of the system 10, at the desired location of the bend
toward an opposite side of the expansion system 10, referred to for
clarity and not limitation, as an inside of the system 10, at the
desired location of the bend using a saw or any other suitable
device. The cut 24 is stopped such that a distance d is defined
from the termination of the cut to the previously applied coating
of the elastomer 20 on the inside of the desired location of the
bend (e.g., approximately one half inch from the previously applied
coating of elastomer 20 on the inside of the bend). Referring now
to FIG. 5, the core 12' is then bent to an appropriate angle A,
thereby forming a gap G at the outside of the bend. Although a gap
of ninety degrees (90.degree.) is shown in FIG. 5, the present
invention is not limited in this regard as other angles are
possible.
[0044] Still referring to FIG. 5, a piece of core 12' and/or
infused foam lamination 14 constructed in a manner similar to that
described above is inserted into the gap G as an insert piece 30
and held in place by the application of a similar coating of
elastomer 20 as described above. In the alternative, the insert
piece 30 may be held in place using a suitable adhesive.
Accordingly, the angle A around the corner is made continuous via
the insertion of the insert piece 30 located between a section of
the open celled foam extending in the horizontal plane and a
section of the open celled foam extending in the vertical plane.
Once the gap has been filled and the insert piece 30 is securely in
position, the entire vertical expansion system 10 including the
insert piece 30 is inserted into a similar coating fixture with the
previously applied elastomer 20 coated side facing down and the
uncoated side facing upwards. The uncoated side is now coated with
the same (or different) elastomer 20 as was used on the opposite
face. Again, the elastomer 20 is then allowed to cure in position.
Furthermore, the insert piece 30 inserted into the gap is not
limited to being a lamination 14, as solid blocks or the like may
be used.
[0045] After both sides have cured, the vertical expansion system
10 as the final uninstalled product is removed from the coating
fixture and packaged for shipment. In the packaging operation the
vertical expansion system 10 is compressed using a hydraulic or
mechanical press (or the like) to a size below the nominal size of
the expansion joint at the job site. The vertical expansion system
10 is held at this size using a heat shrinkable poly film. The
present invention is not limited in this regard, however, as other
devices (ties or the like) may be used to hold the vertical
expansion system 10 to the desired size.
[0046] Referring now to FIG. 6, portions of the vertical expansion
system 10 positioned to articulate right angle bends are shown as
they would be positioned in a concrete expansion joint 18c between
substrates 18a and 18b located in a tunnel, archway, or similar
structure. Each portion defines a foam laminate that is positioned
in a corner of the joint 18c. As is shown, the vertical expansion
joint system 10 is installed in the joint 18c between horizontal
coplanar substrate 18a and vertical coplanar substrate 18b.
[0047] Referring now to FIG. 7, an alternate embodiment of the
invention is shown. In this embodiment, the infused core 12' and/or
foam 12, the elastomer coating 20 on the top surface, and the
elastomer coating 20 on the bottom surface are similar to the above
described embodiments. However, in FIG. 7, the expansion joint
system designated generally by the reference number 110 is oriented
in the horizontal plane rather than vertical plane and is
hereinafter referred to as "horizontal expansion system 110." As
with the vertical expansion system 10 described above, the
horizontal expansion system 110 may be configured to transition
right angles. The horizontal expansion system 110 is not limited to
being configured to transition right angles, however, as it can be
configured to accommodate any desired angle.
[0048] In the horizontal expansion system 110, the infused core 12'
and/or foam lamination 14 is constructed in a similar fashion to
that of the vertical expansion system 10, namely, by constructing a
core 12' and/or foam 112 assembled from individual laminations 114
of suitable material, such as a foam material, one or more of which
is infused with, e.g., an acrylic chemistry and/or a fire retardant
material 60. Although the horizontal expansion system 110 is
described as being fabricated from individual laminations 114, the
present invention is not so limited, and other manners of
constructing the core 12' and/or foam 112 are possible (e.g., solid
blocks of material, e.g., foam material, as described above).
[0049] In fabricating the horizontal expansion system 110, two
pieces of the core 12' and/or foam 112 are mitered at appropriate
angles B (45 degrees is shown in FIG. 7, although other angles are
possible). An elastomer, or other suitable adhesive, is applied to
the mitered faces of the infused foam laminations 114. The
individual laminations 114 are then pushed together and held in
place in a coating fixture at a width slightly greater than the
largest joint movement anticipated. At this width the top is coated
with an elastomer 20 and cured, according to embodiments. Following
this, the core 12' and/or foam 112 is inverted and then the
opposite side is likewise coated.
[0050] After both coatings of elastomer 20 have cured, the
horizontal expansion system 110 is removed from the coating fixture
and packaged for shipment. In the packaging operation, the
horizontal expansion system 110 is compressed using a hydraulic or
mechanical press (or the like) to a size below the nominal size of
the expansion joint at the job site. The product is held at this
size using a heat shrinkable poly film (or any other suitable
device).
[0051] In a horizontal expansion system, e.g., system 110, the
installation thereof can be accomplished by adhering the core 12'
and/or foam 112 to a substrate (e.g., concrete, glass, wood, stone,
metal, or the like) using an adhesive such as epoxy. The epoxy or
other adhesive is applied to the faces of the horizontal expansion
system 110 prior to removing the horizontal expansion system from
the packaging restraints thereof. Once the packaging has been
removed, the horizontal expansion system 110 will begin to expand,
and the horizontal expansion system is inserted into the joint in
the desired orientation. Once the horizontal expansion system 110
has expanded to suit the expansion joint, it will become locked in
by the combination of the core 12' and/or foam back pressure and
the adhesive.
[0052] In any system of the present invention, but particularly
with regard to the vertical expansion system 10, an adhesive may be
pre-applied to the core 12' and/or foam lamination. In this case,
for installation, the core 12' and/or foam lamination is 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 done, the adhesive in combination with the
back pressure of the core 12' and/or foam will hold the foam in
position.
[0053] The vertical expansion system 10 is generally used where
there are vertical plane transitions in the expansion joint. For
example, vertical plane transitions can occur where an expansion
joint traverses a parking deck and then meets a sidewalk followed
by a parapet wall. The expansion joint cuts through both the
sidewalk and the parapet wall. In situations of this type, the
vertical expansion system 10 also transitions from the parking deck
(horizontally) to the curb (vertical), to the sidewalk
(horizontal), and then from the sidewalk to the parapet (vertical)
and in most cases across the parapet wall (horizontal) and down the
other side of the parapet wall (vertical). Prior to the present
invention, this would result in an installer having to fabricate
most or all of these transitions on site using straight pieces.
This process was difficult, time consuming, and error prone, and
often resulted in waste and sometimes in sub-standard
transitions.
[0054] In one example of installing the vertical expansion system
10 in a structure having a sidewalk and a parapet, the installer
uses several individual sections, each section being configured to
transition an angle. The installer uses the straight run of
expansion joint product, stopping within about 12 inches of the
transition, then installs one section of the vertical expansion
system 10 with legs measuring about 12 inches by about 6 inches. If
desired, the installer trims the legs of the vertical expansion
system 10 to accommodate the straight run and the height of the
sidewalk. Standard product is then installed across the sidewalk,
stopping short of the transition to the parapet wall. Here another
section of the vertical expansion system 10 is installed, which
will take the product up the wall. Two further sections of the
vertical expansion system 10 are used at the top inside and top
outside corners of the parapet wall. The sections of the vertical
expansion system 10 are adhered to each other and to the straight
run expansion joint product in a similar fashion as the straight
run product is adhered to itself. In this manner, the vertical
expansion system 10 can be easily installed if the installer has
been trained to install the standard straight run product. It
should be noted, however, that the present invention is not limited
to the installation of product in any particular sequence as the
pieces can be installed in any suitable and/or desired order.
[0055] In one example of installing the horizontal expansion system
110, the system is installed where there are horizontal plane
transitions in the expansion joint. This can happen when the
expansion joint encounters obstructions such as supporting columns
or walls. The horizontal expansion system 110 is configured to
accommodate such obstructions. Prior to the present invention, the
installer would have had to create field transitions to follow the
expansion joint.
[0056] To extend a horizontal expansion system, e.g., system 110,
around a typical support column, the installer uses four sections
of the horizontal expansion system. A straight run of expansion
joint product is installed and stopped approximately 12 inches
short of the horizontal transition. The first section of the
horizontal expansion system 110 is then installed to change
directions, trimming as desired for the specific situation. Three
additional sections of horizontal expansion system 110 are then
joined, inserting straight run pieces as desired, such that the
horizontal expansion system 110 extends around the column continues
the straight run expansion joint on the opposite side. As with the
vertical expansion system 10, the sections may be installed in any
sequence that is desired.
[0057] The present invention is not limited to products configured
at right angles, as any desired angle can be used for either a
horizontal or vertical configuration. Also, the present invention
is not limited to foam or laminates, as solid blocks of foam or
other desired material and the like may alternatively or
additionally be used.
[0058] Moreover, while a core 12' coated with an elastomer 20 on
one or both of its outer surfaces has been primarily described
above, according to embodiments, the present invention is not
limited in this regard. Thus, the vertical and horizontal expansion
joint systems described herein are not limited in this regard. For
example, as shown in FIG. 8, the surface of the infused foam
laminate and/or core 12' opposite the surface coated with elastomer
20 is coated with an intumescent material 16, according to further
embodiments. One type of intumescent material 16 may be a caulk
having fire barrier properties. A caulk is generally a silicone,
polyurethane, polysulfide, sylil-terminated-polyether, or
polyurethane and acrylic sealing agent in latex or elastomeric
base. Fire barrier properties are generally imparted to a caulk via
the incorporation of one or more fire retardant agents. One
preferred intumescent material 16 is 3M CP25WB+, which is a fire
barrier caulk available from 3M of St. Paul, Minn. Like the
elastomer 20, the intumescent material 16 is tooled or otherwise
configured to create a "bellows" or other suitable profile to
facilitate the compression of the foam lamination and/or core 12'.
After tooling or otherwise configuring to have, e.g., the
bellows-type of profile, both the coating of the elastomer 20 and
the intumescent material 16 are cured in place on the foam 12
and/or core 12' while the infused foam lamination and/or core 12'
is held at the prescribed compressed width. After the elastomer 20
and the intumescent material 16 have been cured, the entire
composite is removed from the fixture, optionally compressed to
less than the nominal size of the material and packaged for
shipment to the job site. This embodiment is particularly suited to
horizontal parking deck applications where waterproofing is desired
on the top side and fire resistance is desired from beneath, as in
the event of a vehicle fire on the parking deck below.
[0059] A sealant band and/or corner bead 19 of the elastomer 20 can
be applied on the side(s) of the interface between the foam
laminate (and/or core 12') and the substrate 18 to create a water
tight seal.
[0060] Referring now to FIG. 9, an alternate expansion joint system
of the present invention illustrates the core 12' having a first
elastomer 14 coated on one surface and the intumescent material 16
coated on an opposing surface. A second elastomer 15 is coated on
the intumescent material 16 and serves the function of
waterproofing. In this manner, the system is water resistant in
both directions and fire resistant in one direction. The system of
FIG. 9 is used in applications that are similar to the applications
in which the other afore-referenced systems are used, but may also
be used where water is present on the underside of the expansion
joint. Additionally, it would be suitable for vertical expansion
joints where waterproofing or water resistance is desirable in both
directions while fire resistance is desired in only one direction.
The second elastomer 15 may also serve to aesthetically integrate
the system with surrounding substrate material.
[0061] Sealant bands and/or corner beads 19 of the first elastomer
20 can be applied to the sides as with the embodiments described
above. Sealant bands and/or corner beads 24 can be applied on top
of the second elastomer 15, thereby creating a water tight seal
between the substrate and the intumescent material 16.
[0062] Referring now to FIG. 10, in this embodiment, the foam 12
and/or core 12' is similar to or the same as the above-described
foam and/or core 12', but both exposed surfaces are coated first
with the intumescent material 16 to define a first coating of the
intumescent material and a second coating of the intumescent
material 16. The first coating of the intumescent material 16 is
coated with a first elastomer material 32, and the second coating
of the intumescent material 16 is coated with a second elastomer
material 34. This system can be used in the same environments as
the above-described systems with the added benefit that it is both
waterproof or at least water resistant and fire resistant in both
directions through the joint. This makes it especially suitable for
vertical joints in either interior or exterior applications.
[0063] Sealant bands and/or corner beads 38 of the elastomer can be
applied in a similar fashion as described above and on both sides
of the foam 12 and/or core 12'. This creates a water tight
elastomer layer on both sides of the foam 12 and/or core 12'.
[0064] Referring now to FIG. 11, shown therein is another system,
according to embodiments. In FIG. 11, the core 12' is infused with
a fire retardant material, as described above. As an example, the
fire retardant material can form a "sandwich type" construction
wherein the fire retardant material forms a layer 15', as shown in
FIG. 11, between the material of core 12'. Thus, the layer 15'
comprising a fire retardant can be located within the body of the
core 12' as, e.g., an inner layer, or lamination infused with a
higher ratio or density of fire retardant than the core 12'. It is
noted that the term "infused with" as used throughout the
descriptions herein is meant to be broadly interpreted to refer to
"includes" or "including." Thus, for example, "a core infused with
a fire retardant" covers a "core including a fire retardant" in any
form and amount, such as a layer, and so forth. Accordingly, as
used herein, the term "infused with" would also include, but not be
limited to, more particular embodiments such as "permeated" or
"filled with" and so forth.
[0065] Moreover, it is noted that layer 15' is not limited to the
exact location within the core 12' shown in FIG. 11 as the layer
15' may be included at various depths in the core 12' as desired.
Moreover, it is further noted that the layer 15' may extend in any
direction. For example, layer 15' may be oriented parallel to the
direction in which the joint extends, perpendicular to the
direction in which the joint extends or combinations of the
foregoing. Layer 15' can function as a fire resistant barrier layer
within the body of the core 12'. Accordingly, layer 15' can
comprise any suitable material providing, e.g., fire barrier
properties. No coatings are shown on the outer surfaces of core 12'
of FIG. 11.
[0066] Accordingly, by tailoring the density as described above to
achieve the desired water resistance and/or water proofing
properties of the structure, combined with the infused fire
retardant in layer 15', or infused within the core 12' in any other
desired form including a non-layered form, additional layers, e.g.
an additional water and/or fire resistant layer on either or both
outer surfaces of the core 12', are not be necessary to achieve a
dual functioning water and fire resistant system, according to
embodiments.
[0067] It is noted, however, that additional layers could be
employed if desired in the embodiment of FIG. 11, as well as in the
other embodiments disclosed herein, and in any suitable combination
and order. For example, the layering described above with respect
to FIGS. 1-10 could be employed in the embodiment of FIG. 11 and/or
FIG. 12 described below.
[0068] As a further example, FIG. 12 illustrates therein an
expansion joint system comprising the layer 15' comprising a fire
retardant within the body of the core 12' as described above with
respect to FIG. 11, and also comprising an additional coating 17 on
a surface of the core 12'. Coating 17 can comprise any suitable
coating, such as the elastomer 20 described above, a fire barrier
material including an intumescent material 16 described above or
other suitable fire barrier material, e.g., a sealant, a fabric, a
blanket, a foil, a tape, e.g., an intumescent tape, a mesh, a
glass, e.g., fiberglass; and combinations thereof. Moreover,
embodiments include various combinations of layering and fire
retardant infusion (in layer and non-layer form) to achieve, e.g.,
the dual functioning water and fire resistant expansion joint
systems described herein, according to embodiments. For example,
FIG. 12 illustrates coating 17 on one surface of the core 12' and a
dual coating 17' on an opposite surface of the core 12'. The dual
coating 17' can comprise, e.g., an inner layer 17'a of elastomer
20, as described above, with an outer layer 17'b of a fire barrier
material including, e.g., an intumescent material. Similarly, the
layers 17'a and 17'b of the dual coating 17' can be reversed to
comprise an inner layer of fire barrier material and an outer layer
of elastomer 20.
[0069] Alternatively, only one layer may be present on either
surface of core 12', such as one layer of a fire barrier material,
e.g., sealant, on a surface of the core 12', which is infused with
a fire retardant material in layer 15' or infused in a non-layer
form. Still further, other combinations of suitable layering
include, e.g., dual coating 17' on both surfaces of the core 12'
and in any combination of inner and outer layers, as described
above.
[0070] It is additionally noted that the embodiments shown in,
e.g., FIGS. 8-12 can be similarly constructed and installed, as
described above with respect to, e.g., the embodiments of FIGS.
1-7, modified as appropriate for inclusion/deletion of various
layering, and so forth. Thus, for example, as described above,
while a "bellows" construction is illustrated by the figures, the
embodiments described herein are not limited to such a profile as
other suitable profiles may be employed, such as straight, curved,
and so forth.
[0071] Accordingly, as further evident from the foregoing,
embodiments of the dual functioning fire and water resistant
expansion joint systems can comprise various ordering and layering
of materials on the outer surfaces of the core 12'. Similarly, a
fire retardant material can be infused into the core 12' in various
forms, to create, e.g., the above described layered "sandwich type"
construction with use of, e.g., layer 15'.
[0072] In the embodiments described herein, the infused foam
laminate and/or core 12' may be constructed in a manner which
insures that the amount of fire retardant material 60 that is
infused into the core 12' is such that the resultant composite can
pass Underwriters Laboratories' UL 2079 test program regardless of
the final size of the product. For example, in accordance with
various embodiments, the amount of fire retardant material 60 that
is infused into the core 12' is such that the resultant composite
of the fire and water resistant expansion joint system 10 is
capable of withstanding exposure to a temperature of at least about
540.degree. C. for about five minutes, a temperature of about
930.degree. C. for about one hour, a temperature of about
1010.degree. C. for about two hours, or a temperature of about
1260.degree. C. for about eight hours, without significant
deformation in the integrity of the expansion joint system 10.
According to embodiments, including the open celled foam
embodiment, the amount of fire retardant material that is infused
into the core 12' is between 3.5:1 and 4:1 by weight in ratio with
the un-infused foam/core itself. For example, considering the
amount of infusion as it relates to density, the starting density
of the infused foam/core is approximately 140 kg/m.sup.3, according
to embodiments. Other suitable densities include between about 80
kg/m.sup.3 and about 180 kg/m.sup.3. After compression, the infused
foam/core density is in the range of about 160-800 kg/m.sup.3,
according to embodiments. After installation the laminate and/or
core 12' will typically cycle between densities of approximately
750 kg/m.sup.3 at the smallest size of the expansion joint to
approximately 360-450 kg/m.sup.3, e.g., approximately 400-450
kg/m.sup.3 (or less) at the maximum size of the joint. A density of
400-450 kg/m.sup.3 was determined through experimentation, as a
reasonable value 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, and the foam/core may attain
densities outside of the herein-described ranges.
[0073] It is further noted that various embodiments, including
constructions, layering and so forth described herein can be
combined in any order to result in, e.g., a dual functioning water
and fire resistant expansion joint system. Thus, embodiments
described herein are not limited to the specific construction of
the figures, as the various materials, layering and so forth
described herein can be combined in any desired combination and
order.
[0074] Moreover, as explained above, embodiments of the invention
are not limited to transition corners at angles. For example,
embodiments of the joint systems and materials described therefore
can be configured in any suitable shape and configuration including
straight sections, curved sections, coiled sections provided as,
e.g., fixed length members or coiled on a roll, and so forth.
[0075] Thus, the descriptions set forth above with respect to,
e.g., the core 12' and any coatings/materials thereon and/or
therein, also apply to non-corner transition configurations. Such a
configuration is shown, e.g., in FIG. 13, which illustrates a
tunnel expansion joint system 210, according to embodiments,
positioned along structural joint 202 in one or more of a roof, a
floor and a wall of a tunnel 200 and thereby extending from a
straight section configuration along the roof or floor to a curved
section configuration as the construction transitions to extend up
down or up to the wall of the tunnel 200. As with the above
described embodiments, the tunnel expansion joint system 210 may be
used to securely fill, with non-invasive, non-mechanical fastening,
the structural joints 202 to accommodate seismic, thermal, concrete
shrinkage and other movement in the roof, floor and wall of the
tunnel 200, while maintaining fire rating of surfaces of the
tunnel.
[0076] As is known in the art, Rijkswaterstaat (RWS) is a tunnel
fire standard created as a result of testing done in 1979 by the
Rijkswaterstaat, the Ministry of Infrastructure and the
Environment, in the Netherlands. As illustrated in FIGS. 14A and
14B, the RWS standard is based, in part, on a worst case scenario
of a typical fuel tanker having a full payload of about 1765
ft.sup.3 (50 m.sup.3) of fuel igniting within the relatively small
confines of a tunnel. The resultant heat load was determined to be
approximately 300 MW, with temperatures reaching 2012.degree. F.
(1100.degree. C.) after about five (5) minutes, peaking at about
2462.degree. F. (1350.degree. C.) with a fire burn duration of
about two (2) hours. Products that meet the RWS standard are able
to keep an interface between the fire protection and the concrete
surface below the interface at about 716.degree. F. (380.degree.
C.) for the entire two (2) hour duration of the RWS fire curve. As
illustrated in FIG. 14B, concrete that is not coated with a fire
proofing can spall due to exposure to the above noted temperatures
resulting in a loss of portions of the concrete, as shown generally
at 220, and thus compromise the structural integrity of the tunnel
200. Significant spalling may require costly remediation post-fire
to restore structural integrity and if left unchecked, may result
in complete tunnel collapse.
[0077] Linings or coatings such as, for example, a high density
cement based fireproofing material sold under the brand name
Monokote.RTM. Z146T by W. R. Grace & Co., Columbia Md., or
Isolatek.RTM. Type M-II by Isolatek International, Stanhope, N.J.,
may be used to treat the surface of the concrete of the roof, the
floor and the walls of the tunnel 200 and to provide the interface,
described above, between the fire protection and the concrete
surface. However, the structural joints 202 in the roof, floor and
wall of the tunnel 200 have been found to create a gap in this
layer of fire protection. Accordingly, the embodiments of the
expansion joint systems 10, 110 and 210 depicted herein in FIGS.
1-16, especially the tunnel expansion joint system 210 of FIGS.
13-16, are particularly suitable for tunnel applications and in
conjuction with the coatings such as, e.g., the aforementioned
Monokote.RTM. Z146T coating, seal the gap in the layer of fire
protection of the tunnel 200.
[0078] FIGS. 15 and 16 depict embodiments of the tunnel expansion
joint system 210 used in conjunction with a coating 230, such as
the Monokote.RTM. Z146T coating, to provide the layer of fire
protection to the tunnel 200. In one embodiment, illustrated in
FIG. 15, the tunnel expansion joint system 210 is positioned within
the structural joint 202 in one or more of the roof, the floor and
the wall of the tunnel 200. Through experimentation and finite
element analysis a preferred thickness of the coating 230 is
determined relative to use with the tunnel expansion joint system
210 to provide a fire protection barrier that meets the RWS
standard. As shown in FIG. 15, a first thickness of the coating 230
labeled CT1 is applied (e.g., spray applied and/or troweled) over
the concrete surfaces of the tunnel 200 until the coating 230
reaches a predetermined distance CD1 from one of the structural
joints 202. In one embodiment, the first thickness CT1 of the
coating 230 is about one (1) inch (25 mm) until reaching the
predetermined distance CD1 of about six (6) inches (150 mm) from an
edge of the structural joint 202, and thus an edge of the tunnel
expansion joint system 210 positioned within the joint 202. As
shown in FIG. 15, over the predetermined distance CD1 to the tunnel
expansion joint system 210, the thickness of the coating 230 is
gradually increased to a second thickness of the coating 230
labeled CT2 at the edge of the structural joint 202, e.g., the edge
of the tunnel expansion joint system 210 disposed in the joint 202.
In one embodiment, the second thickness CT2 of the coating 230 is
about one and one half (1.5) inches (40 mm). As shown in a
partially enlarged portion of FIG. 15, a sealant band and/or corner
bead 19 of the elastomer 20 or equivalent fire rated sealant, can
be applied on the sides of the interface between the tunnel
expansion joint system 210, the coating 230 and the edge of the
joint 202 to create a water tight and/or fire rated seal and thus
ensure a continuity in the layer of fire protection for the tunnel
200.
[0079] FIG. 16 illustrates another embodiment where the roof, the
floor and/or the wall of the tunnel 200 include chamfered edges 204
at the transition to the structural joint 202. As shown in FIG. 16,
providing the chamfered edges 204 permits application of a uniform
thickness of the coating 230 labeled CT3 over the concrete surfaces
of the tunnel 200 until the coating 230 reaches the structural
joints 202. At the structural joints 202, the chamfered edges 204
are filled with the coating 230.
[0080] As illustrated in FIGS. 13-16, embodiments of the present
invention provide an expansion joint that, among other
characteristics, fills a gap in the tunnel floor, wall or roof,
provides movement and supports RWS fire rating, e.g., performs
within RWS time/temperature curve and other tunnel fire standards.
However, other fire resistant, fireproof coatings could also be
employed with the expansion joint systems described herein to
provide, e.g., a build up of thickness of the coating 230 and
protect the tunnel or other desired structure.
[0081] 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, and further that the
features of the embodiments described herein can be employed in any
combination with each other. 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.
* * * * *