Expansion Brochure


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Expansion Brochure

  1. 1. Bridge ProductsSteelflex® Modular Expansion Joint Systems Steelflex® Strip Seal Expansion Joint SystemsDelcrete™ Strip Seal Expansion Joint Systems Delastic® Preformed Neoprene Compression Seals Protect Your Investment
  2. 2. Meeting the Challenge TheProtect Your For example, D. S. Brown pioneered D.S. Brown CompanyInvestment processing improvements of its Steelflex® rail profiles from the Founded in 1890 andSince the early 1960’s The D.S. Brown traditional extrusion method to the based in North Baltimore,Company has provided expansion joint innovative hot-rolled/machined and hot- rolled/non-machined technology. Ohio, USA, The D.S. Brownsystems and structural bearing assem- Company is a worldwideblies for bridges around the globe. Quality is further improved through in-Bridge expansion joint systems are house neoprene sealing element designer, manufacturerdirectly exposed to vehicular wheel extrusion capabilities. Together, these and supplier ofloads and, therefore, must resist initiatives have allowed D.S. Brown to engineered products fordynamic forces causing fatigue and improve the watertight integrity of its the highway and bridgewear. In addition, these expansion joint expansion joint systems while reducing the cost of these assemblies to the construction markets.systems must remain watertight toprotect the bridge superstructure and owner/agency. D.S. Brown is fullysubstructure from corrosion. Use the design guide below to select and integrated, performingTo satisfy the demanding needs of specify the appropriate D.S. Brown and controlling allbridge expansion joint systems, bridge product. The D.S. Brown requirements of a projectD.S. Brown is committed to product Company’s Steelflex® and Delastic® Expansion Joint Systems are designed to internally:research and development, supported byworld-renowned, independent testing protect your investment. • Research andlaboratories. Development • Engineering Design/ CAD DetailingDesign Guide / Table of Contents • Rubber compounding,Approximate Total <2” 3” 4” >4” mixing, extruding and PagesJoint Movement (51mm) (76mm) (102mm) (102mm) moldingSteelflex® Modular 3-6Expansion Joint Systems • Custom steel fabrication and machiningMaurer System™ SwivelExpansion Joint Assembly 7by The D.S. Brown Company • Load TestingSteelflex® Strip Seal 8 - 10Expansion Joint Systems With offices and fabrication facilitiesDelcrete™ Strip SealExpansion Joint Systems 11 throughout the USA and Asia, D.S. Brown is well-Delastic® Preformed positioned to satisfy allNeoprene Compression 12Seals of your structural bearing assembly,Fabricated Steel expansion joint system 13Products and specialty bridgeCableguard™ Elastomeric product requirements. 13 - 14Wrap System2
  3. 3. Steelflex® Modular Expansion Joint SystemsD.S. Brown Steelflex® Modular for accommodating and sealing large research activities, each joint system isExpansion Joint Systems have gained joint movements on bridge structures. designed to provide watertight, fatigueoverwhelming worldwide acceptance By incorporating the results of recent resistant, long-term maintenance-free performance. Steelflex® Edge Beam Steelflex® Centerbeam Welded Connection Support Bar Stainless Steel Sliding Surface Slide Bearing Precompressed Spring Control Spring Maximum Unsupported Span Length as Determined by Design Requirements 3
  4. 4. Steelflex® Modular Expansion Joint SystemsSystem ComponentsSteelflex® Modular Expansion Joint Systems are highly engineeredassemblies which consist of Steelflex® centerbeams and edgebeams. The centerbeams and edge beams not only carry thedynamic wheel loads but also accept the series of strip seal stylesealing elements that create a watertight joint. All Steelflex®Modular Expansion Joint Systems are designed to accommodate upto 80mm of movement per neoprene sealing element and, thus, thejoint designation is presented in multiples of 80mm (i.e. D-160,D-240, etc.).Each Steelflex® centerbeam is rigidly supported by its own supportbar using a full-penetration welded connection. Support bars spanthe joint opening and are arranged below the centerbeams in adirection parallel to the structural movement. Stainless steel slideplates are attached to each end of the support bars (both top andbottom surfaces) to provide a low coefficient-of-friction surface.Movements up to ±0.79 inches (20mm) transverse to the supportbars (for D-320 joint assemblies and larger) can be accommodatedby a Steelflex® Modular Expansion Joint System. For largelongitudinal movements and transverse movements beyond theallowable limits, the Maurer System™ Swivel Expansion JointAssembly by The D.S. Brown Company should be considered(see page 7).Elastomeric springs and bearings containing a PTFE slidingsurface are utilized to accommodate all longitudinal, transverse,and rotational movements. The precompressed springs and slidebearings are located directly above and below the support bar,respectively. The precompressed spring is designed to have aspecific compression force on the support bar which, in turn,produces a downward force on the slide bearing. This arrangementallows the spring and bearing to work together and resist uplift ofthe support bar as vehicular loads travel across the assembly.Closed-cell polyurethane control springs are installed in allSteelflex® Modular Expansion Joint systems to provide equidistantspacing between centerbeams throughout the joint system’scomplete movement range. The control spring orientation issuch that the maximum compressive force is generated on thecenterbeams when the modular expansion joint assembly is at itsmaximum opening.4
  5. 5. Steelflex® Modular Expansion Joint SystemsDesign Principles Steelflex® Modular Expansion Joint Systems solve these problems with theirFatigue Resistance excellent watertight design characteris- tics. Each system not only bridges theModular expansion joint assemblies are joint gap but also protects the structuresubjected to millions of high dynamic from premature corrosion. Design ofstress cycles due to passing vehicle the strip seal sealing element is based onloads. Recognizing the significance of compression of the neoprene seal lugthese dynamic loads on the long-term into the gland recess of the centerbeamperformance of expansion joint systems, and edge beam. This mechanically-D.S. Brown became the first North locked neoprene seal not only providesAmerican company to introduce fatigue- excellent watertight characteristics butresistant design principles to modular also achieves high pullout resistance.expansion joint assemblies. It is The strip seal sealing element hasstrongly recommended that a superior performance characteristics Fatigue Testing, Lehigh University,specification which includes fatigue over the box seal design, including ATLSS Laboratory, Bethlehem, PA, USA.design provisions be included in the improved watertight capabilities, pulloutcontract documents. strength and replaceability. • Setting to line and gradeThe results of extensive field and • Setting proper joint openinglaboratory research have been utilized to Installation Considerations • Blockout reinforcementachieve a fatigue-resistant expansion • Concrete consolidationjoint system. All primary members have As in all other expansion joint systembeen fatigue tested to determine the solutions, a proper installation is Detailed information on recommendedfatigue design category of each required to ensure long-term, installation practices can be found incomponent (i.e. Steelflex® centerbeam, maintenance-free performance of The D.S. Brown Modular Expansioncenterbeam/support connection and modular expansion joint systems. Joint Assembly Installation Data Sheet.support bar). Using these test results, Special attention is directed to It is also suggested that the contractor/a fatigue-resistant joint assembly installation considerations such as: owner utilize the services of a trainedcan be detailed to satisfy the contract D.S. Brown technical representative tospecifications and ensure the owner of a • Joint lifting and handling review proper installation techniquesmaintenance-free expansion joint • Field splices (when necessary) and be on-site during the initial installa-system solution. tion of a Steelflex® Modular Expansion Joint System.Watertight IntegrityIn the past, unsealed fabricated steeljoint systems have been specifiedon structures with large movements.Unfortunately, these older joint systemsolutions have not been effective inpreventing water and debris frompassing through the deck joint tothe underlying superstructure. Thisaccumulation of water and debriscorrodes steel components, deterioratesconcrete and results in unnecessaryrehabilitation costs. Even when theseunsealed, fabricated joint systems utilize atrough to collect drainage, in mostcases problems develop as they becomefilled with debris. Bear Mountain Bridge, Bear Mountain, NY, USA. 5
  6. 6. Steelflex® Modular Expansion Joint SystemsJoint Selection &Design DataSelection of the proper Steelflex® structural movements parallel andModular Expansion Joint System is perpendicular to the joint assembly.based primarily on the anticipated The largest of these two movementsstructural movement at the joint should be used to select the appropriatelocation. For joint assemblies oriented Steelflex® Modular Expansion Jointperpendicular to the structural System.movement, simply select the Steelflex®Modular Expansion Joint System with The table below provides expansiona total movement range larger than the joint assembly and blockout dimensionsanticipated structural movement. Joint for a wide range of Steelflex® Modularassemblies installed on curved or skewed Expansion Joint Sizes.structures require the calculation of Model Total Cells “A” “B” “C” “C” “W” “X” Symbol Number Movement Blockout Blockout Min. Max. Mid Temp Depth Width 6.30 14 15 3.35 5.71 8.17 12.2 D-160 2 (160) (356) (391) (85) (145) (208) (310) 9.45 14 18 4.92 9.65 12.24 12.2 D-240 3 (240) (356) (457) (125) (245) (311) (310) D-320 12.60 14 22 6.50 13.78 16.32 12.2 4 (320) (356) (559) (165) (350) (415) (310) D-400 15.75 14 25 8.07 17.91 20.39 12.2 5 (400) (356) (635) (205) (455) (519) (310) D-480 18.90 14 28 9.65 21.85 24.47 12.2 6 (480) (356) (711) (245) (555) (622) (310) D-560 22.05 14 31 11.22 25.98 28.54 12.2 7 (560) (356) (787) (285) (660) (725) (310) D-640 25.20 15.25 34 12.80 30.12 32.62 13.3 8 (640) (387) (864) (325) (765) (829) (338) D-720 28.35 15.5 37 14.37 34.06 36.69 13.6 9 (720) (394) (940) (365) (865) (932) (345) Dimensions are based on design provisions in NCHRP Report 402. Dimensions are based on 0 degree skew. Bold numbers represent inches; metric (mm) shown in parentheses. Shallower depths (X) may be possible upon special request.6
  7. 7. Steelflex® Modular Expansion Joint SystemsMaurer System™ Performance Features Seismic Movement CapabilitySwivel Expansion By utilizing a common-to-all- Dynamic tests conducted at theJoint Assembly by centerbeam swiveling support bar, the University of California at BerkeleyThe D.S. Brown Co. Maurer System™ Swivel Expansion subjected the Maurer System™ Joint Assembly by The D.S. Brown Swivel Expansion Joint AssemblyConventional large movement expan- Company is able to accommodate large by The D.S. Brown Company tosion joint devices, such as D.S. Brown’s longitudinal displacements (X), exten- high-velocity seismic displace-Steelflex® Modular Expansion Joint sive transverse displacements (Y), and ments. This first-of-its-kind testSystem, are limited to primarily vertical displacements (Z), as well as program included velocities of morelongitudinal movements and/or less vertical rotations (Φx, Φy) of up to 10 than 40 inches per secondthan ±0.79 inches (20mm) transverse degrees. The centerbeams are free (1015mm/sec) in both longitudinaldisplacement. For joint locations which to slide on swiveling support bars, and transverse directions. Theproduce more demanding structural which provide equidistant control for successful test results proved themovements, the Maurer System™ Swivel centerbeams without the limitations unique capabilities of this patentedExpansion Joint Assembly by The D.S. of typical mechanical control devices. device in seismic applications.Brown Company is provided in the To ensure long-term performance, allU.S.A. through an exclusive license Maurer System™ Swivel Expansion Jointagreement with Maurer Söhne, Munich, Assemblies by The D.S. Brown Com-Germany. Typical applications include: pany are designed and fabricated using fatigue-resistant connection details.• Long-span structures• Structures located in seismic zones For assistance with selecting the• Curved structures appropriate size patented Maurer• Structures with differential System™ Swivel Expansion Joint longitudinal movements or Assembly by The D.S. Brown Company, differential vertical movements please contact D.S. Brown.• Structures with anticipated substructure settlement Lacey V. Murrow Floating Bridge, Seattle, WA, USA.Dynamic Testing, University of California, Berkeley, CA, USA. 7
  8. 8. Steelflex® Strip Seal Expansion Joint SystemsFor decades, cast-in-place Steelflex® Recent design improvements haveStrip Seal Expansion Joint Systems have eliminated all horizontal “legs” onprovided superior watertight perfor- the proprietary steel rail profiles tomance and longevity over bolt-down, facilitate proper concrete placementsegmental and pourable expansion during installation. Independent fieldjoint systems. Because of this proven and laboratory testing has demonstratedperformance, Steelflex® Strip Seal that improperly consolidated concreteExpansion Joint Systems have become around the steel rail, anchorage, and/orthe overwhelming choice of owners and reinforcement could lead to performancespecifying engineers around the world issues. Anchorage of the proprietaryfor accommodating up to five inches steel rail profile into the deck concrete is(127mm) of total structural movement. the primary load carrying mechanism and, therefore, is critical to ensure long-term performance. Research hasSystem Components confirmed that properly sized and spaced shot-on studs provide anCast-in-place Steelflex® Strip Seal economical, field-proven anchorageExpansion Joint Systems consist of method.two proprietary components: steel railprofiles and a matching neoprene Because it is field-proven, the Steelflex®sealing element. SSCM2 rail profile has become widely accepted worldwide as an economical standard in the industry. Other propri- etary steel profiles are available to satisfySteel Rail Profiles your specific project needs.Steelflex® rail profiles are one-piececonstruction, manufactured usinginnovative hot rolled/non-machined andhot rolled/machined technology. Allproprietary steel rails are available in *SSCM available upon requestASTM A36 or ASTM A588 steel grades.8
  9. 9. Steelflex® Strip Seal Expansion Joint SystemsSystem ComponentsNeoprene Sealing ElementsSelection of a neoprene strip seal dimension for A2R-O and L2R-O seals issealing element is based on the maxi- approximately 3.0 inches (76mm).mum movement either perpendicular(MRL) or parallel (MRT) to the All D. S. Brown neoprene sealingSteelflex® Strip Seal Joint Assembly. elements are in-house designed andTo assist in your selection, the following tested to provide a watertight seal attable provides movement ranges for the connection to the Steelflex® raileach sealing element type and the profile. Factory molded neoprene sealingcorresponding proprietary steel rail element splices can also be produced toprofile. Information is also provided on accommodate your specific project needs.the range of joint opening dimensions.The preferred joint opening dimensionsfor sealing element installation isapproximately 2.0 inches (51mm).However, the preferred joint opening Sealing Element Sealing Movement Range Joint Corresponding Cross-Section Element Opening Steelflex® MRL MRT Rail A2R – 400 4.0 ±2.0 0.5 – 4.5 (102) (51) (13) (114) A2R SSCM2 A2R – XTRA 7.0 ±2.0 0.5 – 7.5 SSA2 (178) (51) (13) (191) SSE2 A2R – O 4.0 ±0.5 1.0 – 5.0 (102) (13) (25) (127) A2R-O L2 – 400 4.0 ±2.0 0 – 4.0 (102) (51) (0 (102) L2 L2-500 5.0 ±2.0 0 – 5.0 SSPA (127) (51) (0) (127) SSCM L2-O 4.0 ±0.5 1.0 – 5.0 (102) (13) (25) (127) L2-O Bold numbers represent inches; metric (mm) in parentheses. 9
  10. 10. Steelflex® Strip Seal Expansion Joint SystemsDesign concrete barrier. The upturn angle varies depending on the barrier detail,Considerations joint skew and Steelflex® rail profile. Horizontal Miter DetailsAnchorage Highly skewed structures often requireAnchorage type, size and spacing for the fabrication of a horizontal break in theSteelflex® SSCM2 joint system is joint system to orient the steel rail 90illustrated. Anchorage details for other degrees to the face of the concreteSteelflex® rail profiles are available. barrier. Neoprene strip seal sealing elements are installed in a continuous piece, without vulcanization, up to a 35Upturn Details degree angle.A watertight joint system is maintainedthrough a simple upturn detail into theEast Fork White River Bridge, Columbus, IN, USA.10
  11. 11. Delcrete™ Strip Seal Expansion Joint SystemsSince its introduction in 1983, the Following are the design features of the technical representative or a representa-Delcrete™ Elastomeric Concrete/ industry’s premier elastomeric tive of its licensed applicator shall beSteelflex® Strip Seal Expansion Joint concrete: present on the job site during all phasesSystem has been utilized on hundreds of the installation.of bridges worldwide as an alternative • Polyurethane chemistryto more labor intensive, cast-in-place • Non-brittle over extreme Basic installation considerations include:expansion joint rehabilitation solutions. temperature rangesThis expansion joint system also offers • Resistant to nearly all chemicals • Minimum ambient and concretesuperior long-term performance when • One hour cure time substrate temperature: 45ºF (7ºC)compared to various pourable joint • Permanent, long-term repair • Sandblast entire blockout, includingsolutions. solution steel rail profile, followed by a compressed air sweepComponents to this system include: Although initially developed for the • Blockout area must be completely drylow profile SSA2 or SSE2 Steelflex® bridge rehabilitation market, the before installationrail profiles and Delcrete™ Elastomeric outstanding performance record ofConcrete. Delcrete™ has resulted in bridge owners A comprehensive list of installation specifying Delcrete™ Strip Seal Expan- procedures is found in The D.S. BrownDelcrete™ Elastomeric Concrete is a sion Joint Systems for new bridge Delcrete™ Strip Seal Expansion Jointpour-in-place, free-flowing, two-part construction projects as well. System Installation Data Sheet.polyurethane-based elastomericconcrete. Delcrete™ has beencompounded to bond to a variety of Installationsurfaces including steel and concrete. Proper installation of Delcrete™ is essential to ensure long-term perfor- mance. Therefore, a D.S. Brown 11
  12. 12. Delastic® Preformed Neoprene Compression SealsIn 1960 The D. S. Brown Company In addition to highway and bridge 35ºF (2ºC) to 80ºF (27ºC). Atbegan designing and extruding the applications, Delastic® Neoprene temperatures below this rangefirst generation of Delastic® Preformed Compression Seals have also been used the lubricant/adhesive has limitedNeoprene Compression Seals. Since in spillways, dams, parking structures, effectiveness, while at temperatures abovethat time continuous improvements have stadium ramps and pedestrian over- this range the seals become difficult tobeen made to this versatile, cost- passes. Information on additional seal compress for installation.effective joint sealing solution. To designs is available.withstand the demanding requirements Manual and automatic tools areof bridge/highway installations, all Installation available to facilitate ilnstallation. D.S.Delastic® Preformed Compression Brown Delastilube™ or Delastilube™ HSSeals are extruded from neoprene In all installation applications, the joint lubricant/adhesive is used primarily to(polychloroprene) compounds which width must be properly set for the lubricate the seal for installationsatisfy the ASTM standard specification specified Delastic® seal. Also, the purposes. The Delastilube™ productsD3542 for Preformed Polychloroprene vertical faces of the joint must be clean meet ASTM D2835 and D4070Elastomeric Joint Seals for Bridges. and free of spalled concrete. Desirable standards. installation temperatures range fromDesign DataThe table below can be used to select the appropriate Delastic® NeopreneCompression Seal for your project. In addition to accommodating perpendicularmovements (summarized in the table), Delastic® seals are also capable of acceptingapproximately 15-20% lateral shear, vertical shear and rotational movements. Delastic® SEAL CHARACTERISTICS JOINT DESIGN CRITERIA Delastic® Seal Nominal Nominal Max. Narrowest Widest Minimum Width (W) Height (H) Movement Opening (A) Opening (A) Depth (B) 1.25 1.25 0.50 0.56 1.06 1.63 CV-1250 (32) (32) (13) (14) (27) (41) 1.63 1.88 0.60 0.73 1.38 2.25 CV-1625 (41) (48) (15) (19) (35) (57) 1.75 1.75 0.70 0.79 1.49 2.40 CV-1752 (44) (44) (18) (20) (38) (61) 2.00 2.00 0.75 0.95 1.70 2.75 CV-2000 (51) (51) (19) (24) (43) (70) 2.25 2.33 0.90 1.01 1.91 3.00 CV-2250 (57) (59) (23) (26) (49) (76) 2.50 2.50 1.00 1.13 2.13 3.20 CV-2502 (64) (64) (25) (29) (54) (81) 3.00 3.25 1.20 1.34 2.55 4.25 CV-3000 (76) (83) (31) (34) (65) (108) 3.50 3.50 1.40 1.58 2.98 4.45 CV-3500 (89) (89) (36) (40) (76) (113) 4.00 4.00 1.65 1.75 3.40 5.63 CV-4000 (102) (102) (42) (44) (86) (143) 4.50 4.50 1.80 2.03 3.83 6.13 CV-4500 (114) (114) (46) (52) (97) (156) 5.00 5.00 2.35 1.90 4.25 6.25 CA-5001 (127) (127) (60) (48) (108) (159) 6.00 6.00 2.90 2.20 5.10 7.75 CA-6000 (152) (152) (74) (56) (129) (197) Bold numbers represent inches; metric (mm) shown in parentheses. Joint opening dimensions (A) are based on minimum and maximum pressures allowed in ASTM D3542. Minimum depth dimensions (B) include a 0.25 inch (6mm) recess below the roadway surface.12
  13. 13. Fabricated Steel ProductsFabricated steel plate expansion joint To ensure high-quality workmanship,systems, such as finger joint assemblies all fabricated steel products should beand sliding plate and armor joint fabricated in an AISC-Major Steel Bridgesystems, are still specified on many certified facility.bridge projects due to proven long-termstructural performance. These jointsystems are also convenient to install onbridge rehabilitation projects requiringa shallow joint depth and/or stagedconstruction.In addition to fabricated steel plateexpansion joint systems, D.S. Brownalso supplies the following fabricatedsteel products:• Steel Diaphragms• Pin and Link Assemblies• Bridge Railings• Other Custom Steel Fabrications Finger Joint Assembly.Cableguard™ Elastomeric Wrap SystemDue to the premature failure ofcorrosion protection systems on cable-supported structures, D.S. Brown begandevelopment of its patentedCableguard™ Elastomeric Wrap Systemin the early 1990s. This alternativecorrosion protection system, developedexclusively for bridge cables, isapplicable during construction orrehabilitation of cable-stayed andsuspension bridges.The Cableguard™ wrap is based oncross-linking a chlorosulfonatedpolyethylene polymer that is manufac-tured into a 45 mil (1.14mm) thick,three-ply (polymer-fabric reinforce-ment-polymer) laminated construction.Several Cableguard™ Elastomeric Wrapfeatures are highlighted as follows: Anthony Wayne Bridge, Toledo OH, USA. 13
  14. 14. Cableguard™ Elastomeric Wrap SystemHighlighted FeaturesEnvironmentally Friendly into the cable. However, even though the Cableguard™ wrap shrinks securelyCableguard™ Elastomeric Wrap is to the cable, it does not fuse or bond toapplied directly over existing poly- the cable. Therefore, partial removal forethylene, paint or galvanized cable inspection of the internal strands is notsurfaces using a Skewmaster™ automatic impaired.wrapping device. The Cableguard™Elastomeric Wrap encapsulates theentire cable. The Cableguard™ system Proprietary Cable Band Treatmentdoes not require sandblasting, high-pressure washing or any type of solvent. The Cableguard™ Elastomeric WrapTherefore, containment and disposal of System features a watertight sealinghazardous materials is eliminated. mechanism at the cable bands of suspension bridges. This proprietarySimple Installation system includes an extruded neoprene wedge and stainless steel clampingAfter applying the Cableguard™ Wrap, straps.intimate heat is applied to fuse the 50percent overlapped wrap (total thicknessof 90 mils) and shrink the wrap snuggly Color-Fastto the cable surface. This fusion andshrinkage creates an impermeable Cableguard™ wrap is available in Cable Band Treatment.barrier against the intrusion of moisture virtually any color without applying paint. Heat Blanket Application. Skewmaster™ Wrapping Device.14
  15. 15. Notes
  16. 16. Steelflex® Expansion Joint Systems Fred Hartman Bridge, Houston, Texas, USA. KaoPing Bridge, Kaohsiung, Taiwan. Longport Bridge, Ocean City, NJ, USA. The D.S. Brown Company 300 East Cherry Street North Baltimore, OH 45872 419.257.3561 Fax: 419.257.2200 email: dsb@dsbrown.com Delastic® and Steelflex® are registered trademarks of The D.S. Brown Company. Cableguard™, Delastilube™, Delcrete™ and Skewmaster™ are trademarks of The D.S. Brown Company. The Maurer System™ Swivel Expansion Joint Assembly by The D.S. Brown Company is provided© 2007 The D.S. Brown Company through an exclusive U.S. license arrangement with Maurer Söhne GmbH & Co., Munich, Germany.