Document Control No.: BGS07900-SR 11/19/04

SECTION 07900 EXTERIOR EXPANSION AND SEISMIC JOINT SYSTEM SPECIFICATION

DuraFlexTM “SR” Series – Steel Rail System Heavy Duty/Vehicular Series Expansion Control System

PART 1 - GENERAL

1.01 Related Documents

A. Drawings and general provisions of the Contract, including General Conditions, Supplementary Conditions and Division-1 General Requirements, apply to the work of this section.

1.02 Work Included

A. The work shall consist of furnishing and installing expansion joint systems in accordance with the details shown on the plans and the requirements of the specifications. The joints are proprietary designs utilizing an extruded elastomeric seal, engineered steel embedment shapes and anchorage system and an elastomeric concrete nosing material. In the event of any discrepancy between the contract drawings and specifications, the specifications shall govern.

1.03 Related Work

A. Related work which is specified elsewhere. 1. Division 3 – Section 03300 on Concrete 2. Division 3 – Section 03450 on Architectural Precast Concrete 3. Division 7 – Section 07900 on Waterproofing, Sealants and Caulking

1.04 References

A. Publications listed herein are part of this specification to the extent referenced. The criteria established in the specifications shall take precedence over the standards referenced herein. 1. American Society for Testing and Materials (ASTM): a. ASTM A36, Standard Specification for Carbon Structural Steel. b. ASTM A588, Standard Specification for High-Strength Low-Alloy Structural Steel with 50 ksi [345 Mpa] Minimum Yield Point to 4-in. [100mm] Thick. c. ASTM E1399, Standard Test Method for Cyclic Movement and Measuring the Minimum and Maximum Joint Widths of Architectural Joint Systems.

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1.05 Submittals

A. Shop Drawings and Product Data – Submit typical expansion joint cross- sections indicating pertinent dimensioning, general construction, joint dimensioning and product data information. Drawings will also show transition and installation details.

B. Samples – Submit one (1) sample piece at least 6” long, of each type required, to the Project Architect/Engineer for approval.

1.06 System Description

A. DuraFlexTM “SR” Series – Steel Rail System as manufactured by Balco, Inc. 1. The joint seal shall be a watertight deck expansion control system that is capable of accommodating HS20 loads. 2. The joint system shall accommodate multi-directional movement. 3. The system shall consist of steel rails having formed anchor bars welded thereto and having channels into which an extruded elastomeric seal engages. 4. The system is secured to the deck using a proprietary ambient-cured elastomeric concrete nosing material.

1.07 Quality Assurance

A. Manufacturer: Obtain joint seals through one source from a single manufacturer. 1. The Manufacturer shall be ISO 9001:2000 Certified. a. The manufacturer shall have documented management and control of the processes that influence the quality of its products. b. The manufacturer shall have documented management and control of the processes that influence the quality of its customer service. c. Manufacturers in the process of obtaining ISO 9001:2000 Certification shall not be considered. 2. The manufacturer shall have a minimum of ten (10) years of experience in the fabrication of expansion joint system assemblies.

B. Installer: The installer shall be acceptable to the system manufacturer. 1. The installer shall be insured and also licensed, as required, by the local state agency within the project’s jurisdiction. 2. The approved installer shall prepare and submit details of all special conditions to the manufacturer for review and approval prior to installation.

1.08 Product Delivery, Storage and Handling

A. Deliver joint seal systems to the jobsite in new, clean, intact, labeled, unopened crates, containers, pallets, reels, or bundles of sufficient size and strength to protect the materials during transit.

B. Store all components under shelter in a dry, cool location. Store off the ground; protect from freezing, direct sun exposure, weather and construction

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activities. All resin components, including Primer 2 Part A and Part B and Elastomeric Concrete – EC11 Part A and Part B, shall be stored at temperatures between 50°F and 80°F.

C. Until used, all components should be left in the manufacturer’s original, unopened labeled crates, containers, pallets, reels or bundles.

1.09 Project Conditions

A. Joint Opening – The work may proceed only after the Installer has reviewed the joint opening/temperature information, and coordinated that information with the Engineer’s design calculations.

B. Environmental Conditions – Do not proceed with installation of the elastomeric concrete nosing and the SR Series System under the following conditions: 1. When ambient and substrate temperature conditions are outside the limits permited by the Manufacturer. 2. When the joint substrates are wet.

C. The expansion joint blockout and opening concrete surfaces must be sandblasted to remove laitance, loosely bonded material and any other contaminant. They shall be free of dust, oil, grease, wax, moisture and frost. The joint interface walls shall be clean.

1.10 Warranty

A. Warranty: The specified products shall be warranted when installed in strict accordance with the manufacturer’s technical specifications, details, installation instructions and general procedures as well as good industry practice in effect for normal traffic usage and suitable applications under specific design movements and loading conditions.. 1. The expansion joint system shall be warranted for a period of one (1) year. 2. The specified products shall be warranted for a period of [one (1) year] [three (3) years] [_____ years] when installed by a certified installer, factory trained by the manufacturer and certified in the proper installation of the system.

PART 2 - PRODUCT

2.01 Acceptable Manufacturer

A. Furnish and install as noted in the specifications and as indicated on the drawings DuraFlexTM “SR” Series – Steel Rail System(s) [SRC-400] [SRW- 400] as manufactured by: Balco, Inc., PO Box 17249, 2626 S. Sheridan, Wichita, Kansas 67217; phone: 800-767-0082 or (316) 945-9328; fax: (316) 945-0789.

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B. Alternate manufacturers and their products will be considered, provided they meet the design concept and are produced of materials that are equal to or superior to those called for in the base product specification.

C. Any proposed alternate system must be submitted and receive approval 21 days prior to bid. Proposals made subsequently will not be considered. This submission shall be in accordance with information shown in Division 1 “Request for Substitution”.

2.2 Components and Materials

A. Elastomeric Seal: 1. Shall be a [type C, single-ply seal] [type W, chambered seal]. 2. Shall have side lugs designed to engage into channels in steel rails, ensuring leak resistance and proper joint performance. 2. Shall be extruded from a flexible, Neoprene compound exhibiting the physical properties listed in the table below.

The Elastomeric Seal shall have the following properties:

Tensile strength, min. psi (Mpa); ASTM D412 1700 Ultimate elongation, min, %; ASTM D412 225 Hardness, Type A durometer; ASTM D2240 65 +/-5 Tear strength, min.; ASTM D624 125 lb./in. Compression set, %, 22h @ 212oF max.; D395 30 Heat aging, 70h @ 212oF; ASTM D573 Hardness increase, max. durometer pts. 10 Change in tensile, %, maximum 15 Change in elongation, %, maximum 40 Ozone resistance, 100h @ 104oF; ASTM D1149 no cracks

B. Steel Rail: 1. ASTM A36 Steel (shapes) or ASTM A588 Steel (extrusions).

C. Stud Anchors: 1. Steel Stud Anchors, 0.5” x 9” bent 90o at 3”.

D. Elastomeric Concrete: 1. Balco, Inc. Elastomeric Concrete – EC11 ambient-cured header material consisting of polyurethane liquid components “A” and “B” and a proprietary aggregate system. 2. The elastomeric concrete shall be mixed at the jobsite. It shall have the following properties:

Tensile strength, psi; ASTM D412 1680 psi Elongation at break, min., %; ASTM D638 240 Durometer hardness, Type A; ASTM D2240 75 +/-3 Tear resistance, min., lbs/inch; ASTM D624 195 Adhesion Properties Bond to Concrete, psi, min.; ASTM C109 422 Pot life, min. 20 minutes

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Ozone Resistance: ASTM D1149 No Cracks UV Resistance; ASTM G53 Excellent Compression Strength; ASTM D695 5% deflection, psi, min. 1442 Resilience, %, min. 96

E. All concrete in contact with the seal must be primed using Primer 2, two component primer, mixed in accordance with the manufacturer’s instructions.

F. Accessories: 1. Provide other materials required for complete installation of the DuraflexTM “SR” Series – Steel Rail System(s) in accordance with the manufacturer’s written installation instructions.

2.03 Fabrication

A. Ship the elastomeric seal in the longest practical continuous length, coiled on Manufacturer’s standard reel or on wooden pallets shrink-wrapped.

B. Butt splice connections shall be fabricated on the jobsite in accordance with the Manufacturer’s written instructions.

C. Transitions, such as 90o corners, shall be [factory fabricated] [fabricated on the jobsite].

D. Steel Stud Anchors shall be welded to the Steel Rails spaced at 9” O.C.

E. Ship Primer and Elastomeric Concrete Header in Manufacturer’s approved containers.

2.04 Finishes

A. Steel Rails: Mill finish.

B. Elastomeric seal shall be supplied in standard color: black.

C. Elastomeric Concrete Header material shall be supplied in standard color: black.

PART 3 - EXECUTION

3.01 Inspection

A. The blockout and joint opening shall be solid, properly formed, properly cured concrete and shall be formed per the manufacturer’s instructions, recommendations and details and per the project requirements. Any edge or area needing repair shall be repaired utilizing one of the Balco, Inc. recommended concrete repair materials to provide a solid and square blockout.

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B. Blockouts requiring the use of patching compounds must be cured in accordance with the manufacturer’s recommendations and instructions prior to placement of Balco, Inc. Elastomeric Concrete – EC11.

C. Clean dirt, stones, and all other contaminants and impurities from the blockout and the joint opening and sandblast the blockout to expose aggregate to remove laitance and contaminants and to prepare the surfaces for the installation of the Elastomeric Concrete Header material.

D. Mask areas adjacent to the joint with tape to assure neat, clean joint lines. Remove the tape prior to the curing process.

3.02 Examination

A. Verify that field measurements and blockout dimensions are as shown on shop drawings prior to releasing materials for fabrication by the manufacturer.

B. Installer shall examine conditions under which work is to be performed and shall notify the contractor in writing of unsatisfactory conditions. Installer shall not proceed with the installation until unsatisfactory conditions have been corrected in a manner acceptable to the installer.

3.03 Installation

A. Protect all expansion joint system component parts from damage during installation, placement of concrete and thereafter until completion of the structure.

B. Do not install Balco, Inc. Elastomeric Concrete – EC11 if the ambient temperature is below 40oF. Balco, Inc. Elastomeric Concrete – EC11 will cure at temperatures down to 32oF; however, the application temperature must not be below 40oF.

C. Immediately prior to installation, the blockout and joint interfaces should be blown out using compressed air.

D. Prepare the installation area in accordance with the manufacturer’s recommendations and instructions.

E. Unpackage the elastomeric seal, uncoil it and allow it to relax to relieve any temporary coiling from shipment packaging and storage.

F. Install the SR Series – Steel Rail System in accordance with the manufacturer’s recommendations and instructions. Ensure that the Primer and Elastomeric Concrete components are mixed in accordance with the manufacturer’s recommendations and instructions.

G. Clean up the work area after installation of the system is completed.

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H. Once poured and cured, the elastomeric concrete shall allow traffic in approximately 4 – 6 hours)

3.04 Adjusting and Protection

A. Protect the completed expansion joint work from damage during construction. 1. Heavy construction vehicles shall not be permitted to cross the joint without the specific and written permission of the Engineer. 2. Subsequential damage to the Membrane System shall be repaired at the contractor’s expense.

B. After work is complete, clean exposed surfaces with a suitable cleaner (Toluene or Xylene) that will not harm or attack the finish.

End of Section

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