Expansion joint seal system

Abstract

An expansion joint seal system which includes intumescent to protect uncoated edges of substrates. A fire rated compressed expansion joint sealant is provided having an intumescent proximate, but below the water-resistant top of the fire-retardant foam, so that when exposed to fire, the intumescent expands to protect the exposed vertical surface of the adjacent concrete substrate. The end of the concrete is therefore protected in a manner which does not require joint overlap between the horizontal fire resistant coating and the compressible sealant.

Claims

1. An expansion joint seal system, comprising, a body of compressible foam, the body of compressible foam being fire retardant, the body of compressible foam having a body first face intermediate a body top and a body bottom and a body second face opposite the body first face, a first intumescent member, the first intumescent member having a first intumescent member first outer surface, the first intumescent member made integral to the body of compressible foam, the first intumescent member first outer surface substantially aligned with the body first face, a second intumescent member, the second intumescent member having a second intumescent member first outer surface, the second intumescent member made integral to the body of compressible foam, the second intumescent member first outer surface substantially aligned with the body second face.

2. The expansion joint seal system of claim 1, wherein the body of compressible foam has a body length, and the first intumescent member and the second intumescent member have an intumescent member length equivalent to the body length.

3. The expansion joint seal system of claim 2, wherein the body first face is adapted to contact a first substrate end face and the body second face is adapted to contact a second substrate end face.

4. The expansion joint seal system of claim 2, wherein the body of compressible foam further comprises a first body channel, the first body channel in the body of compressible foam (118) below a body first face segment in the body first face along a body length and a second body channel, the second body channel in the body of compressible foam below a body second face segment in the body second face along a body length, and wherein the first intumescent member is adhered to the body of compressible foam at a first intumescent member second outer surface in the first body channel and the second intumescent member is adhered to the body of compressible foam at a second intumescent member second outer surface in the second body channel.

5. The expansion joint system of claim 4, wherein the first intumescent member has a quarter-circle profile and a top surface parallel to the body top and the second intumescent member has a quarter-circle profile and a top surface parallel to the body top.

6. The expansion joint system of claim 1, wherein the first intumescent member is force injected into the body of compressible foam in the body first face below a body first face segment along the body length and the second intumescent member is force injected into the body of compressible foam in the body second face below a body second face segment along the body length.

7. The expansion joint system of claim 1, further comprising: a flexible, expanding, intumescent membrane positioned within the body of compressible foam, aligned laterally with the first plane, and extending from a position adjacent the body first face to a position adjacent the body second face, the membrane positioned below a bottom of the first intumescent member and a bottom of the second intumescent member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] So that the manner in which the described features, advantages, and objects of the disclosure, as well as others which will become apparent, are attained and can be understood in detail; more particular description of the disclosure briefly summarized above may be had by referring to the embodiments thereof that are illustrated in the drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate only typical preferred embodiments of the disclosure and are therefore not to be considered limiting of its scope as the disclosure may admit to other equally effective embodiments.

[0022] In the drawings:

[0023] FIG. 1 is an illustration of a side view of the expansion joint system of the present disclosure installed between two substrates to extend above the top of the adjacent substrates.

[0024] FIG. 2 is an illustration of an isometric view of the expansion joint system of the present disclosure.

[0025] FIG. 3 is an illustration of an isometric view of the expansion joint system of the present disclosure from a different view.

[0026] FIG. 4 is an illustration of a side view of the expansion joint system of the present disclosure installed between two substrates after exposure to high temperature.

[0027] FIG. 5 is an illustration of a side view of an expansion joint system of the present disclosure installed between two substrates at an alternative location well below the top of the adjacent substrates.

[0028] FIG. 6 is an illustration of an alternative embodiment where the first intumescent member is formed by force injection of a then-liquid containing intumescent.

[0029] FIG. 7 is an illustration of an alternative embodiment further containing an intumescent barrier.

DETAILED DESCRIPTION

[0030] The expansion joint system 100 of the present disclosure includes a body of compressible foam 118, at least one intumescent member 128, and may include at least one elastomer layer 127 which provide an integral, but flexible, expansion joint system which has reduced susceptibility to shearing and delamination while providing fire-protection to substrate upper portions, edges and adjacent surfaces. Referring to FIGS. 1-3 and 5, the expansion joint system 100 is illustrated when imposed under compression between a first substrate 102 and a second substrate 104, typically occurring at a joint 103 between two substrates 102, 104. A side view of the expansion joint system of the present disclosure when installed between two substrates to extend above the top of the adjacent substrates is illustrated in FIG. 1. A side view of an expansion joint system of the present disclosure when installed between two substrates at an alternative location well below the top of the adjacent substrates is illustrated in FIG. 5. Substrates 102 and 104 are typically concrete. As with most construction surface, such as roadways, walls, and, in the case of tunnels, ceilings, the first substrate 102 and the second substrate 104 are generally co-planar to a first plane 106, i.e. at least substantially but not necessarily precisely co-planar. To avoid fracture during expansion, such as during summer heating, the substrates 102, 104, are separated, such as by a first distance 108. To prevent contaminants and water from entering the gap between the substrates 102, 104, the expansion joint system is imposed between the substrates 102, 104. The first substrate 102 has a first substrate thickness 110, and has a first substrate end face 112 generally perpendicular to the first plane 106, i.e. at least substantially but not necessarily precisely perpendicular. Likewise, the second substrate 104 has a second substrate thickness 114 and has a second substrate end face 116 generally perpendicular to the first plane, forming an exposed vertical surface, i.e. at least substantially but not necessarily precisely perpendicular. Using a compressible foam ensures the expansion joint system provides a sufficient seal to the two substrates 102, 104 to prevent contaminates, or freezing water, was accumulating between the two substrates 102, 104. The compressible foam is sized to be compressible to a width less than the first distance 108, i.e. sufficiently compressible to be wedged into the gap between the two substrates 102, 104, but being larger than the first distance 108, i.e. so that the expansion joint system 100 maintains force against, and therefore provides the seal to the two substrates 102, 104. The compressible foam has a sufficient body thickness 204 to provide the sufficient seal to the two substrates 102, 104

[0031] The body of compressible foam 118 of the expansion joint system 100 is fire retardant to reduce the likelihood of damage from a fire atop the first substrate 102 or the second substrate 104, and has a body first face 120, a body first fact segment 138 proximate the body first face 120, a body second face 122 opposite the body first face 120, a body second fact segment 140 proximate the body second fact 122, a body top 124, a body bottom 126 opposite the body top 124, a body width 202, a body thickness 204, a body length 206, and a first body channel 208a. The body first face 120 contacts the first substrate end face 112 when imposed under compression between the first substrate 102 and the second substrate 104, and may include an adhesive on one or both of its faces to ensure seal operation. Likewise, the body second face 122 contacts the second substrate end face 116 when imposed under compression between the first substrate 102 and the second substrate 104, and may include an adhesive on its face to ensure seal operation. The body of compressible foam 118 includes a body width 202 extending from the body first face 120 to the body second face 122 and has a body width 202 greater than the first distance 108 to ensure fit of the body of compressible foam 118 into the gap between the first substrate 102 and the second substrate 104. The body of compressible foam 118 includes a body thickness 204 extending from the body top 124 to the body bottom 126, where the body thickness 204 is equivalent to one of the first substrate thickness 110 and the second substrate thickness 114, but preferably not substantially greater than either. In one embodiment, the body of compressible foam 118 further includes a first body channel 208a in the body first face 120 proximate the body top 124 along the body length 206. The first body channel 208a in the body first face 120 is sufficiently near the body top 124 to permit activation of the first intumescent 128 to readily protect the adjacent substrate 102, 104 from fire damage. The first body channel 208a may be adjacent, near to, or proximate the body top 124, but is not, at its lowest portion, at or above the body top 124. So that the first intumescent member 128 does not substantially affect the flexibility of the body of compressible foam 118, the first body channel 208a is preferably no wider than 25% of the body width 202 and is preferably no taller than 25% of the body thickness 204. The first body channel 208a is found in the top third of the body thickness 204, preferably at the body first face 120 below the body first face segment 138 along the body length 206, and extends from the body first face 120 not more than one quarter of the distance from the body first face 120 to the body second face 122.

[0032] In this embodiment, the first intumescent member 128 is bonded to, such as by adhesion, the body of compressible foam 118 so as to maintain position during installation and during flexing of the body of compressible foam 118 during substrate contraction and expansion. Referring now to FIG. 3, the first intumescent member 128 has a first intumescent member first outer surface 302, a first intumescent member second outer surface 304, and a first intumescent member length 306. The first intumescent member first outer surface 302 is generally flat, i.e. at least substantially but not necessarily precisely flat, but the first intumescent member second outer surface 304 may be flat, or curved, or polygonal, such as a triangle, so that the first intumescent member 128 may have a semicircle, a quarter-round, a rectangular, or even a triangular profile, preferably where any top flat surface 134 is parallel to the first plane 106. The first intumescent member 128 is adhered to the body of compressible foam 118 at this first intumescent member second outer surface 304 and is the positioned in the first body channel 208a so that the first intumescent member first outer surface 302 is generally aligned with the body first face 120, i.e. at least substantially but not necessarily precisely aligned. Thus, the first body channel 208a is entirely filled with the first intumescent member 128. Likewise, the first intumescent member length 306 is equivalent to, and aligned with, the body length 206.

[0033] In an alternative embodiment, illustrated in FIG. 6, the first intumescent member 128 is formed by force injection of a then-liquid containing intumescent into the body of compressible foam 118 in the body first face 120 below the body first face segment 138 or in the top third of the body thickness 204, and along the body length 206, and extends into the body of compressible foam 118 from the body first face 120 toward the body second face 122 not more than one quarter of the distance from the body first face 120.

[0034] In the various embodiments, the body first face segment 138 may be sized for positioning entirely above the first substrate 102, thus positioning the first intumescent member 128 proximate, and preferably so that its top is equal to, the top of the first substrate 102. As a result, when exposed to heat, the first intumescent member 128 expands to fit about the exposed portion of the first substrate 102, whether that is simply the exposed first substrate end face 112 or includes some portion of the top of the first substrate 102 due to degradation of the cementious fireproofing 136.

[0035] Alternatively, the body first face segment 138 may be sized for positioning the first intumescent member 128 below the top of the first substrate 102, as illustrated in FIG. 1, reducing the exposure of the expansion joint system 100 to wear and tear. As a result, when exposed to heat, the first intumescent member 128 still expands to fit about the exposed portion of the first substrate 102, but is subject to limited, or no, expansion to protect the top of the first substrate 102 due to degradation of the cementious fireproofing 136.

[0036] Referring to FIG. 4, in operation, when the expansion joint system 100 has been compressed, imposed between the two substrates 102, 104, and permitted to expand, and exposed to fire or high heat, the expansion joint system 100 provides a first intumescent member 128 which contacts and protects the exposed first substrate end face 112. The top of the first substrate 102 may be covered with a cementious fireproofing 136, but this fireproofing does not extend past the first substrate end face 112 lest it interfere with the sealing function of the expansion joint system 100. Alternatively, the top of the first substrate may be covered with a solid board for the same purpose. Similarly, the expansion joint system 100 preferably does not extend substantially above the first substrate 102 or the second substrate 104, such as beyond the top of the cementious fireproofing 136 at all, or to such an extent as to preclude the waterproofing benefit of the first elastomer layer 127, lest the expansion joint system 100 interfere with the cementious fireproofing or permit water penetration in the joint. Additionally, the expansion joint system 100, when installed, does not bond to or apply pressure to the cementious fireproofing 136. As a result, the first substrate first end face 112 is preferably exposed at its uppermost portion nearest the corner, though it may be fully contacted by the expansion joint system 100 as provided previously. In the event of heating above standard operation range, the first intumescent member 128 is activated, and expands to protect the first substrate first end face 112, an exposed vertical surface, as illustrated in FIG. 4. When the first intumescent member 128 is positioned proximate the top of the first substrate 102, the first intumescent member 128, while expanding, will expand past the top of the first substrate 102, fully protecting the exposed corner and potentially expanding to cover any area exposed by loss of the cementious fireproofing 136. In an alternative embodiment, illustrated in FIG. 7, and the expansion joint system of the present disclosure may be installed between two substrates well below the top of the adjacent substrates.

[0037] The expansion joint system 100 may be made water-resistant by imposition of a first elastomer layer 127, which may be silicone, adhered to the body of compressible foam 118 at the body top 124 and extending from the body first face 120 to the body second face 122, wherein the first elastomer layer provides a water-resistant top layer. A second elastomer layer 130, which may be silicone, may be adhered to the body of compressible foam 118 at the body bottom 126 and extending from the body first face 120 to the body second face 122. To facilitate an increased surface area for bonding of the first elastomer layer 127 and the second elastomer layer 130 to the body of compressible foam 118, and particularly to ensure that the first elastomer layer 127 and the second elastomer layer 130 extend from the first substrate end face 112 of first substrate 102 to the second substrate end face 116 of the second substrate 104 at all points between expansion and compression of the two substrates 102, 104, altering the distance 108 between them, the body top 124 and the body bottom 126 may have profiles which likewise provide for expansion and compression, like an accordion, which may be formed of sequential semi-circular like shapes or which may be triangular in appearance, such that the first elastomer layer 127 and the second elastomer layer 130 have an overall distance greater than the first distance 108.

[0038] Referring now to FIG. 2, to also protect the second substrate 104, the expansion joint system 100 may include a second body channel 208b and a second intumescent member 132, which performs in the same manner as the first intumescent member 128. Where utilized, a second body channel 208b is provided in the body of compressible foam 118 in the body second face 122 proximate, adjacent, or near the body top 124 along the body length 206. The second intumescent member 132, having a second intumescent member first outer surface 210, a second intumescent member second outer surface 212, and a second intumescent member length 214, is adhered to the body of compressible foam 118 at the second intumescent member second outer surface 212 in the second body channel 208. The second intumescent member first outer surface 210 generally aligned with the body second face 122, i.e. at least substantially but not necessarily precisely aligned. The second intumescent member length 214 equivalent to, and positioned consistent with, the body length 206, so as to provide a unitary whole. The second body channel 208b may be adjacent, near to, or proximate the body top 124, but is not at or above the body top 124. So that the second intumescent member 132 does not substantially affect the flexibility of the body of compressible foam 118, the second body channel 208b is preferably no wider than one quarter of the body width 202 and is preferably no taller than one quarter of the body thickness 204.

[0039] Similarly, in an alternative embodiment, a second intumescent member 132 is provided and formed by force injection of a then-liquid containing intumescent into the body of compressible foam 118 in the body second face 122 below the body second face segment 140 and along the body length 206 or in the top third of the body thickness 204, and extends from the body second face 122 not more than one quarter of the distance from the body first face 120 to the body second face 122.

[0040] In a further embodiment, the expansion joint system 100 may be a seismic expansion joint system which, by virtue of the aforementioned structure, includes two intumescent segments 128, 132 strategically integrated in a highly-resilient compressible foam 118 to protect the uncoated edge of the adjacent substrates 102, 104. The fire-rated compressed expansion joint sealant system 100 is provided with an intumescent 128, 132 proximate, but below the water-resistant top layer 127 of the fire retardant foam 118, so that if the joint 103 is exposed to fire, the intumescent 128, 132 will expand, protecting the exposed vertical surface 112, 116 of the adjacent substrate 102, 104. Positioning of intumescent 128, 132 in body channels 208a, 208b in the fire retardant foam 118 adjacent, near to, or proximate the body top 124, but not at or above the body top 124, provides a common flat provide at the body face 120, 122 prior to installation, provides for protection of the substrate 102, 104 while not reducing the operable movement range of the fire retardant foam 118 of the expansion joint seal 100. The end of the substrates 102, 104, which may be concrete, is therefore protected in a system which does not require joint overlap between the horizontal fire resistant coating 128, 132, and the compressible sealant 127, allowing for a greater range of use that is current provided by intumescent sealants, that are known in the art to have limited capacity and cycling. Therefore each expansion joint sealant system 100 may include a body end face 246 having single plane profile 250, which may be perpendicular to the plane 248 associated with the length 214 of the expansion joint sealant system 100 or which may be at an angle to that length 206, thus providing a flat face for abutment of an additional adjacent expansion joint sealant system 100.

[0041] In a further embodiment, illustrated in FIG. 7, the seismic expansion joint system 100 further comprises a flexible, expanding, intumescent membrane 702 which extends laterally, preferably generally parallel to the first plane 106, from near the body first face 120 to near the body second face 122, thus maintaining the integrity of the foam 118, and a position sufficiently below the bottom of at least one intumescent member 128 and/or the second at least one intumescent member 132 to force each upward while seeking to maintain the integrity of the foam 118. The flexible, expanding, intumescent membrane 702 is positioned within the body of compressible foam 118, aligned laterally with the first plane 106, and extends from a position adjacent the body first face 120 to a position adjacent the body second face 122. The membrane 702 is therefore positioned below a bottom of the first intumescent member 128 and the second intumescent member 132. In operation, when exposed to heat, the intumescent membrane 702 expands and drives the portion of the seismic expansion joint system 100 containing the at least one intumescent member 128 and/or the second at least one intumescent member 132 toward the heat source, speeding the protection provided by a seismic expansion joint system 100, wherein the at least one intumescent member 128 and/or the second at least one intumescent member 132 will expand to overlap and protect the front edges of the first and second joint substrates 102, 104, such as from heat spalling where the first and second joint substrates 102, 104 are composed of concrete. This expansion may be accomplished in a period of about ten (10) seconds, or in a relatively short period of time sufficient to limit substrate damage in response to increased temperatures, which may be less than or greater than ten (10) seconds, including potentially a matter of only a few seconds or in time frames measured in a minute or more.

[0042] When configured as a seismic expansion joint, the expansion joint system 100 is capable, due to material selection, of movement of nearly ±50% of width, and simultaneously meets Class II and III cycling per ASTM International stand E-1399-97 (2013), entitled “Standard Test Method for Cyclic Movement and Measuring the Minimum and Maximum Joint Widths of Architectural Joint Systems.” A seismic expansion joint having such flexibility while simultaneously providing for protection of adjacent substrate in the event of fire is unknown.

[0043] The present disclosure thus provides for focused substrate protection in a precise and predictable way without limiting the water-resistant function of the joint during its lifespan. Further, by using this intumescent 128, 132 located as drawn or slightly inset under the surface of the foam 118 has proven to reduce the amount of fire retardant components required to pass certain fire ratings, such as UL 2079, entitled Tests for Fire Resistance of Building Joint Systems (as revised Mar. 19, 2006). With the substrate protecting intumescent 128, 132, the present disclosure allows for a lower compression density of the fire-retardant compressible foam, such as in the range of between 70-300 kg/m.sup.3 which allows for a higher movement range. Surprisingly, even higher compression and densities ranges have been found to work well within standard cycling regimes such that they still meet seismic classifications per ASTM E-1399-97 (2000) while still meeting the current TT endurance of the RWS curve.

[0044] To further promote the operation of the expansion joint system as both a seal against foreign contaminants and a protection of the substrate faces, the body of compressible foam 118 may be an open-celled foam infused with a fire retardant, may be an open-celled foam composed of a fire retardant material, or may be a closed-cell foam composed of a fire retardant material.

[0045] The foregoing disclosure and description is illustrative and explanatory thereof. Various changes in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.