Bridge ProductsThe D.S. Brown Company

World-wide designer, manufacturer and supplier of engineered products for the bridge, airport andhighway construction markets.

Company Overview

Company OverviewEstablished in 1890

Began manufacturing Expansion Joint Products in the 1950’s

In the early 1970’s started the production of Bearing Assemblies

Services Include:

Company OverviewFully-Integrated Manufacturer

Load Testing

Custom Steel Fabrication

AISC certification: Simple and Major Steel Bridges with Sophisticated

Paint endorsement

Custom Steel Machining

Rubber Extruding and Molding

Rubber Compounding and Mixing

In-House Engineering Design Group

Research & Development

D.S. Brown Engineering DepartmentCompany Overview

25 Full-Time Engineering Staff with 5 Registered Professional Engineers– Design of Expansion Joint Systems, Structural

Bearing Assemblies and Specialty Structural Bridge Components.

– CAD Drawing

production

Full time QA/QC staff• CWI Certification• NDT Certification

Manhattan Bridge, New York

Moderate Movement Systems

Delastic® Neoprene Compression Seals

• Worldwide Acceptance

• Tested to ASTM and DOT

Specifications

• Approximately 50mm of

Movement

• Proven Performance since the

1950’s

• Economical

Moderate Movement Systems

• Used in both Commercial and

Highway

• Proven Performance

• Easy to Install

• Concrete and Steel Adhesive is

VOC Compliant

• Fatigue Tested for One Million

Cycles

Delastic® J - Seals

Delastic® JP - Seals

Delastic® J & JP Architectural SealsModerate Movement Systems

The Matrix 502 Asphaltic Plug Bridge Joint System

meets requirements of ASTM D6297, Standard

Specification for Asphaltic Plug Joints for Bridges.

Approximately 38mm of movement

Primary application: asphalt overlay

Matrix 502 Asphaltic Expansion Joint SystemModerate Movement Systems

• Designed For Movements up to 122mm

• Long-term, low maintenance solution

• Most Economical

• Number one in performance since 1970’s

• Replaceable sealing element• Cast-in-place • Flexible installation methods

Steelflex® Strip Seal Expansion Joint SystemsCast In Place Strip Seal ShapesCast In Place Strip Seal Shapes

Moderate Movement Systems

Steelflex® Strip Seal Expansion Joint SystemsCast In Place Strip Seal Shapes and Anchorage Options

Elimination of horizontal flange to improve performance

Expansion Joint Systems

• Many early strip seal systems utilize horizontal flange (SSCM style)

• Horizontal flange on frame rail can cause poor concrete consolidation and performance problems (TX DOT Research)

• Flangeless alternative introduced in 1994

Expansion Joint Systems

Steelflex® SSCM2 Research

• Research conducted at the University of Texas by Dr. Karl Frank

• Utilizes hot-rolled steel frame rail (A36 or A588)

• Over 750,000 LF of joint system successfully installed since 1994

Expansion Joint Systems

Steelflex® SSCM2 Research

Moderate Movement SystemsSteelflex® Strip Seal/Delcrete m Expansion Joint

System

Larger Movement Systems

San Francisco Oakland Bay Bridge, California

Larger Movement SystemsSteelflex® Modular Expansion Joint System

• Movements greater than 100mm

• Watertight with strip seal gland

• Proven performance since 1970s

• Structurally sound, fatigue tested

• Fabrication by AISC, Major Steel Bridge Structures facility

• Economical, low life-cycle cost

Centerbeams(63 x 127mm Steel) Edge Beam

(32 x 127mm Steel)

Welded Connection(Full Penetration)

Support Barsw/ Stainless Steel

NeoprenePrecompressedSpring

NeopreneSlide Bearings

EquidistanceControl Springs

• Objective of NCHRP 12-40 Research Project

– Develop specification for the design of modular expansion joint systems

• Primary Tasks– Field Studies– Laboratory Tests

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

Objectives of Field Testing

• Determine static and dynamic response

• Verify structural analysis models

• Investigate durability issues

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

Mvertical

MHor

Objectives of Laboratory Testing

• Static tests on complete joint assemblies

• Fatigue resistance of common connection details

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

Full-Penetration Weld Detail– AASHTO Category C

– Fatigue limit of 69 MPa

Centerbeam

Support Bar

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

Fillet Weld Detail– Below AASHTO Category E’

– Fatigue limit of 18 MPa

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

Bolted Detail

– AASHTO Category D

– Fatigue limit of 48 MPa

– Bolt must be properly tightened to prevent early failure

Steelflex™ Modular Expansion Joints Design Based on NCHRP Project 12-40 Research

• Incorporates full penetration weld between

centerbeam and support bar

• Support box spacing of less than 1.3m to meet

Category C fatigue requirement

Steelflex™ Modular Expansion Joints

Features of Steelflex™ Modular Joints

Design Based on NCHRP Project 12-40 Research

< 1.3m

• Solid steel centerbeam with 63mm x 127mm cross section

• Utilize durable neoprene spring and bearing components in support boxes

• All steel components galvanized to prevent corrosion

Steelflex™ Modular Expansion Joints

Features of Steelflex™ Modular Joints

Design Based on NCHRP Project 12-40 Research

• All expansion joints require that

installation procedures be

followed very carefully to ensure

long-term performance

• DS Brown suggests that bridge

owners take an active role

inspecting the installation

process to prevent the following:

Steelflex™ Modular Expansion Joints Durable Performance with Proper Installation

Steelflex™ Modular Expansion Joints Durable Performance with Proper Installation

Example of Good Installation

Transverse rebar to minimize deck cracking

Protective cover over joint to prevent damage from concrete

Vibrating concrete to flow under support boxes

Continuation of longitudinal rebar into joint blockout

Larger Movement Systems

• Segmental Fabrication• Smooth Ride• Long Project History• Owner/Project Specific Design

Fabrication by AISC, certified facility

Finger Plate Expansion Joint System

Structural Bearing Assemblies

Veterans’ Glass City Skyway Bridge Construction, Ohio

Structural Bearing Assemblies

• Designed for Section 14 of AASHTO Code

• Various Sizes and Configurations

• Project Specific/Custom Fabrication

• Economical

Specialty Products

Specialty Bridge ProductsCableguard™ Elastomeric Wrap System

Suspension bridges Corrosion protection

system for main cables

Cable-Stayed bridges Corrosion protection

system for stay cables

Specialty Bridge ProductsCableguard™ Elastomeric Wrap System

Patented Design Features

• Durable 3-ply, color-fast elastomeric wrap

• Wrapped under constant tension with Skewmaster™ machine

• Layers of wrap are fused together under intense heat

• Watertight

• Environmentally friendly