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Laminations as a Build Choice
and
Waterproof at the
Deck Level???
Laminated foam, injected bands & waterproof at deck level?
Competitor claims:
"Laminations as a Build Choice -- The Anatomy of Quality in Pre-Compressed Foam Sealants. In their case, as in ours, this is irrelevant as long as the material performs monolithically in the range for which it is intended.
Why laminations? Because, although it costs more, it helps to ensure consistency and quality."
The manufacture of impregnated foam sealants involves distributing a chemical emulsion onto the foam cell walls and into the foam cell cavities. This is better and more consistently achieved by impregnating laminations than large blocks of foam. Driving the emulsion deep into larger blocks of foam can leave dry-pockets of untreated foam that are detrimental to quality.
Source: Emseal website http://emseal.com/Knowledge/Laminations/Laminations-in-manufacture-of-precompressed-sealant.htm
But are these claims accurate or are you asking:
"Where's the foam" in you joint sealant?
HYBRIDS
“Where’s the Beef in Joint Sealants?”“What if you develop a sealant that uses the best features of both liquid sealant and impregnated foam sealants AND eliminates their weaknesses?”Hybrid sealants available today shine in many applications including:1) movement joints,2) large joints over 25mm (1- inch),3) where resilience or the need to resist air-pressure and thermal differentials is essential,Under development throughout the world, other hybrids include:anywhere a structural or new to-existing gap needs filling and sealing combinations of chemically-resistant liquid sealants and impregnated foam sealants for use in wastewater, caustic and other harsh environments;2) combinations of materials to provide fully fire-rated, watertight movement joints;3) combinations of hydrophilic or hydrophobic materials with impregnated foam sealants to handle below-grade and head of-water applications.Source:Hensely, Lester, SWRI Applicator Vol. 23, No. 2 Spring 2001Emseal website Posted July 26, 2013 -- Lester Hensley Our position on unbonded laminations is simple and based on the fundamental understanding that all hybrid foam joint sealants rely on the proper function of the impregnated foam sealant.
Waterproofing at the deck or substrate is another way of saying "we are relying on the silicone coating to provide the waterproofing. The impregnated foam is a "resilient foam backer" and is just a really expensive backer rod.
Laminated foam composite materials often lead to this question:
“Where’s Foam in these Joint Sealants?”
Waterproofing at the deck or substrate leads to adhesive or cohesive failure of the thin silicone coating and results in a failed expansion joint system.
http://www.slideshare.net/StevenRobinson/lamination-photo-sampler
http://www.slideshare.net/StevenRobinson/laminations-as-build-choice-waterproof-deck-traffic-level
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Waterproof at the deck and traffic level systems. However, one need look no further than Table A on page 6 of the declaration to see that lllger and AI-Tabaqchall differ in their composition and would not be expected to perform in the same manner.
Application/Control Number: 90/013,511 Art Unit: 3993 Page 32 The use of "thermal conductivity" to assert unexpected results is confusing and misleading.
The declaration has not shown that the impregnation of the core portions of Baerveldt '708 with a fire retardant material as taught by lllger would have been unobvious to those of ordinary skill in the art, or would have produced unexpected results.
To the contrary, the modification of Baerveldt '708 would have been obvious and the results would have been predictable in light of the teachings of lllger when taken as a whole.
Response to Arguments Applicant's arguments filed December 23, 2015 have been fully considered but they are not persuasive.
lllger provides many additional teachings which have not been addressed by PO: • The impregnation of polyurethane foams with a dispersion consisting substantially of an aluminum hydroxide, a polyurethane latex, and mixing stabilizers results in foams having excellent and unexpected flame resistant properties. (column 2, lines 9-19) • The impregnated foam can contain anywhere from 10-95% by weight of aluminum hydroxide. (column 2, lines 24-26) • The formulation for producing thefoams need not be altered for the flame proofing and, in particular, there is no impairment of the mechanical properties of the foam by the addition of flame retardingagents. (column 3, lines 38-41) • The foams produced by the process according to the invention are suitable for all fields of application in which flame retardantflexible or semi-rigid foams have previously been used, such as... structural elements. (paragraph bridging columns 6 and 7) Thus, lllger teaches that a fire retardantmaterial may be impregnated into a foam material, and aluminum hydroxide in particular provides the desired fire resistance without impairing the mechanicalproperties of the foam. With respect to the arguments regarding an alleged lack of motivation and alleged hindsight (pages 34-35, 39), the rejection does not rely onthe UL 2079 standards for a teaching of how to create a product which would pass the test, as asserted by PO. However, the UL standards are well-known to those ofskill in particular arts, in this case the building art, and are often the standard used in building codes. If a product is intended for use in a manner governed by abuilding code, such as a seal assembly for an expansion joint, it stands to reason that one of ordinary skill in the art would design it to meet or exceed the applicablebuilding codes so that it could actually be used in the intended structure. This is evident from Joffre (U.S. Patent 5,744,199 to Joffre et al.). Joffre discloses a sealassembly for an opening of a building, and the sealing elements are tested in accordance with the applicable standards based on the desired or required properties.
c12) United States Patent Hensley et al.
(54) PRECOMPRESSED FOAM EXPANSION JOINT SYSTEM TRANSITION
(75) Inventors: Lester Hensley, Westborough, MA (US); Bill Witherspoon, Guelph (CA)
(73) Assignee: EMSEAL JOINT SYSTEMS LTD., Westborough, MA (US)
( *) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 80 days.
(21) Appl. No.: 12/635,062
(22) Filed: Dec.10,2009
Related U.S. Application Data
(60) Provisional application No. 61/121,590, filed on Dec. 11, 2008.
(51) Int. Cl. E04B 1168 (2006.01)
(52) U.S. Cl. CPC .................................... E04B 116812 (2013.01)
(58) Field of Classification Search CPC ......... EOlD 19/06; E04B 1/6812; E04B 1/68;
E04B 1/6815; E04B 1/948; E04D 11/02; E04D 13/151
USPC ........... 52/393, 396.04, 396.07, 586.1, 586.2, 52/741.4; 404/47, 68
See application file for complete search history.
(56) References Cited
U.S. PATENT DOCUMENTS
3,355,846 A 3,372,521 A 3,551,009 A * 3,670,470 A 3,672,707 A *
12/1967 Tillson 3/1968 Thorn
12/1970 Lester eta!. .................. 285/226 6/1972 Thorn 6/1972 Russo eta!. .................. 285/229
111111 1111111111111111111111111111111111111111111111111111111111111
CA DE
US009200437Bl
(10) Patent No.: (45) Date of Patent:
US 9,200,437 Bl Dec. 1, 2015
3,677,145 A 7/1972 Wattiez 3,934,905 A * 111976 Lockard ........................ 285/229 3,956,557 A 5/1976 Hurst 4,058,947 A 1111977 Earle eta!. 4,362,428 A 12/1982 Kerschner 4,401,716 A 8/1983 Tschudin-Mahrer 4,455,396 A * 6/1984 Al-Tabaqchall eta!. ....... 521154 4,566,242 A 111986 Dunsworth 4,637,085 A 111987 Hartkorn 4,773,791 A 9/1988 Hartkorn 4,781,003 A * 1111988 Rizza ......................... 52/396.07 4,916,878 A 4/1990 Nicholas 4,942,710 A 7/1990 Rumsey
(Continued)
FOREIGN PATENT DOCUMENTS
2640007 A1 3/2009 19809973 C1 7/1999
(Continued)
OTHER PUBLICATIONS
EMSeal, COLORSEAL, Jan. 2000, COLORSEAL TechData, p. 1-2.*
(Continued)
Primary Examiner- Elizabeth A Plummer (74) Attorney, Agent, or Firm- MKG LLC
(57) ABSTRACT
A water resistant expansion joint system for installation into a building joint in vertical and horizontal configurations is designed such that it can be used for either an inside or outside corner. The system comprises open celled foam having a water-based acrylic chemistry infused therein. A layer of an elastomer is disposed on the open celled foam and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The system is delivered to a job site in a pre-compressed state ready for installation into the building joint.
7 Claims, 6 Drawing Sheets
10
c12) United States Patent Hensley et al.
(54) PRECOMPRESSED FOAM EXPANSION JOINT SYSTEM TRANSITION
(75) Inventors: Lester Hensley, Westborough, MA (US); Bill Witherspoon, Guelph (CA)
(73) Assignee: EMSEAL JOINT SYSTEMS LTD., Westborough, MA (US)
( *) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 80 days.
(21) Appl. No.: 12/635,062
(22) Filed: Dec.10,2009
Related U.S. Application Data
(60) Provisional application No. 61/121,590, filed on Dec. 11, 2008.
(51) Int. Cl. E04B 1168 (2006.01)
(52) U.S. Cl. CPC .................................... E04B 116812 (2013.01)
(58) Field of Classification Search CPC ......... EOlD 19/06; E04B 1/6812; E04B 1/68;
E04B 1/6815; E04B 1/948; E04D 11/02; E04D 13/151
USPC ........... 52/393, 396.04, 396.07, 586.1, 586.2, 52/741.4; 404/47, 68
See application file for complete search history.
(56) References Cited
U.S. PATENT DOCUMENTS
3,355,846 A 3,372,521 A 3,551,009 A * 3,670,470 A 3,672,707 A *
12/1967 Tillson 3/1968 Thorn
12/1970 Lester eta!. .................. 285/226 6/1972 Thorn 6/1972 Russo eta!. .................. 285/229
111111 1111111111111111111111111111111111111111111111111111111111111
CA DE
US009200437Bl
(10) Patent No.: (45) Date of Patent:
US 9,200,437 Bl Dec. 1, 2015
3,677,145 A 7/1972 Wattiez 3,934,905 A * 111976 Lockard ........................ 285/229 3,956,557 A 5/1976 Hurst 4,058,947 A 1111977 Earle eta!. 4,362,428 A 12/1982 Kerschner 4,401,716 A 8/1983 Tschudin-Mahrer 4,455,396 A * 6/1984 Al-Tabaqchall eta!. ....... 521154 4,566,242 A 111986 Dunsworth 4,637,085 A 111987 Hartkorn 4,773,791 A 9/1988 Hartkorn 4,781,003 A * 1111988 Rizza ......................... 52/396.07 4,916,878 A 4/1990 Nicholas 4,942,710 A 7/1990 Rumsey
(Continued)
FOREIGN PATENT DOCUMENTS
2640007 A1 3/2009 19809973 C1 7/1999
(Continued)
OTHER PUBLICATIONS
EMSeal, COLORSEAL, Jan. 2000, COLORSEAL TechData, p. 1-2.*
(Continued)
Primary Examiner- Elizabeth A Plummer (74) Attorney, Agent, or Firm- MKG LLC
(57) ABSTRACT
A water resistant expansion joint system for installation into a building joint in vertical and horizontal configurations is designed such that it can be used for either an inside or outside corner. The system comprises open celled foam having a water-based acrylic chemistry infused therein. A layer of an elastomer is disposed on the open celled foam and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The system is delivered to a job site in a pre-compressed state ready for installation into the building joint.
7 Claims, 6 Drawing Sheets
10
(56) References Cited
US 9,200,437 Bl Page 2
U.S. PATENT DOCUMENTS
2010/0275539 A1 2010/0319287 A1 2012/0117900 A1
1112010 Shaw 12/2010 Shaw
5/2012 Shaw
4,957,798 A * 5,094,057 A 5,115,603 A 5,130,176 A * 5,213,441 A * 5,249,404 A 5,327,693 A * 5,335,466 A 5,338,130 A 5,365,713 A 5,450,806 A * 5,508,321 A * 5,572,920 A 5,628,857 A 5,887,400 A 5,935,695 A * 6,014,848 A 6,128,874 A 6,460,214 B1 6,491,468 B1 * 6,499,265 B2 6,532,708 B1 * 6,860,074 B2 6,948,287 B2 7,114,899 B2 7,240,905 B1 7,748,310 B2 7,941,981 B2 8,171,590 B2 8,317,444 B1 8,341,908 B1 8,365,495 B1
2003/0110723 A1 * 2006/0030227 A1 * 2008/0193738 A1 *
9/1990 3/1992 5/1992 7/1992 5/1993
10/1993 7/1994 8/1994 8/1994
1111994 9/1995 4/1996
1111996 5/1997 3/1999 8/1999 112000
10/2000 10/2002 12/2002 12/2002 3/2003 3/2005 9/2005
10/2006 7/2007 7/2010 5/2011 5/2012
1112012 112013 212013 6/2003 2/2006 8/2008
Bogdany ......................... 428/95 Morris Blair Baerveldt . . . . . . . . . . . . . . . . . . . . . . 4 28/192 Baerveldt ........................ 404/66 Leek eta!. Schmid. Langohr Baerveldt Nicholas et a!.
52/396.D2
Jean . 114/74 A Brebner 523/179 Kennedy et a!. Baerveldt Bratek eta!. Baerveldt . . . . . . . . . . . . . . . . . . . . . . 4 28/218 Hilburn, Jr. Olson eta!. Chang Hagen ........................... 403/291 Shreiner Baerveldt . 52/396.05 Stanchfield Korn Gass eta!. Stahl, Sr. Kennedy Shaw Kim Hensley Hensley eta!. Witherspoon Baerveldt . 52/396.04 Hairston eta!. .............. 442/136 Hensley eta!. ............ 428/308.4
DE EP GB wo
FOREIGN PATENT DOCUMENTS
10200505437 5 A1 1118715 A1 2377379 A
2007024246 A1
5/2007 7/2001 112003 3/2007
OTHER PUBLICATIONS
EMSeal, COLORSEAL & SEISMIS COLORSEAL, May 1997, Install Data---COLORSEAL & SEISMIC COLORSEAL, p. 1-2.* Polyurethane Foam Field Joint Infill Systems, Sep. 23, 2007 (via Snagit), PIH, pp. 1-4. EMSeal Joint Systems, Drawing 010-0-00-00, Dec. 6, 2005. EMSeal Joint Systems, Techdata, Jun. 1997. Snagit Capture Polyurethane Foam Field Joint Infill Systems, Sep. 23, 2007. EMSeal Joint Systems, Drawing SJS-100-CHT-N, Nov. 20, 2007. EMSeal Technical Bulletin, Benchmarks of Performance for HighMovement Acrylic-Impregnated, Precompressed, Foam Sealants When Considering Substitutions, Jul. 3, 2012. EMSeal Material Safety Data Sheet, Apr. 2002. EMSeal, Is There a Gap in Your Air Barrier Wall Design?, Jul. 19, 2012. EMSeal, "Pre-cured-Caulk-And_Backerblock" Not New, Not Equal to EMSeal's COLORSEAL, Jul. 19,2012. Manfredi, Liliana; eta!. "Thermal degradation and fire resistance of unsaturated polyester, modified acrylic resins and their composites with natural fibres" Polymer Degradation and Stability 91; 2006; pp. 255-261. Stein, Daryl et a!. "Chlorinated Paraffins as Effective Low Cost Flame Retardants for Polyethylene" Dover Chemical Corporation.
* cited by examiner
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US 9,200,437 Bl 1
PRECOMPRESSED FOAM EXPANSION JOINT SYSTEM TRANSITION
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application No. 61/121,590, filed on Dec. 11, 2008, the contents of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
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
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.
In the case of an exterior 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.
Many expansion joint products do not fully consider the irregular nature ofbuilding 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.
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
2 rework, or it is simply scrapped and re-manufactured. Both return to the manufacturer and scrapping andre-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
The present invention is directed to water resistant expansion joint systems for installation into building joints. In one
10 aspect, the present invention resides in a system for use in vertical or horizontal configurations and is designed such that it can be used for either an inside or outside corner. The system comprises open celled foam having a water-based acrylic chemistry infused therein. A layer of an elastomer is
15 disposed on the open celled foam and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The system is delivered to a job site in a pre-compressed state ready
20 for installation into the building joint.
In another aspect, the present invention resides in a vertical expansion joint system comprising a first section of open celled foam extending in a horizontal plane and a second section of open celled foam extending in a vertical plane. An insert piece of open celled foam is located between the first
25 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 foam is infused with a water-based acrylic chemistry. A layer of an elastomer is disposed on the foam to impart a substantially waterproof
30 property thereto. The vertical expansion joint system is precompressed 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
35 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.
In another aspect, the present invention resides in a horizontal expansion joint system, the system being pre-com-
40 pressed and installable between horizontal coplanar substrates. The system comprises first and second sections of open celled foam extending in a horizontal plane, the sections being joined at a miter joint. The open celled foam is infused with a water-based acrylic chemistry. A layer of an elastomer
45 is disposed on the foam, the elastomer imparting a substantially waterproof property to the foam. Although the horizontal expansion joint system is described as transitioning right angles in the horizontal plane, it should be understood that the transition of the angles is not limited to right angles as the
50 system may be used to accommodate any angle and may also be used in planes that are not horizontal.
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
55 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
60 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 to a premature failure at the point of modification, which may 65
result in subsequent damage to the property. In the second case, product is oftentimes returned to the manufacturer for
FIG. 1 is a perspective view of a vertical expansion joint system of the present invention.
US 9,200,437 Bl 3
FIG. 2 is an end view of the vertical expansion joint system taken along line 2-2 of FIG. 1.
FIG. 3 is an end view of the vertical expansion joint system installed between two substrates.
FIG. 4 is a perspective view of an assembly of foam laminations being prepared to produce the vertical expansion joint system of FIG. 1.
4 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.
In the fixture, the assembled infused laminations 14 are coated with a waterproof elastomer 20. 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.
FIG. 5 is a perspective view of the assembly of foam laminations being further prepared to produce the vertical expansion joint system of FIG. 1.
FIG. 6 is a perspective view offour sections of the vertical expansion joint system used in a building structure.
FIG. 7 is a perspective view of a horizontal expansion joint system of the present invention.
10 The preferred elastomer 20 for coating laminations 14 for a horizontal deck application where vehicular traffic is expected is PECORA 301 (available from Pecora Corporation, Harleysville, Pa.) or DOW 888 (available from Dow Coming Corporation, Midland, Mich.), both of which are
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
15 traffic grade rated silicone pavement sealants. For vertical wall applications, the preferred elastomer 20 for coating the laminations 14 is DOW 790 (available from Dow Corning Corporation, Midland, Mich.), DOW 795 (also available from Dow Coming Corporation), or PECORA 890 (available The present invention provides a resilient water resistant
expansion joint system able to accommodate thermal, seismic, and other building movements while maintaining water resistance characteristics. The present invention is especially suited for use in concrete buildings and other concrete structures including, but not limited to, parking garages, stadiums, tunnels, bridges, waste water treatment systems and plants, 25
potable water treatment systems and plants, and the like.
20 from Pecora Corporation, Harleysville, Pa.). A primer may be used depending on the nature of the adhesive characteristics of the elastomer 20.
Referring now to FIGS. 1-3, one embodiment of the present invention is an expansion joint system oriented in a vertical plane and configured to transition comers at right angles. This system is designated generally by the reference 30
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 35
desired angle. The vertical expansion joint system 10 comprises sections of open celled polyurethane foam 12 (hereinafter "foam 12") that have been infused with a water-based acrylic chemistry. It should be understood, however, that although the present invention is described as comprising 40
polyurethane foam, the open celled foam can be any other suitable type of foam.
As is shown in FIG. 2, the foam 12 comprises individual laminations 14 offoam, one or more of which are infused with a suitable amount of the acrylic chemistry. It should be noted 45
that the present invention is not so limited as other manners of constructing the foam 12 are also possible. For example, the foam 12 of the present invention is not limited to individual laminations 14 assembled to construct the laminate, as the foam 12 may comprise a solid block of non-laminated foam 50
of fixed size depending upon the desired joint size, laminates comprising laminations oriented horizontally to adjacent laminations, or combinations of the foregoing.
Also as is shown in FIG. 3, the vertical expansion joint system 10 is positionable between opposing substrates 18 55
(which may comprise concrete, glass, wood, stone, metal, or the like) to accommodate the movement thereof. In particular, opposing vertical surfaces of the foam 12 are retained between the edges of the substrates 18. The compression of the foam 12 during the installation thereof between the sub- 60
strates 18 enables the vertical expansion system 10 to be held in place.
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 65
distance between opposing substrates 18 into which the vertical expansion system 10 is to be installed), are compiled and
During or after application of the elastomer 20 to the !aminations 14, 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.
Referring now to FIGS. 4 and 5, when the elastomer 20 has cured in place, the infused foam lamination 14 is cut in a location at which a bend in the vertical expansion system 10 is desired to accommodate a comer. The cut, which is designated by the reference number 24 and as shown in FIG. 4, is made from the outside of the desired location of the bend to the inside of 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 lamination 14 is then bent to an appropriate angle A, thereby forming a gap G at the outside of the bend. Although a gap of 90 degrees is shown in FIG. 5, the present invention is not limited in this regard as other angles are possible.
Still referring to FIG. 5, a piece of infused foam lamination constructed in a manner similar to that described above is inserted into the gap Gas 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 comer 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.
US 9,200,437 Bl 5
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.
Referring now to FIG. 6, portions of the vertical expansion system 10 positioned to articulate right angle bends are shown
6 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 expansian system 110 has expanded to suit the expansion joint, it will become locked in by the combination of the foam back pressure and the adhesive.
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 foam lamination. In this case, for instal-
10 lation, the 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
as they would be positioned in a concrete expansion joint located in a tunnel, archway, or similar structure. Each por- 15
tion defines a foam laminate that is positioned in a comer of the joint. As is shown, the vertical expansion joint system 10
pressure of the foam will hold the foam in position. 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
is installed between horizontal coplanar substrates 18a and vertical coplanar substrates 18b.
Referring now to FIG. 7, an alternate embodiment of the invention is shown. In this embodiment, the infused foam, the elastomer coating on the top surface, and the elastomer coating on the bottom surface are similar to the first embodiment. 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.
In the horizontal expansion system 110, the infused foam lamination is constructed in a similar fashion to that of the
20 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 (hori-
25 zontal) 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
30 sub-standard transitions.
vertical expansion system 10, namely, by constructing a foam 35
112 assembled from individual laminations 114 of foam
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 expan-
material, one or more of which is infused with an acrylic chemistry. 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 foam 112 are possible (e.g., solid blocks of foam material).
In fabricating the horizontal expansion system 110, two pieces of the 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. The individuallaminations 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. Following this, the foam 112 is inverted and then the opposite side is likewise coated.
sion 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
40 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
45 used at the top inside and top outside comers 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 sys-
50 tern 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 After both coatings of elastomer 20 have cured, the hori
zontal expansion system 110 is removed from the coating fixture and packaged for shipment. In the packaging opera- 55
tion, 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).
be installed in any suitable and/or desired order. In one example of installing the horizontal expansion sys-
tem 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 colunms or walls. The horizontal expansion sys-
60 tern 110 is configured to accommodate such obstructions. In the horizontal expansion system 110, the installation
thereof is accomplished by adhering the 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
Prior to the present invention, the installer would have had to create field transitions to follow the expansion joint.
To extend the horizontal expansion system 110 around a typical support column, the installer uses four sections of the
65 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
US 9,200,437 Bl 7
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 colunm 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.
The present invention is not limited to products configured 10
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 laminates, as solid foam blocks and the like may alternatively or additionally be used.
Although this invention has been shown and described 15
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. In addition, modifications may be made to adapt a particular 20
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 25
the scope of the appended claims.
What is claimed is:
8 at an angle of about 90 degrees, wherein the precompressed foam of the first section, the second section and the insert piece are precompressed to a size below the size of an expansion joint, and are configured to expand and create a waterproof seal around a corner when installed in the expansion joint; and
a layer of the elastomer disposed on the foam, the elas-tomer imparting a substantially waterproof property to the foam, and wherein the layer of the elastomer is a continuous layer of the elastomer from the second plane to the first plane and the layer of elastomer is a continu-ous layer of the elastomer over the insert piece, and the insert piece is held in place by the continuous layer of the elastomer, and the expansion joint system, including the foam and the insert piece, is configured to accommodate thermal and seismic movement in the system by expand-ing and contracting while maintaining the continuous layer of the elastomer and the waterproof property thereof;
wherein the water resistant expansion joint system is installed between substrates by adhering the foam to the substrates, and creates the waterproof seal around the corner in the expansion joint upon expansion of the foam in the expansion joint.
2. The expansion joint system of claim 1, wherein the foam is open celled foam and comprises one or more individual laminations assembled to construct a laminate.
3. The expansion joint system of claim 1, wherein the foam is open celled polyurethane foam.
4. The expansion joint system of claim 1, wherein the elastomer disposed on the foam comprises a silicone.
1. A water resistant expansion joint system comprising: foam, which is cut and bent into a first section of precom
pressed foam extending in a first plane; and a second 30
section of precompressed foam extending in a second plane, the first section being connected to the second section and forming an angle A therebetween of about
5. The expansion joint system of claim 1, wherein the elastomer disposed on the foam is selected from the group consisting of polysulfides, acrylics, polyurethanes, poly-ep-
35 oxides, silyl-terminated poly ethers, and combinations of one or more of the foregoing.
90 degrees, wherein a gap G is located in the foam opposite the angle A and configured to receive an insert piece of precompressed foam to transition between the first section and the second section;
the insert piece of precompressed foam located in the gap G between the first section of foam extending in the first plane and the second section of foam extending in the 40
second plane, the insert piece being configured to transition the first section of the foam from the first plane to the second plane of the second section of the foam also
6. The expansion joint system of claim 1, wherein a waterbased acrylic chemistry is infused into at least one of the first section and the second section of the foam.
7. The expansion joint system of claim 1, wherein the expansion joint system is a vertical expansion joint system or a horizontal expansion joint system.
* * * * *
EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581
EMSEAL, LLC 120 Carrier Drive, Toronto, ON, Canada M9W 5R1
PH: 508.836.0280 FX: 508.836.0281
PH: 416.740.2090 FX: 416.740.0233Toll Free: 1-800-526-8365
Copyright © 2015 by EMSEAL JOINT SYSTEMS, LTD. All Rights Reserved
DATA
TECH
DSM SYSTEMWatertight Joint System for Decks and
Below-Grade Walls
DSM SYSTEM TECH DATAJANUARY 2015, PAGE 1 OF 2
Figure 1: DSM SYSTEM in Typical Installation--New or Retrofit
Product Description
The DSM SYSTEM builds on a trackrecord of over 30 years of sealinghorizontal plane and below-grade jointswith impregnated foam sealants.
The system is comprised of:1) Precompressed, sil icone-and-impregnated-foam hybrid installed into2) field-applied epoxy adhesive on thejoint faces; with the silicone bellowslocked to the joint faces with3) a silicone sealant band(see Figure 1).
The DSM SYSTEM features an innovationin sealant technology in the form of apatent-pending acrylic adhesive infusedinto the cellular foam base material.This new chemistry incorporates ahydrophobic microsphere componentnever before available in a sealantformulation.
The material features sealingperformance significantly greater thanany acrylic impregnated predecessor.In addition, it is odorless, cleanhandling, UV stable, non-staining,and features low temperatureflexibility not previously available inasphalt, wax, or isobutylene-basedpredecessors.
The result is extension of the usability ofthe product to applications where asphaltand wax-based predecessors did notwork well under conditions of thermalshock (rapid opening and closing ofjoints during large temperature swings).These applications include joint-faceadhered installations on top decks aswell as intermediate decks.
Suitabil ity is further extended tohorizontal-plane joint applications incolder geographical regions to whichasphalt and wax-based predecessorshave not previously been recommended.
Features
Watertight—the tensionless siliconebellows are installed just below the decksurface. This ensures watertightness isachieved at the deck surface.
Non-Invasive Anchoring—there areno hard metal-to-concrete connectionswith the DSM SYSTEM. This includesembedded pins, anchors, screws, boltsor tracks, trays or rails. The system islocked to the joint faces by means of the1) backpressure of the foam; 2) theepoxy adhesive, and 3) the injected
www.emseal.com
silicone sealant band at the joint face tofoam and silicone bellows interface.
Continuity of Seal—as in all EMSEALexpansion joint systems, continuity ofseal through changes in plane anddirection is an essential performancedifferentiator. Details for watertight,field-fabricated transitions from deck towall, at curbs, sidewalks, parapets, tees,and crosses are available from EMSEAL.
Movement Capability+30% and -25% (Total 55%) of nominalmaterial size (see "Performance").
Aesthetics & Versatility—Standardcolor is gray (other colors available),
®
uniform bellows appearance, fuelresistance, and an enhanced ability tohandle variations in joint size are amongother system features.
Performance
• Capable, as a dual-seal, of movementsof +30%, -25% (55% total) of nominalmaterial size. DSM will remainwatertight up through movements of+50% of nominal material size withthe silicone bellows providing thewaterproofing, but at these levels ofextension use should be limited towhere no direct pedestrian or highpoint-load traffic is possible--as in deck-to-wall conditions or where the DSMSYSTEM is protected by a coverplate.
Note: For material sizes 1 -1/4 -inch (30 mm) and less, a smooth, convex, single-bellow
coating is supplied.
Uses
• Ideal for new construction and retrofit of old or failed joint systems in concreteor in embedded metal angles where demolition and removal of the metal anglesis not feasible or affordable.
• Ideal for lasting replacement of tee-to-tee caulk joints in precast parking decksand stadiums or where pedestrian or vehicular traffic is expected.
• decks • runways • stadiums • mall bridge connectors• parking decks • airport aprons • arenas • below-grade walls• roadways • sidewalks • ice-floors • tunnel walls
• stair towers • perimeter joints
3) FIELD-INJECTED SILICONE
SEALANT BANDS (Silicone
supplied by EMSEAL)
2) EPOXY ADHESIVE AT
JOINT FACE
(Epoxy supplied by EMSEAL)
1) DSM MODIFIED-ACRYLIC
IMPREGNATED FOAM
FACTORY-APPLIED AND
CURED SILICONE BELLOWS*
FACING
Figure 2: DSM SYSTEM in Existing Steel Angles--Retrofit
EXISTING STEEL
ANGLES WHERE
REMOVAL IS NOT
FEASIBLE OR
AFFORDABLE
DAMAGED CONCRETE
AT BACK EDGES OF
EMBEDDED ANGLES
ROUTED AND SEALED
(BY OTHERS)
EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581
EMSEAL, LLC 120 Carrier Drive, Toronto, ON, Canada M9W 5R1
PH: 508.836.0280 FX: 508.836.0281
PH: 416.740.2090 FX: 416.740.0233Toll Free: 1-800-526-8365
DSM SYSTEM TECH DATADECEMBER 2013, PAGE 2 OF 2www.emseal.com
Composition
• DSM is produced by coating animpregnated cellular foam withhighway-grade silicone.
• The silicone external facing is factoryapplied to the foam at a width greaterthan maximum joint extension and iscured before final compression.
• Silicone application and curing takesplace in a factory-controlledenvironment. In contrast to fieldapplied liquid sealant and backer rodinstallations, no movement takes placeduring curing that can causedeformation or stresses in the material.
• When compressed, a bellows is createdin the coating. As joint movementoccurs the bellows simply folds andunfolds free of tension on the bondline,
and virtually free of tensile stressesin the silicone material.
• The foam provides a resilient backingto the silicone coating, making thesystem capable of resistingreasonable transient point loads (seePerformance).
• DSM SYSTEM is supplied in 6.56 LF(2m) shrink-wrapped lengths (sticks).It is precompressed to less than thejoint size for easy insertion. Afterremoval from the shrink-wrap andhard board restraining packaging, itexpands gradually.
Installation
IMPORTANT: The following instructionsare a summary. Refer to "DSM SYSTEMInstall Data" and job-specificinstructions of an EMSEAL technicianfor complete procedures.• Store indoors at room temperature.
Expansion is quicker when warm,slower when cold.
• Ensure material nominal size matchesjoint size.
• Mix epoxy and trowel a thin layeronto the joint faces to at least thedepth of the DSM foam
• Apply a thin layer of epoxy to bothsides of the joint face.
N/AN/A
ASTM D3574 EASTM D3574 EASTM C711
ASTM G155-00A
ASTM G155-00A
COLOR
Percent Solids (minimum)SPECIFIC GRAVITY
Following tests conducted on Sealant Cured after 21 days at25°C (77°F) and 50% RH:ELONGATION PERCENT MINIMUM
Joint Modulus at 50 percent Elongation, psi (kPa) maximumJOINT MODULUS AT 100 PERCENT ELONGATION, PSI (KPA) MAXIMUM
Joint Modulus at 150 percent Elongation, psi (kPa) maximumADHESION TO CONCRETE, MINIMUM PERCENT ELONGATION
Adhesion to Asphalt, minimum percent ElongationJOINT MOVEMENT CAPABILITY, +100/-50 PERCENT, 10 CYCLES
WeatherabilityFLEXIBILITY
CELLULAR, HIGH DENSITY, POLYURETHANE FOAM
Proprietary, modified, water-based, acrylic
22.3 PSI MIN (153 KPA)157% min
185°F (85°C)-40°F (-40°C)NO CHANGES--2000 HOURS
NO CHANGES--2000 HOURS
BASE MATERIAL
Impregnation
TENSILE STRENGTH
Elongation - ultimateTEMPERATURE SERVICE RANGE
HIGH
LOW
UV RESISTANCE
(Accelerated Weatherometer)
RESISTANCE TO AGING
Bleeding:-40°F to 180°F (-40°C to 85°C)
COMPRESSION SET
Property Value
Table 1: Typical Physical Properties of DSM Foam
Property Value
Table 2: Typical Physical Properties of Silicone Coating
DARK GRAY
961.26 - 1.34
14007(48)8(55)9(62)+600+600NO FAILURE
Unaffected by climatic extremesCURED SEALANT STAYS RUBBERY FROM -45 TO
149°C (-50 TO 300°F)
Test Method
1 1/2"(40mm)
1-1/2"(40mm)
2"(50mm)
2"(50mm)
2 1/2"(65mm)
2-1/2"(65m)
2-1/2"(65mm)
2-1/2"(65mm)
2-3/4"(70mm)
2-3/4"(70mm)
3-1/4"(80mm)
3-1/2"(90mm)
3-1/2"(90mm)
3-1/2"(90mm)
3-1/2"(90mm)
5-1/2"(140mm)
6"(150mm)
Depthof Seal
Nominal Material Size(Joint Size at Mean T°F)
1/2"(12mm)
3/4"(20mm)
1"(25mm)
1-1/4"(30mm)
1-1/2"(40mm)
1-3/4"(45mm)
2"(50mm)2-1/4"
(55mm)
2-1/2"(65mm)
2-3/4"(70mm)
3"(75mm)
3-1/4"(85mm)
3-1/2"(90mm)
3-3/4"(95mm)
4"(100mm)
5"(125mm)
6"(150mm)
Table 4: DSM SYSTEM Sizing
Table 3: Approximate Volume Change of Silicone Coating after Exposure to Fluids:
Silicone Joint Sealant5-20 PERCENT
NoneNONE
None
FluidJP-4Skydrol B50/50 GLYCOL/H2OHydraulic Fluid
Percent Volume Swell - Visual
AFTER DRYING, ALL SAMPLES PASSED +100/-50% MOVEMENT TESTING.
• Remove shrink-wrap packaging andhardboard. Allow partial expansion untilsnug when inserted into epoxied joint faces.
• Insert material into joint until bellows isflush with (below-grade or deck-to-wall) orrecessed by 1/4" (6mm) in trafficapplications.
• Join lengths by pushing silicone coatedends firmly together.
• Wipe silicone facing using clean,lint-free rag made damp with solvent.
• Before the epoxy cures, force the tip of thesealant tube between the foam and thesubstrate and inject a silicone sealant band.Tool overflow sealant into a cove beadbetween the top of the silicone bellows andthe substrate. Tool silicone between joinedlengths so that bellows is not restrained byexcess silicone.
Warranty
Standard or project-specific warranties are
available from EMSEAL on request.
CAD Details & Guide Specs
Guide specifications and CAD details are
available at www.emseal.com.
Availability & Price
DSM SYSTEM is available for shipment
internationally. Prices are available from
local representatives and/or directly from
the manufacturer. EMSEAL® reserves the
right to modify or withdraw any product without
prior notice.
Max. Joint(opens to)
Min. Joint(closes to)
5/8"(16mm)
15/16"(24mm)
1-1/4"(30mm)
1-5/8"(42mm)
2"(50mm)
2-1/4"(55mm)
2-5/8"(67mm)
2-7/8"(73mm)
3-1/4"(85mm)
3-1/2"(90mm)
3-7/8"(98mm)
4-1/4"(110mm)
4-1/2"(115mm)
4-7/8"(120mm)
5-1/4"(135mm)
6-1/2"(165mm)
7-1/8"(180mm)
3/8"(10mm)
9/16"(14mm)
3/4"(20mm)
7/8"(22mm)
1-1/8"(28mm)
1-1/4"(30mm)
1-1/2"(40mm)
1-5/8"(42mm)
1-7/8"(47mm)
2"(50mm)
2-1/4"(55mm)
2-1/2"(65mm)
2-5/8"(67mm)
2-3/4"(70mm)
3"(75mm)
3-3/4"(95mm)
4.5"(115mm)
Copyright © 2015 by EMSEAL JOINT SYSTEMS, LTD. All Rights Reserved
(see “Performance” for movement capabilities & limitations)
No bleeding when compressed to minimum of claimedmovement i.e. -25% of nominal size and when simulateouslyheated to 180°F (85°C) FOR 3 HOURS
MATERIAL RECOVERS TO +30% OF NOMINAL SIZE WITHIN 24 HOURS OF COMPRES-SION TO -25% AND SIMULTANEOUS HEATING TO 180°F (85°C) FOR 3 HOURS
• Substrates must be parallel, plumb andcapable of resisting approx. 2.5 psibackpressure from the foam.
• Standard sizes from 1/2" (12mm) to 6"(150mm). Other sizes available subjectto review of application: consultEMSEAL.
• Fuel Resistance: Silicone sealant is notdegraded by contact with fuel. Someswelling of the material will normallyoccur, but it will return to its originalshape upon evaporation of the fuel.
• Sizes in excess of 4” consult EMSEAL• For sizes not shown consult EMSEAL.• Select nominal material size to correspond to joint-gap size
at mean temperature.• Material supplied in shrink-wrapped sticks of 6.56 ft. (2 M).
EMSEAL_DSM_TD_01-09-2015
