12th Pilot Project: Sealing of expansion joints against ... · Sealing of expansion joints against...

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Newsletter

12th Pilot Project:

Sealing of expansion joints against stone chippings

and water flow

Wolf Kabeltechnik GmbH of Stuttgart was commissioned by DB Netz AG Hannover with

the task of finding a quick but lasting solution for sealing a 46-metre long expansion joint

against stone chippings and water flow. The railway bridge crosses the B522 highway to

Hanover airport. Due to defective joint sealing tapes, the passage of trains causes small

stones to fall through the 46-metre expansion joint onto the road below. Fortunately, this

has so far not caused any accidents or serious damage.

03/14

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The problem:

It was soon clear that our standard expansion-joint sealing cushions against water flow would not

provide a long-term solution for this particular case. Additional measures would be required to

ensure protection against small stones.

The solution: A further development of the expansion-joint sealing cushion:

Art. No. 21.3 SVS-QADK/V L, for protection against small stones

The aim of this further development was to optimise the tried and tested

Art. No. 21.1 QADK/V in such a way that it could be set into the joint cavity from the road, in the

course of renovation work, and would provide lasting protection against friction from small stones

and grit.

The task of was fulfilled with the development of a protective material, Art. No. 21.4 SVS-VF-QV

140x2x60, which is added to the upper side of the air-inflated

expansion-joint sealing cushion No. 21.1 QADK/V L. Laboratory tests have shown that for longer

expansion-joint sealing cushions (here 2 x 23 m) it is too complicated to assemble the protective

material on-site, so they should be delivered pre-assembled, but the assembly of shorter lengths

on-site is no problem.

Pic. 1:

Art. No. 21.3 SVS-QADK/V L Protective device against stone chippings and grit

Pic. 2:

Protective device installed in a functional model with joint width 6 cm

Pic. 3:

View from below into the expansion joint (model pic. 2) with installed protective device


RIGHT! Protective film in overlap area of 21.4 F-SVS-QADK/V

WRONG! No protective film in overlap area.

Danger of water leakage!

The project:

Mr Mike Dinter of DB Netz AG,

responsible for maintenance and

special repair work in facilities in the

northern region, was present at the talk

on “The economical sealing of expansion

joints with swelling-material expansion-

joint sealing cushions” given by our

affiliated company, Fibre Optics CT

GmbH, at the ARGE meeting in Cologne

in September 2013. He was able to

examine the functional model for

expansion joints that was on display.

In the course of his research for a solution to his problem, and after discussion with the

colleagues in charge of the western and central regions regarding their practical experience with

Wolf expansion-joint sealing cushions, Mr Dinter contacted Wolf Kabeltechnik GmbH on

26.06.2015, to discuss the technical feasibility of sealing against falling stones and water flow

and to request a quotation. On receipt of the order on 09.07.2015, Fibre Optics CT GmbH

started on the modification of the standard sealing cushion for pilot project No. 12, and the new

product was supplied on 22.07.2015.

In the meantime, Mr Dinter was busy with preparations for the installation of the new protection

material. He organised assembly teams and the road closure that would be necessary during

the installation of the protection material in the 46-metre expansion joint on 23.07.2015. He also

found a locality for the training session that Fibre Optics CT GmbH would give as part of the

assembly process.

Mr Roland Wolf of Fibre Optics CT GmbH in Stuttgart had set to work on the development

immediately after hearing of the problem situation. He tested the protective material in the lab

on 3 functional models. The lab tests made it clear that additional protection against water entry

would be required in the overlap area between two lengths of stone-protection material. This

meant that when the pilot project was actually carried out, all necessary materials were

available to ensure a reliable, lasting seal. As a consequence of water entry, icicles can form

and ice can build up on the road, which can cause accidents or damage. (See picture.)

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22.07.2015 Training session in theory and praxis given by Fibre Optics CT GmbH

On the day before the installation of the 46-metre expansion-joint seal and the practical briefing for

it, the DB Netz AG employees were introduced to the theory and praxis of the sealing system and

the materials used in a training session given by Mr Roland Wolf.

Functional tests on products samples of

swelling material, sealing cushions and

laminated film

Art. No. 13.1 VF-QV-DF surface protection,

Art. No. 13.2 VF-QV-DES liquid and diffusion

barrier

Test No. 1: Pressure test

with small stones, 85 kg/ 10x10 cm

Test No. 4

Resistance and positional stability of the sealing system

with repeated vertical movement.

Test No. 2: Tightness of the swelling-material sealing system i.e. no water entry, despite - holes in the laminated foil - the foil being attached by screws

Test No. 3: (carried out by the bridge inspector) Tightness of the swelling material even after damage (a cut 1.5 cm in length)


23.07.2015 Expansion joint renovation on the railway bridge

with installation instructions from given by

Mr Roland Wolf of Fibre Optics CT GmbH

Project (diagrammatic representation)

Start 08.40

Lane closure on the B522, the quick route to

Hanover airport

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09.00 – 09.15 Team 1 from DB Netz Hanover Team 2 from DB Netz Braunschweig scaffolding in lane 1 erects scaffolding in lane 2

Lanes 1 + 2 are closed while the scaffolding The sealing cushion 21.3 SVS-QADK/V L, is erected length 23 m, is rolled up with the valve end at the beginning

Closure of road

lanes 1 and 2,

carried out by B.A.S


09.15 Start of installation

On the scaffolding "emergency exit" lane 1, The end of the sealing cushion is folded over

sealing cushion 21.3 SVS-QADK/V L 23 m, 180° for ~1.5 m and laid in the joint cavity of the

weight 9.3 kg, is raised to a height of 5.2 m bridge support, with the blue SVS protective

layer facing in the direction of the stones

The sealing cushion is laid in the joint cavity Lane1, 09.30 at a height of 7.5 m, with the blue SVS protective layer towards the stones. A gradient is produced, with the aid of PE round cord and fixed in place transversely at 3-metre intervals.

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09.30 – The sealing cushion installation is completed in the bridge support and emergency exit areas, lane 1. The scaffolding is moved over to lane 2.

10.00 The sealing cushion is fixed in place trans-versely between lanes 2 and 3. 10.15 The scaffolding is taken down for removal to lane 4

10.15 – 10.30 The road closure is transferred to lanes 4 and 5 and the vehicles repositioned

10.15 – 10.30 The scaffolding from lane 1 is moved to lane 4 and from lane 2 to lane 3

Scaffolding is erected in lanes 3 and 4

10.15 The joint sealant over lane 3 is removed

The other end of the sealing cushion SVS-QADK/V L 23m is transported from lane 4 to lane 3

10.30 – 11.00 The protective aluminium strips are dismantled over lane 4


Installation of the protective foil F-SVS-QADK/V for the prevention of water flow in the overlap area of two sealing cushions

11.00 Both ends of the cushion overlap in the joint over lane 3 by about 0.5 m, and are fixed in place with PE round cord

11.00 – 11.25 Inflation of the first 23 m SVS-QADK/V

The inflated sealing cushion with PE round cord

11.28 – 11.45 The scaffolding is taken from lane 3 to lane 6. The sealing cushion in lane 4 is fixed in position.

Demonstration of the functional model with the sealing cushion SVS-QADK/V L used here.

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Functional test carried out on-site 13.1 VF-QV-DF surface protection 13.2 VF-QV-DES liquid & diffusion barrier Demonstration of thewatertightness of a test strip with a hole made by a screw (as used for attachment)

12.00 – 12.50 All the aluminium strips have been removed over lane 4

12.50 – 13.10 To fit the sealing cushion ends (valve side), approx. 2m are folded over 180°and fixed in position in the joint.

13.10 – 13.20 Inflation of the second sealing cushion to 0.5 bar. Removal of scaffolding, lane 5.

13.30 Completion of inspection of the SVS-QADK/V joint seal

Team DB Netz AG Hanover

Team DB Netz AG Braunschweig


Summary:

Time required

− From beginning of lane closure to the end (total duration) 360 min

− Erection and removal of scaffolding (total) 70 min

− Removal of aluminium strips and remains of the old joint sealant 85 min

− Lane closure processes/repositioning of vehicles ~ 70 min

− Fitting the sealing cushions, incl. transverse fixture ~ 135 min

Project planning and implementation

Excellent project planning, the exemplary cooperation of both installation teams from the DB

Netz AG and the assistance of the construction-site barrier service made it possible to carry out

a traffic-friendly, accident-fee installation in a relatively short time.

Assessment of the installation procedure

After the scaffolding had been removed, we saw from the photo documentation that the fixture

in position of the sealing cushions with PE round cord had not always been carried out as

prescribed.

This could have been caused by the bad lighting conditions in the 7.5 m

high joint cavity and uneven joint widths of 6.7 cm or narrower. It may

be that in a few places the PE round cord became twisted when the

sealing cushion was inserted and pulled and that it may now lie

between the joint wall and the cushion. It is possible that water could

enter at these points.

Research into this is already being carried out by Fibre Optics CT and Wolf KT. The results will

show if it is necessary to make corrections.

Wolf Kabeltechnik GmbH - over 30 years of innovative products!

Quality management system

The Wolf KT company is not certified according to DIN ISO IEC 17025:2000. The company's

internal Q-system is based on the specifications of DIN ISO 9001:2000 and corresponds to the

QS specifications of German Telekom “T-Com”. As quality certification, Wolf Kabeltechnik

GmbH supplies a tightness test report with each expansion-joint cushion (valve).

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Fibre Optics GmbH

The quality of joint sealing carried out with Wolf expansion-joint sealing technology depends largely

on good planning and how the installation process is carried out.

FibreOptics CT offers training sessions for familiarisation with Wolf products. For example:

Expansion-joint sealing technology & surface protection

on 22nd-23rd of October, 2015 A specialist conference

for construction supervisors and engineers, bridge inspectors and system decision-makers

(see Wolf Newsletter WO03/15)

3-day seminar

for construction supervisors and installation teams

(equivalent to Wolf WO03/15)

On successful completion, each participant is

awarded a certificate.

All information, pictures and graphic representations correspond to our current state of information and are correct to the best of our knowledge and belief. However, they cannot be considered as a binding warranty of the properties described. Such a warranty applies only to our product standards. The user must judge for himself on his own responsibility whether the product described is suitable for his intended application. Our liability for this product is based exclusively on our general terms and conditions of business. We reserve the right to alter our specifications without prior notice. We reserve the right to alter our specifications without prior notice..

Supplier Your local sales partner

National sales

Kabeltechnik GmbH,

Zazenhäuser Str. 52, 70437 Stuttgart, Germany

Tel. ++49 (0) 711 87 39 41 Fax ++49 (0) 711 87 12 30 e-mail: [email protected] www.wolfkabeltechnik.de

International Tel.: +49 (0)7071 9597-94 Email: [email protected]

mailto:[email protected]

mailto:[email protected]

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