IC-QA-B318 - Bonded Metal-Elastomer Expansion Joints
Transcript of IC-QA-B318 - Bonded Metal-Elastomer Expansion Joints
Edition 2 / Revision 1 TRANSPORT FOR NSW
June 2020
TRANSPORT FOR NSW (TfNSW)
QA SPECIFICATION B318
BONDED METAL-ELASTOMER EXPANSION JOINTS
NOTICE
This document is a Transport for NSW QA Specification. It has been developed for use with
roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not
suitable for any other purpose and must not be used for any other purpose or in any other context.
Copyright in this document belongs to Transport for NSW.
REVISION REGISTER
Ed/Rev
Number
Clause
Number Description of Revision
Authorised
By Date
Ed 1/Rev 0 First Issued GM, RNIC 10.09.02
Ed 2/Rev 0 Updated to new AS 5100 standard
“Superintendent” changed to “Principal”
GM, IC (Warren
Stalder)
01.09.08
Ed 2/Rev 1 Global References to “Roads and Maritime
Services” or “RMS” changed to “Transport
for NSW” or “TfNSW” respectively.
DCS 22.06.20
Edition 2 / Revision 1 TRANSPORT FOR NSW
June 2020
QA SPECIFICATION B318
BONDED METAL-ELASTOMER
EXPANSION JOINTS
Copyright – Transport for NSW
IC-QA-B318
VERSION FOR:
DATE:
Bonded Metal-Elastomer Expansion Joints B318
Ed 2 / Rev 1 i
CONTENTS
CLAUSE PAGE
FOREWORD ............................................................................................................................................... II TfNSW Copyright and Use of this Document ............................................................................... ii Revisions to Previous Version ....................................................................................................... ii Project Specific Changes ............................................................................................................... ii
1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of the Specification ......................................................................................... 1 1.3 Proprietary Products ....................................................................................................... 1 1.4 Warranty ......................................................................................................................... 1
2 DESIGN ........................................................................................................................................... 2 2.1 General ........................................................................................................................... 2 2.2 Design Loads on Joint .................................................................................................... 2 2.3 Anchors .......................................................................................................................... 2 2.4 Design Certification ........................................................................................................ 3
3 MATERIALS .................................................................................................................................... 3 3.1 Elastomer ........................................................................................................................ 3 3.2 Metal ............................................................................................................................... 4 3.3 Corrosion Protection ....................................................................................................... 4
4 NOISE ............................................................................................................................................. 5
5 CONFORMITY ................................................................................................................................. 5
6 INSTALLATION ............................................................................................................................... 5
ANNEXURES B318/A TO B318/B – (NOT USED) ...................................................................................... 7
ANNEXURE B318/C – SCHEDULES OF HOLD POINTS AND IDENTIFIED RECORDS .................................... 7 C1 Schedule of Hold Points ................................................................................................. 7 C2 Schedule of Identified Records....................................................................................... 7
ANNEXURES B318/D TO B318/L – (NOT USED) ...................................................................................... 7
ANNEXURE B318/M – REFERENCED DOCUMENTS .................................................................................. 8
LAST PAGE OF THIS DOCUMENT IS ............................................................................................................ 8
B318 Bonded Metal-Elastomer Expansion Joints
ii Ed 2 / Rev 1
FOREWORD
TFNSW COPYRIGHT AND USE OF THIS DOCUMENT
Copyright in this document belongs to Transport for NSW.
When this document forms part of a contract
This document should be read with all the documents forming the Contract.
When this document does not form part of a contract
This copy is not a controlled document. Observe the Notice that appears on the first page of the copy
controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW
Internet website: http://www.rms.nsw.gov.au/business-industry/partners-
suppliers/specifications/index.html
REVISIONS TO PREVIOUS VERSION
This document has been revised from Specification TfNSW B318 Edition 2 Revision 0.
All revisions to the previous version (other than minor editorial and project specific changes) are
indicated by a vertical line in the margin as shown here, except when it is a new edition and the text
has been extensively rewritten.
PROJECT SPECIFIC CHANGES
Any project specific changes are indicated in the following manner:
(a) Text which is additional to the base document and which is included in the Specification is
shown in bold italics e.g. Additional Text.
(b) Text which has been deleted from the base document and which is not included in the
Specification is shown struck out e.g. Deleted Text.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
Ed 2 / Rev 1 1
TfNSW QA SPECIFICATION B318
BONDED METAL-ELASTOMER EXPANSION JOINTS
1 GENERAL
1.1 SCOPE
This Specification sets out the requirements for the supply and installation of bonded metal-elastomer
expansion joints which comprise reinforced elastomeric units, sealants and anchorage systems.
This type of expansion joint consists of a metal reinforced elastomeric pad that spans the joint gap and
is rigidly attached on each side of the gap. The joint movements are accommodated by deformation of
the elastomer. The metal reinforcement embedded in the elastomer supports traffic crossing the gap.
1.2 STRUCTURE OF THE SPECIFICATION
This Specification includes a series of annexures that detail additional requirements.
1.2.1 Schedules of HOLD POINTS and Identified Records
The schedules in Annexure B315/C list the HOLD POINTS that must be observed. Refer to
Specification TfNSW Q for the definition of HOLD POINTS.
The records listed in Annexure B318/C are Identified Records for the purposes of TfNSW Q
Annexure Q/E.
1.2.2 Referenced Documents
Unless specified otherwise, the applicable issue of a referenced document, other than a TfNSW
Specification, is the issue current at the date one week before the closing date for tenders, or where no
issue is current at that date, the most recent issue.
For convenience standards, specifications and test methods are referred to in an abbreviated form (e.g.
AS 1234). Their full titles are given in Annexure B318/M – Referenced Documents.
1.3 PROPRIETARY PRODUCTS
Where the Drawings nominate a particular proprietary bonded metal-elastomer expansion joint, a joint
other than the nominated joint must not be used without the prior authorisation of the Principal, in
accordance with the Conditions of Contract.
1.4 WARRANTY
Proprietary bonded metal-elastomer expansion joints must be supplied with a warranty in the name of
Transport for NSW. The warranty from the joint supplier must cover defective workmanship, material
and serviceability of the joint for a minimum period of five years from the date of installation.
Serviceability must include watertightness of the joint. Any joints becoming defective within this
period must be rectified by the supplier at no cost to the Principal.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
B318 Bonded Metal-Elastomer Expansion Joints
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2 DESIGN
2.1 GENERAL
Design bonded metal-elastomer expansion joints to possess the necessary properties of extension,
compression and deformation to give the required range of movement, as shown on the Drawings and
in accordance with AS 5100.4. The wearing surface of the joint must be of metal which is wear and
skid resistant.
The required profile of the bonded metal-elastomer joint to match the bridge cross section may be
obtained by sealing together straight lengths of joint by means of a sealant recommended by the
manufacturer of the expansion joint.
The maximum transverse movement of the joint in service must be not more than 1/12 of the total
maximum movement range.
2.2 DESIGN LOADS ON JOINT
Design the joint to withstand the following loads:
(a) A vertical live load from an A160 individual heavy axle in accordance with AS 5100.2; and
(b) A concurrent longitudinal live load that is a minimum of 35% of the vertical load acting at road
level parallel to the direction of traffic.
Apply the design lanes at any location on the deck joint to give the worst loading case.
The dynamic load allowance must be 0.6.
Multiply the design load with the dynamic load allowance by a factor of 1.8 for ultimate limit state
effects, 1.0 for serviceability limit state effects and 0.6 for fatigue.
2.3 ANCHORS
The supplier must comply with AS/NZS ISO 9001 Clause 7.3 with respect to the design of the
anchors. Design the anchors to meet the requirements of AS 5100.4 and the following additional
requirements:
(a) The forces in the anchors must be calculated in accordance with the laws of statics, assuming
that the concrete above the line joining the points of connection between the anchors and the
member is ineffective;
(b) Anchors must have a minimum thickness of 12 mm if rectangular bars and must not be less than
20 mm in diameter if round bars;
(c) Bars used as anchorages must form a loop of sufficient size to be permit anchoring into the
concrete with the contribution of the transverse and other reinforcement;
(d) Any welding of anchorage bars must develop the full strength of the bar and accommodate an
infinite number of fatigue cycles;
(e) Stud welded shear connectors used as anchors must be at least 16 mm diameter and 150 mm in
length and welded only by resistance welding using a welding gun. Do not weld steel stud
shear connectors to aluminium;
(f) Anchors must be designed to allow easy replacement of the joint.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
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2.4 DESIGN CERTIFICATION
Submit details of the proposed design and a certificate from an Engineer who is eligible for
membership of the Engineers Australia certifying that the proposed joint has been designed to meet all
the requirements of AS 5100.4 and this Specification.
HOLD POINT
Process Held: Supply of the bonded metal-elastomer expansion joint.
Submission Details: (a) Calculated loads on the joint and distribution to anchors (see Clause 2.2
and Clause 2.3(a));
(b) Calculated stress in the anchors (see Clause 2.3 (a));
(c) Method of replacing the joint (see Clause 2.3 (f));
(d) Design details and certification (see Clause 2.4).
Release of Hold Point: The Principal will consider the submitted documents prior to authorising the
release of the Hold Point.
3 MATERIALS
3.1 ELASTOMER
The elastomeric material in the joint must be entirely uniform and homogeneous throughout. Any
section showing imperfections, surface splits or indentations must be rejected.
The elastomeric components of the joint must be made from vulcanized compound having
polymerized chloroprene as the only base polymer.
Provide documentary evidence to the Principal to verify that the elastomer used in the manufacture of
the joint has been tested by a laboratory with appropriate NATA registration and that it complies with
the requirements specified in Table B318.1.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
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Table B318.1 – Elastomer Material Requirements
Property Requirement Test Method
1. General
a) Tensile Strength 12.0 MPa minimum AS 1683.11 (Dumb-bell test pieces)
b) Elongation at Break 350% minimum AS 1683.11 (Dumb-bell test pieces)
c) Hardness IRHD 59+5 AS 1683.15.1
2. Accelerated Ageing AS 1683.26 (Method A for 72 hours at 100C)
a) Tensile Strength Change -15% to +15% AS 1683.11 (Dumb-bell test pieces)
b) Elongation at Break Change -40% to 0 AS 1683.11 (Dumb-bell test pieces)
c) Hardness Change IRHD -15 to +15 AS 1683.15.1
3. Resistance to Ozone No visible cracking AS 1683.24 (Ozone concentration 50 pphm in
air, 20% strain, 72 hours at 40C)
4. Change in Volume in Oil +30% maximum AS 1683.23 (Using Oil No. 3, after 72 hours at
100oC)
5. Compression Set 40% maximum AS 1683.13 (72 hours at 100oC)
6. Brittleness Not brittle ASTM D746 (B) (At –30oC)
The Principal may waive the requirement for testing to Table B318.1 provided that:
(a) the supplier of the elastomer for the manufacture of the joint has a third party certified quality
management system to AS/NZS ISO 9001 for the manufacture and supply of elastomer; and
(b) (i) test certificates are supplied to prove that the elastomer meets the properties specified in
Table B318.1 in Type Tests not more than six months old; and
(ii) day to day batch quality control on the manufacture of the elastomer is exercised by
performing a test which accurately measures the cure characteristics of the elastomer and
highlights variations resulting from incorrect ingredients or levels thereof; and
(c) the manufacturer establishes control points and limits on batches which have been Type Tested
and uses these control points and limits for subsequent quality control purposes.
3.2 METAL
Structural steel embedded in the elastomer must conform to AS 3679.1 Grade 250 unless noted
otherwise on the Drawings or in the Specification.
Other embedded metal must conform to the relevant Australian Standard for the strength grade
specified in the design.
3.3 CORROSION PROTECTION
The anchors must be hot dipped galvanized in accordance with AS 4680 or AS 1214, unless shown
otherwise on the Drawings.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
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4 NOISE
It is possible that the centre portion of the expansion joint, in a compressed condition, lifts off the
support, forming a convex profile. As vehicles travel across the joint a thumping noise may emanate.
If required by the Principal, provide field performance of noise levels under similar site and
temperature conditions and state the measures implemented to eliminate noise resulting from the
lifting of the joint.
5 CONFORMITY
Provide a certificate from the supplier of the joint verifying its conformity with the Drawings and this
Specification.
HOLD POINT
Process Held: Dispatch of the bonded metal-elastomer expansion joint to site.
Submission Details: Certificate from the supplier of the joint verifying its conformity with the
Drawings and this Specification.
Release of Hold Point: The Principal will consider the submitted details prior to authorising the
release of the Hold Point.
6 INSTALLATION
The method of placing the joint must be in accordance with the manufacturer’s recommendations.
The joint must not be inserted into the blockout until at least three days after all deck concreting in the
adjacent spans or abutments is completed.
The top surface of the expansion joint must be set 4 mm 1 mm below the deck wearing surface.
Submit the procedure for the installation of the expansion joint including the following information:
(a) Deck preparation, including blockout reinforcement, dimensions and tolerances required;
(b) Anchor locations and presetting required to suit the bridge deck temperature at the time of joint
installation;
(c) Preparation of the blockout base to ensure a true and even surface on which to bed the joint
units;
(d) Methods of sealing joint units at kerbs, gutters and horizontal directional changes in the bridge
deck profile;
(e) Sequence of installation of the units;
(f) Method of achieving a watertight seal at the interfaces between the concrete blockout and the
joint units;
(g) Method of joining adjacent joint units to ensure a watertight seal;
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(h) Torque requirements for anchors and the method of sealing bolt hole cavities;
(i) Filling for the gap between the edges of the unit and the adjacent road surfaces;
(j) Time after completion of installation when traffic is allowed on the road; and
(k) Method for testing of the installed joint for watertightness.
HOLD POINT
Process Held: Installation of the bonded metal-elastomer expansion joint.
Submission Details: Procedure for the installation of the expansion joint required in Clause 6.
Release of Hold Point: The Principal will consider the submitted details, prior to authorising the
release of the Hold Point.
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
Bonded Metal-Elastomer Expansion Joints B318
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ANNEXURES B318/A TO B318/B – (NOT USED)
ANNEXURE B318/C – SCHEDULES OF HOLD POINTS AND
IDENTIFIED RECORDS
Refer to Clause 1.2.1.
C1 SCHEDULE OF HOLD POINTS
Clause Description
2.4 Supply of the bonded metal-elastomer expansion joint
5 Dispatch of the bonded metal-elastomer expansion joint to site
6 Installation of the bonded metal-elastomer expansion joint
C2 SCHEDULE OF IDENTIFIED RECORDS
The records listed below are Identified Records for the purposes of TfNSW Q Annexure Q/E.
Clause Description of Identified Record
1.4 Warranty on the joint by the supplier against defective workmanship, material and
process on the serviceability of the joint for a minimum period of five years
2.4 Method for replacement of joint
2.4 Design details of the proposed joint with Engineer’s Certification
3.1 Documentary evidence that the elastomer complies with the specified requirements
4 Field performance of joint noise levels with measures implemented to reduce noise
resulting from the lifting of the joint (if required)
5 Certificate from the supplier of the joint verifying its conformity with the requirements
of the Drawings and this Specification
6 Procedure for installation of the joint including field jointing and testing of the installed
joint for watertightness
ANNEXURES B318/D TO B318/L – (NOT USED)
(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)
B318 Bonded Metal-Elastomer Expansion Joints
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ANNEXURE B318/M – REFERENCED DOCUMENTS
Refer to Clause 1.2.2.
TfNSW Specifications
TfNSW Q Quality Management System
Australian Standards
AS 1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread
series)
AS 1683 Methods of tests for elastomers
AS 1683.11 Tension testing of vulcanized or thermoplastic rubber
AS 1683.13 Compression set of vulcanized rubber under constant deflection
AS 1683.15.1 International rubber hardness
AS 1683.23 Rubber – Vulcanized – Determination of resistance to liquids
AS 1683.24 Methods of test for rubber – Determination of the resistance of vulcanized or
thermoplastic rubbers to ozone cracking – Static strain test
AS 1683.26 Rubber, vulcanized or thermoplastic - Accelerated ageing and heat resistance
tests
AS 3679.1 Structural steel - Hot-rolled bars and sections
AS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles
AS 5100 Bridge design
AS 5100.2 Part 2 – Design loads
AS 5100.4 Part 4 – Bearings and deck joints
American Society for Testing Materials Standards
ASTM D746 Standard Test Method for Brittleness Temperatures of Plastics and Elastomers
by Impact