The document discusses bridge expansion joint products from D.S. Brown Company, including their Steelflex modular expansion joint systems, Steelflex strip seal expansion joint systems, and Delastic preformed neoprene compression seals. It provides information on system components, design principles, installation considerations, and joint selection/design data for the Steelflex modular expansion joint systems. The summary highlights D.S. Brown's leadership in developing fatigue-resistant bridge expansion joint designs and the benefits of their cast-in-place Steelflex strip seal expansion joint systems.
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Expansion Brochure
1. Bridge Products
Steelflex® Modular Expansion Joint Systems
Steelflex® Strip Seal Expansion Joint Systems
Delcrete™ Strip Seal Expansion Joint Systems
Delastic® Preformed Neoprene Compression Seals
Protect Your Investment
2. Meeting the Challenge
The
Protect Your For example, D. S. Brown pioneered D.S. Brown Company
Investment processing improvements of its
Steelflex® rail profiles from the Founded in 1890 and
Since the early 1960’s The D.S. Brown traditional extrusion method to the
based in North Baltimore,
Company has provided expansion joint innovative hot-rolled/machined and hot-
rolled/non-machined technology. Ohio, USA, The D.S. Brown
systems and structural bearing assem- Company is a worldwide
blies for bridges around the globe. Quality is further improved through in-
Bridge expansion joint systems are house neoprene sealing element designer, manufacturer
directly exposed to vehicular wheel extrusion capabilities. Together, these and supplier of
loads and, therefore, must resist initiatives have allowed D.S. Brown to engineered products for
dynamic forces causing fatigue and improve the watertight integrity of its
the highway and bridge
wear. In addition, these expansion joint expansion joint systems while reducing
the cost of these assemblies to the construction markets.
systems must remain watertight to
protect the bridge superstructure and owner/agency.
D.S. Brown is fully
substructure from corrosion.
Use the design guide below to select and integrated, performing
To satisfy the demanding needs of specify the appropriate D.S. Brown and controlling all
bridge expansion joint systems, bridge product. The D.S. Brown
requirements of a project
D.S. Brown is committed to product Company’s Steelflex® and Delastic®
Expansion Joint Systems are designed to internally:
research and development, supported by
world-renowned, independent testing protect your investment.
• Research and
laboratories.
Development
• Engineering Design/
CAD Detailing
Design Guide / Table of Contents
• Rubber compounding,
Approximate Total <2” 3” 4” >4” mixing, extruding and
Pages
Joint Movement (51mm) (76mm) (102mm) (102mm)
molding
Steelflex® Modular
3-6
Expansion Joint Systems • Custom steel fabrication
and machining
Maurer System™ Swivel
Expansion Joint Assembly 7
by The D.S. Brown Company • Load Testing
Steelflex® Strip Seal
8 - 10
Expansion Joint Systems With offices and
fabrication facilities
Delcrete™ Strip Seal
Expansion Joint Systems
11 throughout the USA and
Asia, D.S. Brown is well-
Delastic® Preformed positioned to satisfy all
Neoprene Compression 12
Seals
of your structural
bearing assembly,
Fabricated Steel expansion joint system
13
Products
and specialty bridge
Cableguard™ Elastomeric product requirements.
13 - 14
Wrap System
2
3. Steelflex® Modular Expansion Joint Systems
D.S. Brown Steelflex® Modular for accommodating and sealing large research activities, each joint system is
Expansion Joint Systems have gained joint movements on bridge structures. designed to provide watertight, fatigue
overwhelming worldwide acceptance By incorporating the results of recent resistant, long-term maintenance-free
performance.
Steelflex® Edge Beam
Steelflex® Centerbeam
Welded Connection
Support Bar
Stainless Steel Sliding Surface
Slide Bearing
Precompressed Spring
Control Spring
Maximum
Unsupported
Span Length as
Determined
by Design
Requirements
3
4. Steelflex® Modular Expansion Joint Systems
System Components
Steelflex® Modular Expansion Joint Systems are highly engineered
assemblies which consist of Steelflex® centerbeams and edge
beams. The centerbeams and edge beams not only carry the
dynamic wheel loads but also accept the series of strip seal style
sealing elements that create a watertight joint. All Steelflex®
Modular Expansion Joint Systems are designed to accommodate up
to 80mm of movement per neoprene sealing element and, thus, the
joint designation is presented in multiples of 80mm (i.e. D-160,
D-240, etc.).
Each Steelflex® centerbeam is rigidly supported by its own support
bar using a full-penetration welded connection. Support bars span
the joint opening and are arranged below the centerbeams in a
direction parallel to the structural movement. Stainless steel slide
plates are attached to each end of the support bars (both top and
bottom surfaces) to provide a low coefficient-of-friction surface.
Movements up to ±0.79 inches (20mm) transverse to the support
bars (for D-320 joint assemblies and larger) can be accommodated
by a Steelflex® Modular Expansion Joint System. For large
longitudinal movements and transverse movements beyond the
allowable limits, the Maurer System™ Swivel Expansion Joint
Assembly by The D.S. Brown Company should be considered
(see page 7).
Elastomeric springs and bearings containing a PTFE sliding
surface are utilized to accommodate all longitudinal, transverse,
and rotational movements. The precompressed springs and slide
bearings are located directly above and below the support bar,
respectively. The precompressed spring is designed to have a
specific compression force on the support bar which, in turn,
produces a downward force on the slide bearing. This arrangement
allows the spring and bearing to work together and resist uplift of
the support bar as vehicular loads travel across the assembly.
Closed-cell polyurethane control springs are installed in all
Steelflex® Modular Expansion Joint systems to provide equidistant
spacing between centerbeams throughout the joint system’s
complete movement range. The control spring orientation is
such that the maximum compressive force is generated on the
centerbeams when the modular expansion joint assembly is at its
maximum opening.
4
5. Steelflex® Modular Expansion Joint Systems
Design Principles Steelflex® Modular Expansion Joint
Systems solve these problems with their
Fatigue Resistance excellent watertight design characteris-
tics. Each system not only bridges the
Modular expansion joint assemblies are joint gap but also protects the structure
subjected to millions of high dynamic from premature corrosion. Design of
stress cycles due to passing vehicle the strip seal sealing element is based on
loads. Recognizing the significance of compression of the neoprene seal lug
these dynamic loads on the long-term into the gland recess of the centerbeam
performance of expansion joint systems, and edge beam. This mechanically-
D.S. Brown became the first North locked neoprene seal not only provides
American company to introduce fatigue- excellent watertight characteristics but
resistant design principles to modular also achieves high pullout resistance.
expansion joint assemblies. It is The strip seal sealing element has
strongly recommended that a superior performance characteristics Fatigue Testing, Lehigh University,
specification which includes fatigue over the box seal design, including ATLSS Laboratory, Bethlehem, PA, USA.
design provisions be included in the improved watertight capabilities, pullout
contract documents. strength and replaceability.
• Setting to line and grade
The results of extensive field and • Setting proper joint opening
laboratory research have been utilized to Installation Considerations • Blockout reinforcement
achieve a fatigue-resistant expansion • Concrete consolidation
joint system. All primary members have As in all other expansion joint system
been fatigue tested to determine the solutions, a proper installation is Detailed information on recommended
fatigue design category of each required to ensure long-term, installation practices can be found in
component (i.e. Steelflex® centerbeam, maintenance-free performance of The D.S. Brown Modular Expansion
centerbeam/support connection and modular expansion joint systems. Joint Assembly Installation Data Sheet.
support bar). Using these test results, Special attention is directed to It is also suggested that the contractor/
a fatigue-resistant joint assembly installation considerations such as: owner utilize the services of a trained
can be detailed to satisfy the contract D.S. Brown technical representative to
specifications and ensure the owner of a • Joint lifting and handling review proper installation techniques
maintenance-free expansion joint • Field splices (when necessary) and be on-site during the initial installa-
system solution. tion of a Steelflex® Modular Expansion
Joint System.
Watertight Integrity
In the past, unsealed fabricated steel
joint systems have been specified
on structures with large movements.
Unfortunately, these older joint system
solutions have not been effective in
preventing water and debris from
passing through the deck joint to
the underlying superstructure. This
accumulation of water and debris
corrodes steel components, deteriorates
concrete and results in unnecessary
rehabilitation costs. Even when these
unsealed, fabricated joint systems utilize a
trough to collect drainage, in most
cases problems develop as they become
filled with debris.
Bear Mountain Bridge, Bear Mountain, NY, USA.
5
6. Steelflex® Modular Expansion Joint Systems
Joint Selection &
Design Data
Selection of the proper Steelflex® structural movements parallel and
Modular Expansion Joint System is perpendicular to the joint assembly.
based primarily on the anticipated The largest of these two movements
structural movement at the joint should be used to select the appropriate
location. For joint assemblies oriented Steelflex® Modular Expansion Joint
perpendicular to the structural System.
movement, simply select the Steelflex®
Modular Expansion Joint System with The table below provides expansion
a total movement range larger than the joint assembly and blockout dimensions
anticipated structural movement. Joint for a wide range of Steelflex® Modular
assemblies installed on curved or skewed Expansion Joint Sizes.
structures require the calculation of
Model Total Cells “A” “B” “C” “C” “W” “X”
Symbol Number Movement Blockout Blockout Min. Max. Mid Temp
Depth Width
6.30 14 15 3.35 5.71 8.17 12.2
D-160 2
(160) (356) (391) (85) (145) (208) (310)
9.45 14 18 4.92 9.65 12.24 12.2
D-240 3
(240) (356) (457) (125) (245) (311) (310)
D-320 12.60 14 22 6.50 13.78 16.32 12.2
4
(320) (356) (559) (165) (350) (415) (310)
D-400 15.75 14 25 8.07 17.91 20.39 12.2
5
(400) (356) (635) (205) (455) (519) (310)
D-480 18.90 14 28 9.65 21.85 24.47 12.2
6
(480) (356) (711) (245) (555) (622) (310)
D-560 22.05 14 31 11.22 25.98 28.54 12.2
7
(560) (356) (787) (285) (660) (725) (310)
D-640 25.20 15.25 34 12.80 30.12 32.62 13.3
8
(640) (387) (864) (325) (765) (829) (338)
D-720 28.35 15.5 37 14.37 34.06 36.69 13.6
9
(720) (394) (940) (365) (865) (932) (345)
Dimensions are based on design provisions in NCHRP Report 402.
Dimensions are based on 0 degree skew.
Bold numbers represent inches; metric (mm) shown in parentheses.
Shallower depths (X) may be possible upon special request.
6
7. Steelflex® Modular Expansion Joint Systems
Maurer System™ Performance Features Seismic Movement Capability
Swivel Expansion
By utilizing a common-to-all- Dynamic tests conducted at the
Joint Assembly by centerbeam swiveling support bar, the University of California at Berkeley
The D.S. Brown Co. Maurer System™ Swivel Expansion subjected the Maurer System™
Joint Assembly by The D.S. Brown Swivel Expansion Joint Assembly
Conventional large movement expan- Company is able to accommodate large by The D.S. Brown Company to
sion joint devices, such as D.S. Brown’s longitudinal displacements (X), exten- high-velocity seismic displace-
Steelflex® Modular Expansion Joint sive transverse displacements (Y), and ments. This first-of-its-kind test
System, are limited to primarily vertical displacements (Z), as well as program included velocities of more
longitudinal movements and/or less vertical rotations (Φx, Φy) of up to 10 than 40 inches per second
than ±0.79 inches (20mm) transverse degrees. The centerbeams are free (1015mm/sec) in both longitudinal
displacement. For joint locations which to slide on swiveling support bars, and transverse directions. The
produce more demanding structural which provide equidistant control for successful test results proved the
movements, the Maurer System™ Swivel centerbeams without the limitations unique capabilities of this patented
Expansion Joint Assembly by The D.S. of typical mechanical control devices. device in seismic applications.
Brown Company is provided in the To ensure long-term performance, all
U.S.A. through an exclusive license Maurer System™ Swivel Expansion Joint
agreement with Maurer Söhne, Munich, Assemblies by The D.S. Brown Com-
Germany. Typical applications include: pany are designed and fabricated using
fatigue-resistant connection details.
• Long-span structures
• Structures located in seismic zones For assistance with selecting the
• Curved structures appropriate size patented Maurer
• Structures with differential System™ Swivel Expansion Joint
longitudinal movements or Assembly by The D.S. Brown Company,
differential vertical movements please contact D.S. Brown.
• Structures with anticipated
substructure settlement
Lacey V. Murrow Floating Bridge,
Seattle, WA, USA.
Dynamic Testing, University of California, Berkeley, CA, USA.
7
8. Steelflex® Strip Seal Expansion Joint Systems
For decades, cast-in-place Steelflex® Recent design improvements have
Strip Seal Expansion Joint Systems have eliminated all horizontal “legs” on
provided superior watertight perfor- the proprietary steel rail profiles to
mance and longevity over bolt-down, facilitate proper concrete placement
segmental and pourable expansion during installation. Independent field
joint systems. Because of this proven and laboratory testing has demonstrated
performance, Steelflex® Strip Seal that improperly consolidated concrete
Expansion Joint Systems have become around the steel rail, anchorage, and/or
the overwhelming choice of owners and reinforcement could lead to performance
specifying engineers around the world issues. Anchorage of the proprietary
for accommodating up to five inches steel rail profile into the deck concrete is
(127mm) of total structural movement. the primary load carrying mechanism
and, therefore, is critical to ensure
long-term performance. Research has
System Components confirmed that properly sized and
spaced shot-on studs provide an
Cast-in-place Steelflex® Strip Seal economical, field-proven anchorage
Expansion Joint Systems consist of method.
two proprietary components: steel rail
profiles and a matching neoprene Because it is field-proven, the Steelflex®
sealing element. SSCM2 rail profile has become widely
accepted worldwide as an economical
standard in the industry. Other propri-
etary steel profiles are available to satisfy
Steel Rail Profiles
your specific project needs.
Steelflex® rail profiles are one-piece
construction, manufactured using
innovative hot rolled/non-machined and
hot rolled/machined technology. All
proprietary steel rails are available in
*SSCM available upon request
ASTM A36 or ASTM A588 steel grades.
8
9. Steelflex® Strip Seal Expansion Joint Systems
System Components
Neoprene Sealing Elements
Selection of a neoprene strip seal dimension for A2R-O and L2R-O seals is
sealing element is based on the maxi- approximately 3.0 inches (76mm).
mum movement either perpendicular
(MRL) or parallel (MRT) to the All D. S. Brown neoprene sealing
Steelflex® Strip Seal Joint Assembly. elements are in-house designed and
To assist in your selection, the following tested to provide a watertight seal at
table provides movement ranges for the connection to the Steelflex® rail
each sealing element type and the profile. Factory molded neoprene sealing
corresponding proprietary steel rail element splices can also be produced to
profile. Information is also provided on accommodate your specific project needs.
the range of joint opening dimensions.
The preferred joint opening dimensions
for sealing element installation is
approximately 2.0 inches (51mm).
However, the preferred joint opening
Sealing Element Sealing Movement Range Joint Corresponding
Cross-Section Element Opening Steelflex®
MRL MRT Rail
A2R – 400 4.0 ±2.0 0.5 – 4.5
(102) (51) (13) (114)
A2R SSCM2
A2R – XTRA 7.0 ±2.0 0.5 – 7.5 SSA2
(178) (51) (13) (191) SSE2
A2R – O 4.0 ±0.5 1.0 – 5.0
(102) (13) (25) (127)
A2R-O
L2 – 400 4.0 ±2.0 0 – 4.0
(102) (51) (0 (102)
L2
L2-500 5.0 ±2.0 0 – 5.0 SSPA
(127) (51) (0) (127) SSCM
L2-O 4.0 ±0.5 1.0 – 5.0
(102) (13) (25) (127)
L2-O
Bold numbers represent inches; metric (mm) in parentheses.
9
10. Steelflex® Strip Seal Expansion Joint Systems
Design concrete barrier. The upturn angle
varies depending on the barrier detail,
Considerations
joint skew and Steelflex® rail profile.
Horizontal Miter Details
Anchorage
Highly skewed structures often require
Anchorage type, size and spacing for the
fabrication of a horizontal break in the
Steelflex® SSCM2 joint system is
joint system to orient the steel rail 90
illustrated. Anchorage details for other
degrees to the face of the concrete
Steelflex® rail profiles are available.
barrier. Neoprene strip seal sealing
elements are installed in a continuous
piece, without vulcanization, up to a 35
Upturn Details degree angle.
A watertight joint system is maintained
through a simple upturn detail into the
East Fork White River Bridge, Columbus, IN, USA.
10
11. Delcrete™ Strip Seal Expansion Joint Systems
Since its introduction in 1983, the Following are the design features of the technical representative or a representa-
Delcrete™ Elastomeric Concrete/ industry’s premier elastomeric tive of its licensed applicator shall be
Steelflex® Strip Seal Expansion Joint concrete: present on the job site during all phases
System has been utilized on hundreds of the installation.
of bridges worldwide as an alternative • Polyurethane chemistry
to more labor intensive, cast-in-place • Non-brittle over extreme Basic installation considerations include:
expansion joint rehabilitation solutions. temperature ranges
This expansion joint system also offers • Resistant to nearly all chemicals • Minimum ambient and concrete
superior long-term performance when • One hour cure time substrate temperature: 45ºF (7ºC)
compared to various pourable joint • Permanent, long-term repair • Sandblast entire blockout, including
solutions. solution steel rail profile, followed by a
compressed air sweep
Components to this system include: Although initially developed for the • Blockout area must be completely dry
low profile SSA2 or SSE2 Steelflex® bridge rehabilitation market, the before installation
rail profiles and Delcrete™ Elastomeric outstanding performance record of
Concrete. Delcrete™ has resulted in bridge owners A comprehensive list of installation
specifying Delcrete™ Strip Seal Expan- procedures is found in The D.S. Brown
Delcrete™ Elastomeric Concrete is a sion Joint Systems for new bridge Delcrete™ Strip Seal Expansion Joint
pour-in-place, free-flowing, two-part construction projects as well. System Installation Data Sheet.
polyurethane-based elastomeric
concrete. Delcrete™ has been
compounded to bond to a variety of Installation
surfaces including steel and concrete.
Proper installation of Delcrete™ is
essential to ensure long-term perfor-
mance. Therefore, a D.S. Brown
11
12. Delastic® Preformed Neoprene Compression Seals
In 1960 The D. S. Brown Company In addition to highway and bridge 35ºF (2ºC) to 80ºF (27ºC). At
began designing and extruding the applications, Delastic® Neoprene temperatures below this range
first generation of Delastic® Preformed Compression Seals have also been used the lubricant/adhesive has limited
Neoprene Compression Seals. Since in spillways, dams, parking structures, effectiveness, while at temperatures above
that time continuous improvements have stadium ramps and pedestrian over- this range the seals become difficult to
been made to this versatile, cost- passes. Information on additional seal compress for installation.
effective joint sealing solution. To designs is available.
withstand the demanding requirements Manual and automatic tools are
of bridge/highway installations, all Installation available to facilitate ilnstallation. D.S.
Delastic® Preformed Compression Brown Delastilube™ or Delastilube™ HS
Seals are extruded from neoprene In all installation applications, the joint lubricant/adhesive is used primarily to
(polychloroprene) compounds which width must be properly set for the lubricate the seal for installation
satisfy the ASTM standard specification specified Delastic® seal. Also, the purposes. The Delastilube™ products
D3542 for Preformed Polychloroprene vertical faces of the joint must be clean meet ASTM D2835 and D4070
Elastomeric Joint Seals for Bridges. and free of spalled concrete. Desirable standards.
installation temperatures range from
Design Data
The table below can be used to select the appropriate Delastic® Neoprene
Compression Seal for your project. In addition to accommodating perpendicular
movements (summarized in the table), Delastic® seals are also capable of accepting
approximately 15-20% lateral shear, vertical shear and rotational movements.
Delastic® SEAL CHARACTERISTICS JOINT DESIGN CRITERIA
Delastic®
Seal Nominal Nominal Max. Narrowest Widest Minimum
Width (W) Height (H) Movement Opening (A) Opening (A) Depth (B)
1.25 1.25 0.50 0.56 1.06 1.63
CV-1250
(32) (32) (13) (14) (27) (41)
1.63 1.88 0.60 0.73 1.38 2.25
CV-1625
(41) (48) (15) (19) (35) (57)
1.75 1.75 0.70 0.79 1.49 2.40
CV-1752
(44) (44) (18) (20) (38) (61)
2.00 2.00 0.75 0.95 1.70 2.75
CV-2000
(51) (51) (19) (24) (43) (70)
2.25 2.33 0.90 1.01 1.91 3.00
CV-2250
(57) (59) (23) (26) (49) (76)
2.50 2.50 1.00 1.13 2.13 3.20
CV-2502
(64) (64) (25) (29) (54) (81)
3.00 3.25 1.20 1.34 2.55 4.25
CV-3000
(76) (83) (31) (34) (65) (108)
3.50 3.50 1.40 1.58 2.98 4.45
CV-3500
(89) (89) (36) (40) (76) (113)
4.00 4.00 1.65 1.75 3.40 5.63
CV-4000
(102) (102) (42) (44) (86) (143)
4.50 4.50 1.80 2.03 3.83 6.13
CV-4500
(114) (114) (46) (52) (97) (156)
5.00 5.00 2.35 1.90 4.25 6.25
CA-5001
(127) (127) (60) (48) (108) (159)
6.00 6.00 2.90 2.20 5.10 7.75
CA-6000
(152) (152) (74) (56) (129) (197)
Bold numbers represent inches; metric (mm) shown in parentheses.
Joint opening dimensions (A) are based on minimum and maximum pressures allowed in ASTM D3542.
Minimum depth dimensions (B) include a 0.25 inch (6mm) recess below the roadway surface.
12
13. Fabricated Steel Products
Fabricated steel plate expansion joint To ensure high-quality workmanship,
systems, such as finger joint assemblies all fabricated steel products should be
and sliding plate and armor joint fabricated in an AISC-Major Steel Bridge
systems, are still specified on many certified facility.
bridge projects due to proven long-term
structural performance. These joint
systems are also convenient to install on
bridge rehabilitation projects requiring
a shallow joint depth and/or staged
construction.
In addition to fabricated steel plate
expansion joint systems, D.S. Brown
also supplies the following fabricated
steel products:
• Steel Diaphragms
• Pin and Link Assemblies
• Bridge Railings
• Other Custom Steel Fabrications
Finger Joint Assembly.
Cableguard™ Elastomeric Wrap System
Due to the premature failure of
corrosion protection systems on cable-
supported structures, D.S. Brown began
development of its patented
Cableguard™ Elastomeric Wrap System
in the early 1990s. This alternative
corrosion protection system, developed
exclusively for bridge cables, is
applicable during construction or
rehabilitation of cable-stayed and
suspension bridges.
The Cableguard™ wrap is based on
cross-linking a chlorosulfonated
polyethylene polymer that is manufac-
tured into a 45 mil (1.14mm) thick,
three-ply (polymer-fabric reinforce-
ment-polymer) laminated construction.
Several Cableguard™ Elastomeric Wrap
features are highlighted as follows:
Anthony Wayne Bridge, Toledo OH, USA.
13
14. Cableguard™ Elastomeric Wrap System
Highlighted Features
Environmentally Friendly into the cable. However, even though
the Cableguard™ wrap shrinks securely
Cableguard™ Elastomeric Wrap is to the cable, it does not fuse or bond to
applied directly over existing poly- the cable. Therefore, partial removal for
ethylene, paint or galvanized cable inspection of the internal strands is not
surfaces using a Skewmaster™ automatic impaired.
wrapping device. The Cableguard™
Elastomeric Wrap encapsulates the
entire cable. The Cableguard™ system Proprietary Cable Band Treatment
does not require sandblasting, high-
pressure washing or any type of solvent. The Cableguard™ Elastomeric Wrap
Therefore, containment and disposal of System features a watertight sealing
hazardous materials is eliminated. mechanism at the cable bands of
suspension bridges. This proprietary
Simple Installation system includes an extruded neoprene
wedge and stainless steel clamping
After applying the Cableguard™ Wrap, straps.
intimate heat is applied to fuse the 50
percent overlapped wrap (total thickness
of 90 mils) and shrink the wrap snuggly Color-Fast
to the cable surface. This fusion and
shrinkage creates an impermeable Cableguard™ wrap is available in Cable Band Treatment.
barrier against the intrusion of moisture virtually any color without applying
paint.
Heat Blanket Application.
Skewmaster™ Wrapping Device.
14