Oct 17, 2015
Bridge Deck Joint Replacement Practices
Brian D. Merrill, P.E.State Bridge Construction & Maintenance
EngineerTexas Department of Transportation
TopicsTopics
Why do we need joints?Why do we need joints? TexasTexas Design Philosophy: Minimize JointsDesign Philosophy: Minimize Joints Joint Types in UseJoint Types in Use Common Failure Modes and Replacement Common Failure Modes and Replacement
PracticesPractices Future DirectionsFuture Directions
Why do we need joints? Allow thermal expansion and contraction Allow translation & rotation of the deck
Why do we need joints? Keep water, off of substructure Protect exposed concrete edges
Minimizing Joints the Texas Way
Joints and the 90% Rule 90% of new bridges use PS beams Poor-Boy Continuous slabs Dont eliminate joints completely Joint failure is inevitable
Fully Continuous Units
Poor-Boy Continuous
400 maximum unit length
Zip-strip3/4 Chamfer orSteel Angle
Controlled Joint
4
Minimizing Joints What we dont do:
Dont eliminate joints completely Change the way we build foundations Moves the maintenance problem
Dont make prestressed beams continuous over the bents Not worth the trouble
Armor Joint (AJ) Sealed Expansion Joints (SEJ) Fabric Joint Underseal Header Type Joint Asphalt Plug Finger Joint Modular Joint
Joint Types
Armor Joint SEJ Fabric Joint Underseal Header Type Joint Asphalt Plug Finger Joint Modular Joint
Joint Types
Typical New Construction
With or without overlay & Seal
Armor Joint
Sealed Expansion Joint
SEJ-A
SEJ-P
SEJ-S(O)
Armor Joint SEJ Fabric Joint Underseal Header Type Joint Asphalt Plug Finger Joint Modular Joint
Joint Types
Reconstruction
Fabric Joint Underseal (FJU) -Features
Use with ACP overlays for small joint movements
18 wide fabric underseal
Center fabric @ Jt
1 sawed opening
Backer rodHot poured rubberHMACP
Surface TreatmentConcrete Deck
Header-Type Joints
Concrete
Wearing SurfaceHeader
Silicone Seal
ExistingAngle orRail
Header-Type Jointswith Overlay
Concrete
HeaderSilicone Seal
Header-Type JointsRepairs
Concrete
Asphalt Plug Joints
Wearing Surface
Blended Polymer Modified Asphalt with Aggregate
Bridging Plate
Seal & Backer Rod
Asphalt Plug Joints
Armor Joint SEJ Fabric Joint Underseal Header Type Joint Asphalt Plug Finger Joint Modular Joint
Joint Types
Specialized New Construction
Finger Joints
Modular Joints
Failure Modes
SEJs and Armor JointsDamaged concrete deck edge or approach slab
edgeDisengaged stud anchors of the steel section from
the concrete deck Damaged strip or silicone sealJoint is locked together
SEJ-Armor Joint Failures/Repairs
Damaged Slab Edge -poor installation-material failure
Partial depth slab repair
SEJ-Armor Joint Failures/Repairs
Damaged Slab Edge -poor installation-material failure
Full depth repairPartial depth repairBelzona repair
SEJ-Armor Joint Failures/Repairs
Remove top plateRepair with Belzona
SEJ-Armor Joint Failures/Repairs
Steel is disengaged-fatigue
Full depth repairReset joint
SEJ-Armor Joint Failures/Repairs
Joint is locked togetherduring hot weather-service limit
Full depth repairReset joint
SEJ-Armor Joint Failures/Repairs
Seals broken or leaking
Failure Modes
Header and Asphalt Plug JointsHeader material delaminates Header material has cracksThe deck concrete fails and the header failsHeader material expands due to moisture during
installationExcessively wide header joint Sealant fails
Header and Plug Joint Failures
Delamination ofHeader Material-incorrect application-material failure-poor installation
Header and Plug Joint Failures
Cracking of HeaderMaterial -material failure
Header and Plug Joint FailuresDeck concrete failure -header material failure
Partial deck repairwith Belzona
Header and Plug Joint Failures
Header bubbledfrom excess moisture-material failure
Header and Plug Joint Failures
Excessively WideHeader Joint-service limit
Header and Plug Joint Failures
Seal fails
Future Directions
Stay with current design practices Warranty specs for header joints Evaluation of new header systems
One year trial installation Always looking for the perfect joint
Smooth ride Stays sealed Low maintenance