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ACI 504R-90 Guide to Sealing Joints in Concrete Structures Reported by ACI Committee 504* Guy, Puccio Michael Jackson Secretary ‘Mitton D. Anderson Charis S. Gloys Pacer Marko Bert E.Colley ‘Arthur Hockman Joseph A. McElroy John P. Cook George Horecrko Leroy T: Ohler Robert V. Costello Vincent Kazakavich hes Seibel, I Edward R. Fyfe Oswin Keifer, Jr Peter Smith Frank D. Gaus Frank Klemm Stewart C. Watson Joseph F. Lamond site Commitee wishes to rexepnie the inpoanconuibuton oe cuent chun, Shera Spel the developmen ths unde \ Mot joints, and seme cracks in concrete structures, require sealing ‘against the adverse effects of environmental and service conditions, This report i a guide to beter understanding ofthe properties of joint Sealants and to where and hon they are used in presen practice. Described and iltasirated are: The functioning of joint sealants; re (quire properties, available materials and applicable specificationsfor {feld-motted sealants and preformed sealants such as wutersops, gas- ets, or compression seats; determination of Joint muvements, widths and depths: outline details of joins and sealems used in general sruc- tures fluid containers, and pavements; methods and equipment for seal ‘ant installaion including preparairy work: performance of sealants: ‘and methods of repairing defective work or maintenance reseaing. Fi nally, improvements needed to insure better joint sealing in the future re indicated. ‘New developments in iekbmolded and preformed sealants and their suse are described together with means of meacuring joint movements, AnpenicC provides alist of specifications and their sources, Keywords bridge decks: Wide struturen: bulings compression scan «ete conscton. conse dar: concrete pul: onctee pavement coetle Pipes: cnet slabs: concetes constuction jit conan eacing Torin: gushes cation jot jit ler: sears ts unction) bn. Ings: masts: parting agents precast cones relorced concrete epi ‘apecifeatons: an (containers: themmapasc eis termoseng rests mM CONTENTS: ‘Chapter 1—General, p. 504R-2 11—Background 1.2—Purpose 1.3_Why joints are required 1.4 Why sealing is needed |.5—Joint design as part of overall structural design 1.6—Types of joints and their function 1-7—Joint configurations "ACI Commitee Reports, Guides, Standard Pactives,and Conmen tures ar itended for uidance in designing, plunsing executing, oF inspecting construction, and in preparing specications, Reference to these document shail not be made inthe Project Document items found in these documents ar dsied oe pat ofthe Project ey shouldbe incorporated directly imo the Project Chapter 2—How joint sealants function, p. 504R-4 2.1-—Basle function of sealants 2.2—Classifietion of sealanis 2.3Behavior of sealants in but joints 2.4—Malfunction of sealans 2.5—Behavior of sealants in lap joints 2.6—Effect of temperature 2.7—Shape factor in fleld-molded sealants 2.8—Function of bond breakers and backup materials 2/9 Function of flrs in expansion joints 2.10—Function of primers Chapter 3—Sealant materials, p. S04R-12 3.1—General 3.2--Requied properties of joint alanis 3.3—Avalable materials 3.4—Fieldmolded sealants 3.5—Preformed seals Chapter 4—Joint movement and design, p.504R-25 “4.1 —Discussion 4.2—Determination of joint movements and locations 4.3—Seletion of but joint widths for eld-moded sealants 4 Selection of but joint shape fr feld-molded sealants 4.5—Selection of size of compression seals for but joins 4.6—Limitations on but joint widths and movements for various types of sealanis 47—Lap joint sealant thickness 4.8—Shape and sizeof rigid waterstops 4.9—Shape and sizeof flexible waterstops 410—Shape and sizeof gaskets and miscellaneous seals 4.11—Measurement of joint movements . ‘Chapter 5—Joint details, p. 504R-31 5.1—Introduction $2—Suuctures 5.3--Siabs on grade, highway, and ports 5.4—Consiruction and insalation considerations Ginga Ameren Cnc ne [Nba rere cog npg nda ey ay ew eg emai of cpey ay phony mice mena dere pee ‘Seed wd road tna pcre re any Somer ‘conde ons perenoe any winter soars s0en2 Chapter 6—Installation of sealants, p, 504R-31 6.1— Introduction 6.2—Joint construction wth sealing in mind {6.3— Preparation of joint sursces {6.4—Inspection of readiness to seal 6.5—Priming, installation of backup materiats and bond breakers {6.6—Insallaton of feld-molded sealants, hot apliee 6.7—Insalation of feld-molded seatens, cold applied 6.8—Instalation of compression seals 6.9—Installation of preassembled devices 6.0—tnsalacion of waterstope 6.11 Insalation of gaskets 6.12—Installaon of fillers 6.13 —Neatness and cleanup 6:14—-Safety precautions Chapter 7—Pertormance, repair, and maintenance of sealants, p. 504R-36 7.1—Poor performance 7.2—Repaits of concrete defects and replacement of sealants 7.3-Normal maintenance v CHAPTER 1—GENERAL 1.1—Background Tris repor is an update of the committee report orginally issued in 1970 and revised in 1977.! Nearly every concrete structure has joins (or cracks) that ‘must be sealed to insure its integrity and serviceability. common experience that satisfactory sealing is not always achieved. The sealant used, or its poor installation, usually teceives the blame, whereas often there have been deficien- If. as lap joint opens or clases. units move closer together or farther apart in plane ar right angles to ‘main movement then compression oF tension of the sealant will also occur. This combination of ‘movements is carimon in many applications to buildings (see Fig. 8). Where both rypes of movement ave expected. the combined movement should be considered to determine the thickness of sealant required in the joint design. Fig. 2—How field-molded sealants work sR. ® compression MANUAL OF CONCRETE PRACTICE MATER aNo otaRis, Powetnares {os Onicuvas worH OF SEAL, Seubert @ Sea to sna © Sea tos aby to recover Seals out of compreion in old weather uacouse awosranos —_raaerie SUAEIRETONE, PRM v ia “S CONCRETE sPALLS muuch ese © Folded or twisted at @ Over compressed and extruded intaon Secpamionjon Faure potied in hot weather }(i) Use wider seal © Install seal straight, Jubricate joint faces and Hacer: | Of Romain tease © ie ua nt formance by: Form or —— in iting during istatson Gi) Uma occurs in pavenente with mined Syne ofexpansowsontseion es ® Use seat with veer properties to provide dro his doen low temperntue feces Form ortav oor wider companion tt Leave av anp on topo er Watestop pete © contamination of sutace prevent bond to coette ‘© Complete brat ve to poor ono mplce ® onerestende tjint-may pit QHoneycomb concrete aes permit eaage QC Selecting size suitable for joint © OO W Proper instalation and concreting Improve movement practices Perfomance by:| Gay Avoid mpd anchored a ypes (iy Sine replacements uly not porate ty pening or bey : Salant a rohedi eases Fig. 3 ~Defects in preformed sealants ‘ JOINT SEALANTS. sone ae saan avo oeanscan 9. pena Associated with Elsie Behavior @Too deep compared to ©) Overextended; may lead ©) Peeling at points of Oa easel ellen © Crease: m ites forcentraton such sedge te @ Aétesion (bond to Cohesion (internal Impact pall it conrete joint face) failure: ® rupture) faiture ® isweak Iinprove eae Mattece | OCOD, tee: are pg (i) Use ofbond beater anajor PBB by ——— to reduce stains to those sealant can withstend backup materials a (iy Chest spacings to eee (Stet eter seat indi mee (© clean ces and rine (00, Saw eer than fem amo etre (ty tmgrovenets (9 to) x geal extend it of sealant Event flr must be expected due to combinations of OO iow stress Felaxaton, permanent kei ‘Nin spe cee of tesa (See OID) blow) Qe i Unity elephantean un Alo sang nd ‘Aochted with owt vena Tched Gamage acto Non easc Sr entc adam of oats Benet ee -e- e ul 7 Deb incon can ed to alg wor @ Extsion or bse D Extrson of Salut mater chage nprope ocaet fier Improve Performance y-— |© ® aD Slt sealant tat wi et intuson———()_ Ute beter shape actor fib. Routine dean o era {Rh lverleint psig Ingestion Oy te hese {iy Avoid mixed expansion contraction jit maura) eS cocgulee movement a eal neon st installation (¥) Select better sealant and more compressible filer and do not ove high joints or set filler foo @ defects Mainly Associated with Flow and Strexs Relaxation @ D 3) Fea ee © Wo sasroruinnumpetterent sion or (il) necks after compression as direction of movement Lite improvement possible if best sealant is being used. Support may help somewhat Fig. 4 Defects in field-molded s soan10 MANUAL OF CONCRETE PRACTICE Hypothetical cases showing the effect of installation tem, assuming the joint width at mean temperature equals the positions. (for peratures in relation to the range of service temperatures, {otal joint movement between fully open and fully closed ilicity of analysis only temperature effects shown) © SEALANT INSTALLED AT MEAN TEMPERATURE (A) INSTALLATION AT MEAN (B) JOINT OPEN AT (C) JOINT CLOSED AT ‘TEMPERATURES $5 F(13 C) “20 F (-29 C) 130 (54C) w w I ‘ ie —elywl— Sealant must extend or compress by SO percent in service. @ SEALANT INSTALLED AT LOW TEMPERATURE ‘/(AVINSTALLATION AT MINIMUM (B) JOINT HALF CLOSED _(c) JOINT CLOSED AT TEMPERATURES --20 F (-29 C) ATSSF(I3C) 130 F (54C) ry pa = Ye ‘Sealant must compress by 66.66 percent in service. Probability of Permanent Deformation or Extrusion, 50 percent more sealant needed. @ SEALANT INSTALLED AT HIGH TEMPERATURE (A) INSTALLATION AT MAXIMUM (B) JOINT HALF OPEN (C) JOINT OPEN AT TEMPERATURE 130 F (54 C) ATSSF (13 C) -20F (29) Whe aw. 3W ‘Sealant must extend by 200 percent in service Adhesion, cohesion, or peeling failure certain. CONCLUSION: The closer the installation temperature isto the mean annual temperature the less will be the strain in the sealant in service and the better it will perform in butt joints. Taking into account practical considerations (see Chapter 4 and 6) an installation temperature range of from 40 to 90 F (4 to 32 C) is acceptable for most applications. Note: (i) Though not iitustrated similar considerations govern the selection of the size of compression seals (see Section 4.5), Failure in case (3) above would however be by loss of contact with joint faces when seal passes out of compression. (4) Maximum deformation of a sealant in lap joints is also governed bx tnstallation temperature. Sealant ‘thickness not tess than joint movement acceptable for all temperatures (see Fig. 2 2) may be reduced 22 provided installation temperature is between 40 and 90 F (4 and 32 C) (movement approximately Ys each way) Fig. S—Effect of temperature on field-molded sealants JOINT SEALANTS soen-tt Cases showing the effect of shape on the maximum strains 'S' which occur on the parabolic exposed surface of ‘elastomeric sealants. Sealant assumed (o be installed at mean joint width so that % change of width of sealant will bbe extension and ¥4 compression, © JOINT DEPTH TO WIDTH RATIO 2:1 eens paar ea4 : Units of Seatant Required: 4 T _ — —- E+ oe @ JOINT DEPTH To WIDTH RATIO 1:1 bn ee SS Se ‘sHe% @ s01nt DEPTH TO WIDTH RATIO 1:2 ft Units of Sealant Required: 1 0 52K ‘20% CONCLUSION: Increasing the width and reducing the depth generally reduces strains and hence improves per- formance of field molded tealants. At the same time les sealant is required. Shape Factor is less important in mastic sealant since plastic not elastic behavior dominates. @ PURPOSE OF BOND BREAKER AND BACK UP: In joints open on one face only the back face of the sealant must not adhere to the bottom of the sealant reservoir so that the sealant is free to assume the desired shape. ‘See (A) below. Control of depth of sealant is achieved as shown in (B) where the joint is formed or sawn. initially deeper than the required depth to width ratio, (Bi) and (Bii) present cases as to desirable shape of \Y backup. (A) FUNCTION OF (8) FUNCTION OF (Bi) CURRENT PRACTICE BOND BREAKER BACKUP MATERIAL lex BACKUP LIMITS: SURFACE SHAPE AND srgga) BOND BREAKER ee nearer sono : 7 AnD cONTROLS roneouce aounsive Finesse stavant cannon doorriowan aenerit ‘rntroRMED ROUND ROD Facet ascowe iSromront seauant ‘On ree sacxor FaMAbOie SURFACE suorwvent a2 ‘Sum eorTon as eicas or (By While Detail (Bi is widely accepted and ‘used, some recent research suggests (B) may be better since, if backup material ‘resents flat face to sealant,peeling stresses at comers are reduced. Fig. 6—Shape factor and strains in field-molded sealants s04n-12 extensibility isa function ofthe shape of the mold in which it ‘vas installed as well as the physical properties of the mate- 1, A mathematical analysis of sealant deformation was ‘made by Tons* whose laboratory measurements showed that the exposed surfaces of an elastically deformed sealant as sume a parabolic shape until close to rupture, Tons concluded that total extensibility is increased directly with width and in- versely with the depth ofthe sealant inthe joint. From Tons'’s data and that of Schutz,’ Fig. 6 (1A, B, C, 2A, B, C, 3A, B, (Cyhas been prepared to illustrate the critical importance (and economy) of using a good shape factor especially with ther- ‘mosetting, chemically curing field-molded sealants. Shape factor pertains tothe ratio between the width ofa sealant and its thickness (depth) determined by experience and lab tests, Temust be remembered that while selections of shape fac- {orare essentially based on accommodating cohesive stresses inthe sealant, atthe time of placement an adequate area must be provided at the joint face to accommodate adhesive (bond) stresses. For this reason, experience has indicated a prefer- ‘7ce in certain applications, such as in concrete pavements, \ a minimum 3:2 (depth to width) shape factor rather than the theoretically more desirable ratio (shown in Fig. 6) of I:1 orl:2 in order to achieve a better service performance. 2.8—Function of bond breakers and backup materials Bond breakers and backup materials are used, a ilus- rated in Fig. 6 (4A, B), to achieve the desired shape factor in field-molded sealants. The principal material requirement for «bond breaker is that it should not adhere to the sealant. Important secondary benéfits of a backup material are that it Supports the sealant and helps resist indentation, sag and al- lows a sealant to take advantage of maximum exter ‘These may often be important considerations when selecting the appropriate type and shape of preformed backup mate: tial. The backup material must also be compressible without extruding the sealant and must recover to maintain contact ‘With the joint faces when the joint is open 3 Function of titers in expansion joints ers are used in expansion joins to assist in making the Joint and to provide room for the inward movement of the abutting concrete units as they expand. Additionally they ‘may be required to provide support for the sealant or limit its depth in the same manner that backup materials do. These requirements are usually met by preformed materials that can be compressed without significant extrusion and preferably recover their original width when compression ceases. Sti ignment during concrete placement and resistance to deterioration due to moisture and other service conditions are also usually required. 2.10—Funetion of primers, Laboratory and field experience indicates that priming Joint faces is essential for certain field-molded sealants and ‘can generally improve their bond strength and hence exten- sibility, especially at low temperatures. Depending on the sealant and condition ofthe sealant-to-joint interface, the im- provement in adhesion may result from one or more of the following: sealing and penetration of the concrete pores, pre- Coating of the concrete pores, precoating of the dust part MANUAL OF CONCRETE PRACTICE cles, reduction in bubble formation. and redluction in the ab- sorption of oils by the conerete. CHAPTER 3—SEALANT MATERIALS 3.1—Generat This chapter deals withthe functional properties of sealing and accessory materials. Because of their physical tions many materials only perform well in joints of smal ini- I width and subsequent movement. The configuration of the joint, the process by which itis constructed (formed) and access for installation of the sealant also impose restrictions om the types of material that may be suitable for a particular application, Inservice, environmental conditions often dictate add tional performance requirements beyond those needed to ac- commodate movements alone. Selection ofthe most appropriate materials for a particular ‘application is nota simple matter in view of all the variables involved. Once an understanding is gained ofthe basic prop- ries of materials required, then available materials can be classified and related to their suitability in various types of ints. This information is conveniently displayed in a series ‘of tables and is cross referenced in later figures which illus- trate the details of various joint applications in concrete structures. This chapter discusses field molded sealing materials used where one surface of the finished joint is open to permit the scaling operation, Sealants used for these applications are listed in Table 1. The joint design for an expansion (isolation) Joint may consist ofa filler strip below the area where the sealant will be placed, bond breaker material to separate the Sealant from an adhering substrate, and backup materials to ‘support the material from sagging. These appurtenant mate- rials are listed in Table 2. Preformed materials used in joints ‘open on at least one surface, materials used as water stops and. ‘gaskets are listed in Table 3. ‘Table 4 shows some of the current uses to which the vari- ‘ous sealants are put, and consideration of storage and han- dling for installation. tn cross-referencing types of materials the Roman numeral system is used in Tables { and 4 and in Fig. 710 2. Individual feld-molded sealant materials are let- tered A. B, C, and so on, as in Table I. Individual preformed sealant materials are identified by numbers given in Table 3. ‘Appendix C lists various specifications and sources of cur rent specifications. 3.2—Required properties of joint sealants For satisfactory performance a sealant must: 1. Be an impermeable materi 2, Deform to accommodate the movement and rate of ‘movement occurring atthe joint 3. Sufficiently retain its original properties and shape if subjected to cyclical deformations. 4. Adhere to conerete. This means that forall sealants, ex- cept those preformed sealants that exert a force against the “(1 )LNIOP JO LN3W3AON s04R.30 ‘wo faces. Itis usually considered that for installations made ‘tnormal temperatures of 40 to 90 F (4 to 32 C) the thickness. of the sealant should be at least one half the anticipated move- ‘ment and where higher or lower temperatures prevail at in- stallation, the thickness ofthe sealant should be equal to the anticipated movement, Where there will be no movement, the sealant thickness can be as little as Min, (3.2. mm), How- ever, in assembling concrete units a minimum thickness of 4 in. (6.4 mm) is desirable to compensate for casting toler- ‘ances or any irregularities in the faces. 4.8—Shape and size of rigid waterstops “Metal waterstops may be either flat stock or folded in Z or M cross-sectional shapes. The choice depends on the move- ‘ment a the joint. End anchored flat shapes permit little or no ‘movement without inducing excessive stresses in the embed- ded portion of the waterstop. Coating one end with asphalt to Permit sliding yet maintain some sealing compatibility may ‘not be entirely satisfactory because leaks may eventually oc- yt The Z cross section can accommodate slight movements aha the M cross section greater movements. .8—Shape and size of flexible waterstops For certain applications, flat shapes may be used but the traditional shape for flexible waterstops has a dumbbell con- figuration at cach end intended to serve both as an anchor and, by pulling it inwards towards the joint as it opens, it acts as a “cork in a bottle” type of seal. This seal is not too effec- tive at small openings and the material is in considerable ten- sion at wider joint openings. To overcome these problems, 4uite elaborate shapes have been developed in recent years, Numerous ribs at the end now provide better anchoring and seating, and O or U bulbs at the joint gap permit considerable Joint movements to be accommodated without unduly Stretching the material. Manufacturers may be helpful with recommendations. For easier installation, both rubber and PVC waterstops are often specified in thicknesses greater than that required for “ir function a sealants 4.10—Shape and size of gaskets and miscellaneous seals ‘Seals used for concrete pipes or building components are usually sized and shaped to suit the joint configuration in- cluding the irregularity of the surfaces being joined. Since the movement is small, the width ofthe sealant may not be the primary consideration. Square, rectangular, trapezoidal, ‘O-ring and H, U and W purposely made shapes, some with ribs, flanges and serrations, are used depending on the ap- plication and how they can be installed. Pressure sensi tapes of suitable widths are used as auxiliary materials to ‘make window and door frames or panels weathertight. 4.11—Measurement of joint movements A better understanding of in-service joint movements in all types of concrete structures is needed in order to confirm the theories and laboratory experiments upon which the design prediction ofjoine widths and sealant performance are based. ‘The factors which influence the.movement of joints and the functional performance of sealants are discussed in Chapters Vand 2 and the preceding part of Chapter 4. MANUAL OF CONCRETE PRACTICE In view of the many variables involved. itis impossible to Specify a standard procedure for the observation and assemn- bly of data on joint movements, the causative factors and sealant behavior. However, itis important that both the short {erm rates of movement over a matter of hours or days and the long term extremes of movernents over the annual environ- ‘mental cycle together with any permanent changes in inter. facial join distance are established 4.11.1 Means of measuring joint movements—Hand ‘gages, cither a simple vernier caliper or reference bar with a dial gage, may be used to measure the distance between refer- ‘ence plugs set on each side ofthe joint. While this system is. simple it only provides a discontinuous record and requires, ‘an operator to make each reading. To overcome these disad- vantages a scratch gage may be employed. These gages have ' scratch probe fixed to one side ofthe joint opening and 2 plate or a hand or power rotated disc aitached to the other Side. The trace of the movement over the movement cycle is then measured. The next stage of sophistication is to use an electronic gage. Usually this isa transducer (or LVDT for sreater precision ata greater cost) to measure the movement Which is then recorded continuously or intermittently ona strip chart or digitally for later analysis, In most structures the measured movement of concem to sealant performance is horizontal (across the plane of the Join). In skewed joints, lateral movement (along the plane of the joint) may also need to be measured or calculated since a skew introduces shear inthe sealant. Vertical movements (at right angles tothe plane ofthe joint) can be measured by fast. fesponse transducers where, as in pavements, moving loads ‘ross the joint. Measurement of other dynamic effects such as vehicle braking, impact and noise generation require spe- ized instruments, Absolute measurements of the relative positions of struc- tural members can be made using standard survey practice techniques against a reference datum clear ofthe structure. 4.11.2 Corresponding measurements of temperature and ‘moisture content—Corresponding data on the thermal and ‘moisture dependen: behavior of abutting structural units are ‘needed to fully interpret joint movement measurements. Re- sponse to ambient temperature change and solar radiation is ‘much greater and faster than that due to seasonal changes in ‘moisture content in the concrete. Since moisture content is difficult to measure and is unlikely to significantly affect the ‘overall findings, itis often ignored ‘Where a continuous record is needed, ambient, surface or intemal temperatures are easy to measure by thermocouples and record on a strip chart or digitally for analysis. Itmust be ‘remembered that, while surface temperature changes induce ‘warping and curling fairly rapidly in thin sections, the inter- nal temperatures ofa structural unit control its overall dimen- sions and hence the end movernents at joints. Especially ‘massive concrete sections there is @ considerable time lag be- (ween change in external and internal temperatures. This must be taken into account in determining any corre- spondence between temperature and movement measure- ‘ments. In massive sections or where the structural configura- tion is complex or where differential heating because of sun and shade is significant it may be prudent also to measure heat flow and solar radiation. Notwithstanding all these ca. tions, as a minimum observation, a thermometer reading of ace tvnismeeiL i ms 58k JOINT SEALANTS, ambient shade temperature should accompany any single ‘measurement of joint width. 4.11.3 Survey of int sealant performance—In addition 10 the measurement of movements and the factors that cause these movements. itis important to note the condition of the installed sealant, joint hardware and abutting concrete as part ‘of any overall appraisal of joint performance. CHAPTER 5—JOINT DETAILS 5.1—Introduction Fig. 7 through 12 illustrate the application of joint sealants toa wide variety of design configurations which occurin con- crete construction (for a key to symbols see Appendix A), ‘The details shown are representative of current practice and cover most standard variations, although other variations in tuse may not be shown. These details ae presented in outline form, omitting for the sake of clarity structural details such as reinforcing steel, dowels, etc., not directly relevant to the sealing of the joint. The location of a join is indicated only ‘where thisis significant to delineate the type of joint and seal- ant that may be suitable. As stated in Sections 1.5 and4.2, the location and spacing of joints for particular applications is beyond the scope of this guide. Similarly, sealant reservoirs (grooves) and expansion or contraction gaps are not dimen- sioned as to width or depth because differing sealants have & wide range of performance capabilities. The required config- uration should be determined as outlined in Chapter 4 and/or ‘may be obtained from suppliers literature. Exposure and environmental service conditions are shown foreach group of applications. since thi is an important con- sideration in selecting a suitable sealant. Often. alternatives exist for a particular application. ‘Therefore no endorsement is intended for selecting one detait ‘over another, or choosing one sealant rather than another. The ‘Buide does endorse and promote those standard design fea- \ tures documented throughout the guide (e.g.. improving the ‘shape factor of field-molded sealants) that will insure the best possible performance of any given seal or sealant. 5.2—Structures Fig. 7 and 8 cover applications to structures in general and ‘buildings in particular, where sealing agains significant Aid pressure is not a consideration. Where ground water must be ‘excluded, as for example in basements or earth-reteining walls, reference should also be made to Fig. II since addi- tional sealing using waterstops may be indicated. Since the appearance of sealed joints in many buildings is important, additional architectural treatment not shown in the figures, for example, V-ing of joint edges may be required. Bridge deck joints are trested separately in Fig. 9, since large movements and special sealing problems are often in- volved. Joint details suitable for bridge substructures gener- ally follow those in Fig. 7. or where water pressure is in- volved those shown in Fig. 11 Containers ofall types are covered in Fig. 10 and 11. Ex: cept where the head is small, the use of waterstops in “in place construction” or gaskets under compression for precast Pipes is almost essential ifthe contents are to be kept i, In s06nat certain uses, for example dams, a second waterstop may be used some distance behind the first as an additional line of insurance against premature failure. Many of the details shown in Fig. 10 and 11 also serve ‘equally well for keeping water which is outside the structure from passing through the joint tothe inside face. The exclu- sion of water from basements. subways and tunnels are exarn- ples of this application. Tunnel epplications are discussed i ereater detail in ACI $04.1R. 5.3—Slabs on grade, highway, and airports Slabs on grade are shown in Fig. 12. These may be outside as on highways, parking garages and airports, or they may be within a building or container with the modifications indi- cated in the figures specific to these applications. Many highway authorities are specifying short contraction joint spacings in both plain ané reinforced concrete pave- ments; some are using a random spacing averaging between 15 and 20 ft (4.57 and 6,10 m) in plain pavements for which the repeating series 13, 18, 19, 12 ft (4.0, 5.5, 5.8, 3.7 m)is popular; some ae also skewing joints at 2 fin 12ft (0.61 min 3.66 m). While the objectives are reducing intermediate slab cracking and improving ride and load transfer, such designs. place less demand on the sealant because of the smaller ‘movement that occurs at each joint. Fuller information on the design and construction of joints in concrete pavements will be found in the reports of ACI Committee 325. 5.4—Construction and installation considerations. ‘The practical aspects of constructing the joint and sealing it must be kept in mind when its details are being designed. ‘The general construction steps for any expansion, contrac tion and construction joint are stated in Fig. 12. The method ‘of making monolithic construction joints is outlined in Fig. 7 (@) Fig. 9 (2B) shows the blockout required where later in- stallation of expansion joint devices is planned. The position- ‘of waterstops is shown in Fig. 11 (4) and further discus- sion on their installation and that of sealants in general follows in Chapter 6. It must be remembered that a joint de- tail that makes it unnecessarily dificult to install the sealant is a poor one likely to lead to premature failure. CHAPTER 6—INSTALLATION OF SEALANTS 6.1—Introduction ‘The most appropriate technique for installing (applying) a Joint sealant depends on the material, the width, shape. in- clination, and accessibility ofthe joint and on whether it is 2 ‘small or large project. Each stepin the construction and prep- aration of the joint to receive the sealant and for its instal tion requires careful workmanship and thorough inspection toavoid initial defects that may be costly and time consuming tocomect, ‘The specification for the work should state how the se- lected sealant is to be installed and any special features re- uired in the construction or preparation of the joint to re- ceive it. Before the containers of sealant are opened. their labels should be checked to make sure that the right sealant has been supplied and that there is no conflict between the S04R-32 specification and the manufacturer's instructions for instala- tion. Any discrepancy should be referred to the architect or engineer before work commences. ‘The most auspicious time for installing field-molded se ants, if the construction schedule permits, is on dry days ‘When the temperature is close to the annual mean. Compres~ sion seals, especially the large ones, are easiest to install on cold days, However, a satisfactory job can and usually must bbe done in less than ideal conditions provided the effects of this are compensated for in the design ofthe joint. Sealant storage and installation requirements are summa- Fized for each material in Table 4. These operations are dis- ‘cussed in greater detail as follows, 6.2—Joint construction with sealing in mind ‘Some ofthe defects resulting from improper concrete joint construction are shown in Fig. 16. These and others can be avoided by the following: 1. Saw or form the joint to the required (and uniform) \L depth, width and location shown on the plans, Manufacture precast units to close tolerances and position them carefully. 2. Align the joint with any connecting joints to avoid blockage to free movement. 3. Judge the time of sawing to avoid edge spalling or plucked aggregate (too early or random cracks (t00 late) 4. Correctly position dowels and other joint hardware, fill. ‘ers, waterstops and bulkheads, and rigidly support them to avoid displacement during concreting. 5. Remove any temporary material or filler used to form the sealant reservoir by raking out or rotary cutting to the specified depth 6. Keep curing compound and other materials from con- ‘aminating joint faces. Apply supplemental curing where the l curing is broken by construction operations before the joint edges and faces have fully cured, 6.3—Preparation of joint surfaces Joint faces must be clean and free of defects that would im- \ air bond with field-motded sealants or prevent uniform con- ‘tact of preformed sealants. Removal of contaminants may re- Quire washing out of debris eft by sawing and wire brushing or routing and sand blasting. Though sand blasting is more expensive, it is more likely to succeed and therefore is wat fanted where relatively expensive thermosetting, chemical ‘curing feld-motded sealants are used. Solvents intended to remove oil, etc, usvally have the op- posite effect and carry the contaminants further into the pores ofthe concrete, Solvents are, however, distinctly useful in cleaning nonporous surfaces such as glass or metal frames. Defects inthe joint faces such as loose aggregate, embedded foreign material and spalls inthe case of compression seals or blockages to free movement require repair (see Section 7.2.1), Final cleanup to remove dust is usually required. This is essential where a good bond must be developed with chem- ically curing thermosetting field-molded sealants. Final

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