Section 03290 JOINTS IN CONCRETE

Section 03290

_{JOINTS IN CONCRETE}

PART 1 - GENERAL

1.1 THE REQUIREMENT

A. The CONTRACTOR shall construct all joints in concrete at the locations shown. Joints required in concrete structures are of various types and will be permitted only where shown, unless specifically accepted by the ENGINEER.

1.2 RELATED WORK SPECIFIED ELSEWHERE A. Section 03100, Concrete Formwork

B. Section 03200, Reinforcement Steel

C. Section 03300, Cast-in-Place Concrete

D. Section 07900, Joint Sealants

1.3 REFERENCE SPECIFICATIONS, CODES, AND STANDARDS

A. Comply with the reference Specifications of the General Requirements and Additional

General Requirements.

B. Comply with the current provisions of the following Codes and Standards.

1. Federal Specifications:

TT-S-0227E(3) Sealing Compound, elastomeric type, Multi- component for Caulking, Sealing, and Glazing Buildings and Other Structures

2. Commercial Standards:

ASTM C 920 Specification for Elastomeric Joint Sealants

ASTM D 624 Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers

ASTM D 638 Test Method for Tensile Properties of Plastics

ASTM D 746 Test Method for Brittleness Temperature of

Plastics and Elastomers by Impact

ASTM D 747 Test Method for Apparent Bending Modulus of

Plastics by Means of a Cantilever Beam

ASTM D 1752 Specification for Preformed Sponge Rubber Cork and Recycled PVC Expansion Joint Fillers for Concrete Paving and Structural Construction

ASTM D 2240 Test Method for Rubber Property -- Durometer

Hardness

1.4 CONTRACTOR SUBMITTALS

A. Submittals shall be made in accordance with General Requirements and Additional

General Requirements.

B. The following submittals and specific information shall be provided.

1. Waterstops: Prior to use of the material required under this contract, qualification samples shall be submitted. Such samples shall consist of extruded or molded sections of each size or shape to be used. The material sample shall be representative of the material to be furnished under this contract. The balance of the material to be used under this contract shall not be produced until after the ENGINEER has reviewed and accepted the qualification samples. The CONTRACTOR shall obtain from the waterstop manufacturer and shall furnish to the ENGINEER for review, current test reports and a written certification of the manufacturer that the material to be shipped to the job meets the physical requirements as outlined in the U.S. Army Corps of Engineers Specification CRD- C572 and those listed herein.

2. Joint Sealant: Prior to ordering the sealant material, the CONTRACTOR shall submit to the ENGINEER for review and acceptance, data to show compliance with the requirements of the Contract Documents. Certified test reports from the sealant manufacturer indicating compliance with the above requirements shall be furnished to the ENGINEER before the sealant is used on the job.

3. Preformed Expansion Joint Material: The CONTRACTOR shall submit to the ENGINEER for sufficient information to determine whether or not the material the CONTRACTOR proposes to use meets the requirements of the Contract Documents.

4. Shipping Certification: The CONTRACTOR shall provide written certification from the manufacturer to show that all of the material shipped to this project meets or exceeds the physical property requirements of the Contract Documents. Supplier certificates are not acceptable.

5. The CONTRACTOR shall submit placement shop drawings showing the location and type of all joints for each structure.

1.5 QUALITY ASSURANCE

A. Waterstop Inspection: It is required that all waterstop field joints shall be subject to inspection, and no such work shall be scheduled or started without having made prior arrangements with the ENGINEER to provide for the required inspections. Not less than

_{24 hours notice shall be provided to the ENGINEER for scheduling such inspections.}

B. All field joints in waterstops shall be free of misalignment, bubbles, inadequate bond, porosity, cracks, offsets, and other defects, which would reduce the potential resistance of the material to water pressure at any point. All defective joints shall be replaced with material which shall pass said inspection, and all faulty material shall be removed from the site and disposed of by the CONTRACTOR at its own expense.

C. The following waterstop defects represent a partial list of defects which shall be grounds for rejection:

1. Offsets at joints greater than 1/16-inch or 15 percent of material thickness, at any point, whichever is less.

2. Exterior crack at joint, due to incomplete bond, which is deeper than 1/16-inch or

15 percent of material thickness, at any point, whichever is less.

3. Any combination of offset or exterior crack which will result in a net reduction in the cross section of the waterstop in excess of 1/16-inch or 15 percent of material thickness at any point, whichever is less.

4. Misalignment of joint which result in misalignment of the waterstop in excess of

1/2 inch in 10 feet.

5. Porosity in the welded joint as evidenced by visual inspection.

6. Bubbles or inadequate bonding.

D. Waterstop Samples: The submitted samples shall be fabricated so that the material and workmanship represent in all respects the fittings to be furnished under this contract. Field samples of fabricated fittings (crosses, tees, etc.) will be selected at random by the ENGINEER for testing. When tested, they shall have a tensile strength across the joints equal to at least 600 pounds per inch.

E. Construction Joint Sealant: The CONTRACTOR shall prepare adhesion and cohesion test specimens as specified herein, at intervals of 5 working days while sealants are being installed.

F. The sealant material shall show no signs of adhesive or cohesive failure when tested in accordance with the following procedure in laboratory and field tests:

1. Sealant specimen shall be prepared between 2 concrete blocks (1-inch x 2-inch x

3-inch). Spacing between the blocks shall be 1/2 inch. Coated spacers (2-inch x 1-

1/2-inch x 1/2 inch) shall be used to insure sealant cross-sections of 1/2-inch x 2 inches with a width of 1/2 inch.

2. Sealant shall be cast and cured according to manufacturer's recommendations except that curing period shall not exceed 24 hours.

3. Following curing period, the gap between blocks shall be widened to one inch. Spacers shall be used to maintain this gap for 24 hours prior to inspection for failure.

1.6 TYPES OF JOINTS

A. Construction Joints: When fresh concrete is placed against a hardened concrete surface, the joint between the two pours is called a construction joint. Unless otherwise specified, all joints in water bearing members shall be provided with a waterstop and sealant groove of the shape specified and as shown on the Plans.

B. Contraction Joints: Contraction joints are similar to construction joints except that the fresh concrete shall not bond to the hardened surface of the first pour, which shall be coated with a bond breaker. The slab reinforcement shall be stopped 4-1/2 inches from the joint; which is provided with a sleeve-type dowel, to allow shrinkage of the concrete of the second pour. Waterstop and sealant groove shall also be provided.

C. Expansion Joints: To allow the concrete to expand freely, a space is provided between the two pours, the joint shall be formed as shown on the Plans. This space is obtained by placing a filler joint material against the first pour, which acts as a form for the second pour. Unless otherwise specified, all expansion joints in water bearing members shall be provided with an approved type waterstop.

Premolded expansion joint material shall be installed with the edge at the indicated distance below or back from finished concrete surface, and shall have a slightly tapered, dressed, and oiled wood strip secured to or placed at the edge thereof during concrete placement, which shall later be removed to form space for sealing material. The space so formed shall be filled with a joint sealant material as specified in the Paragraph in Part 2 entitled "Joint Sealant." In order to keep the two elements in line the joint shall be provided with a sleeve-type dowel as shown.

D. Control Joints: The function of the control joint is to provide a weaker plane in the concrete, where shrinkage cracks will probably occur. A groove, of the shape and dimensions as shown on the Plans, is formed or saw-cut in the concrete and shall be filled with a joint sealant material as specified in the Paragraph in Part 2 entitled "Joint Sealant."

1.7 GUARANTEE

A. The CONTRACTOR shall provide a 5-year written guarantee of the entire sealant installation against faulty and/or incompatible materials and workmanship, together with a statement that it agrees to repair or replace, to the satisfaction of the ENGINEER, at no additional cost to the OCSD, any such defective areas which become evident within said

5-year guarantee period.

PART 2 - PRODUCTS

2.1 PVC WATERSTOPS

A. General: Waterstops shall be extruded from virgin elastomeric polyvinyl chloride (PVC) compound containing plasticizers, resins, stabilizers, and other materials necessary to meet the requirements of these Specifications. Waterstops shall be 6- or

9-inches wide with a 3/4-inch diameter hollow-center bulb, dumbbell-type, as shown on the Plans. No reclaimed or scrap material shall be used.

B. Flatstrip and Center-Bulb Waterstops: Flatstrip and center-bulb waterstops shall be as detailed and as manufactured by: Kirkhill-TA; Greenstreak; Progress Unlimited, Inc.; Or Equal; provided, that at no place shall the thickness of flat strip waterstops, including the center bulb type, be less than 3/8-inch.

C. Multi-Rib Waterstops: Multi-rib waterstops, where required, shall be as detailed and as manufactured by Greenstreak; Progress Unlimited, Inc.; Or Equal. Prefabricated joint fittings shall be used at all intersections of the ribbed-type waterstops.

D. Other Types of Waterstops: When other types of waterstops, not listed above are required and shown, they shall be subjected to the same requirements as those listed herein.

E. Waterstop Testing Requirements: When tested in accordance with the specified test standards, the waterstop material shall meet or exceed the following requirements:

Physical Property, Sheet Material	Requirement	Standard
Specific Gravity	Not Less Than 1.3	ASTM D 792
Tensile Strength-min (pounds per inch)	1,400	ASTM D 638
Ultimate Elongation-min (percent)	250	ASTM D 638
Low Temp Brittleness-max (degrees F)	-35	ASTM D 746
Stiffness in Flexure-min (pounds per inch)	400	ASTM D 747
Accelerated Extraction-min	1,500	CRD-C-572
Alkali Extraction, 7-day Weight Change	Not more than –0.1 percent to +0.25	CRD-C-572
T ype A Shore Durometer, Hardness	70-90	ASTM D 2240

F. Six-inch waterstops shall weigh not less than 130 pounds per 100 linear feet. Nine- inch waterstops shall weigh not less than 200 pounds per 100 linear feet. Thickness shall be 3/8 inch. Allowable tolerances are: width – plus or minus 3/16-inch; thickness – plus or minus 1/32-inch.

2.2 JOINT SEALANT

A. Joint sealant shall be polyurethane polymer designed for bonding to concrete continuously submerged in water.

B. Joint sealant material shall meet the following requirements:

W ork Life	45 – 90 Minutes
T ime to Reach 20 Shore “A” Hardness (At 77 degrees F,2000 gr quantity)	24 Hours, Maximum
Ultimate Hardness	30 – 40 Shore “A”
Tensile Strength	225 pounds per inch, minimum
Ultimate Elongation	400 percent, minimum
Tear resistance (Die C ASTM D 624)	75 pounds per inch of thickness, minimum
Color	Light Grey

C. All polyurethane sealants for waterstop joints in concrete shall conform to the following requirements:

1. Sealant shall be 2-part polyurethane with the physical properties of the cured sealant conforming to or exceeding the requirements of ASTM C 920 or Federal Specification TT-S-00227 E(3) for 2-part material, as applicable.

2. For vertical joints and overhead horizontal joints, only "non-sag" compounds shall be used; all such compounds shall conform to the requirements of ASTM C 920

Class B, or Federal Specification TT-S-00227 E(3), Type II.

3. For plane horizontal joints, the self-leveling compounds which meet the requirements of ASTM C 920 Class A, or Federal Specification TT-S-00227 E(3), Type I shall be used. For joints subject to either pedestrian or vehicular traffic, a compound providing non-tracking characteristics, and having a Shore "A" hardness range of 25 to 35, shall be used.

4. Primer materials, if recommended by the sealant manufacturer, shall conform to the printed recommendations of the sealant manufacturer.

D. Sealants, wherever shown, or required hereunder shall be Pacific Polymers Elasto- thane 227R; LymTal International Iso-Flex 880GB/881; Or Equal.

E. Sealants for non-waterstop joints in concrete shall conform to the requirements of

Section 07900, Joint Sealants.

2.3 PREFORMED JOINT FILLER

A. Preformed joint filler material shall be of the preformed non-extruding type joint filler constructed of cellular neoprene sponge rubber or polyurethane of firm texture. All non- extruding and resilient-type preformed expansion joint fillers shall conform to the requirements and tests set forth in ASTM D 1752 for Type I, except as otherwise specified herein.

B. Bituminous Fiber Expansion Joint Filler: Bituminous fiber expansion joint filler shall not be used unless called for in the Specifications or shown on the Drawings. Bituminous fiber expansion joint filler shall be in accordance with ASTM D 1751. Bituminous expansion joint material shall not be used in joints to be sealed with synthetic rubber sealing compound.

2.4 BACKING ROD

A. Backing rod shall be an extruded closed-cell, polyethylene foam rod or an expanded closed-cell sponge rubber, manufactured from a synthetic polymer neoprene base. The material shall be compatible with the joint sealant material used and shall have a tensile strength of not less than 40 pounds per inch and a compression deflection of approximately 25 percent at 8 pounds per inch. The diameter of the filler rod shall be 25 percent greater than the nominal joint width.

B. Filler rod shall be Sonolastic Backer Rod manufactured by BASF Sonneborn, Inc., or Durafoam manufactured by Monmouth Rubber & Plastics Corp., Or Equal. The manufacturer's instructions for surface preparation and application shall be used as a guide for installation, except that the material shall not be installed by stretching beyond its normal length.

2.5 BOND BREAKER

A. Bond breaker shall be Super Bond Breaker as manufactured by Dayton Superior Edoco, Miamisburg, Ohio; Silcoseal by Nox-Crete Products, Omaha, NE; Or Equal. It shall contain a fugitive dye so that areas of application will be readily distinguishable.

2.6 BENTONITE WATERSTOP

A. Where called for in the Contract Documents, bentonite type waterstop, which shall expand in the presence of water to form a watertight joint seal without damaging the concrete in which it is cast, shall be provided.

B. The bentonite waterstop shall be composed of 75 percent bentonite. The balance of the material shall be butyl rubber-hydrocarbon with less than 1.0-percent volatile matter. The waterstop shall contain no asbestos fibers or asphaltics.

C. The manufacturer's rated application temperature range shall be from 5 to 125 degrees F. The service temperature range shall be from -40 to 212 degrees F.

D. The cross sectional dimensions of the unexpanded waterstop shall be one inch by

3/4-inch.

E. The waterstop shall be provided with an adhesive backing, which will provide excellent adhesion to concrete surfaces.

PART 3 - EXECUTION

3.1 GENERAL

A. Unless otherwise shown, waterstops of the type specified herein shall be embedded in the concrete across joints as shown. All waterstops shall be fully continuous for the extent of the joint. Splices necessary to provide such continuity shall be accomplished in conformance to printed instructions of manufacturer of the waterstops. The CONTRACTOR shall take suitable precautions and means to support and protect the waterstops during the progress of the Work and shall repair or replace at its own expense any waterstops damaged during the progress of the Work. All waterstops shall be stored so as to permit free circulation of air around the waterstop material.

3.2 JOINTS

A. Joints in concrete work shall be of the type and in the position indicated on the Contract Documents. No change in the joint position will be allowed unless accepted by the ENGINEER.

B. All joints in concrete shall be thoroughly cleaned by sandblasting, including reinforcing steel, of all laitance, grease, oil and dirt prior to commencing concrete placement. The CONTRACTOR shall obtain acceptance of the joint details prior to commencing the next pour.

3.3 WATERSTOPS

A. Waterstops of the type specified shall be installed in all joints within water bearing walls, walls exposed to groundwater, and all slabs, and as shown on the Plans.

B. Installation of waterstop, joint sealing and caulking materials shall be performed in accordance with Section 07900, Joint Sealants.

C. Waterstops in the walls shall be carried into lower slabs and shall join the waterstops in the slabs. All waterstops shall be continuous. Waterstops shall be set accurately to the position and line indicated on the Contract Documents. Edges shall be held and securely fixed in position at intervals of not more than 24 inches so that they will not move during the placing of the concrete. No nails shall be driven through the waterstops.

D. Wires at not more than 24 inches on center in the outer bulbs shall be used to tie the waterstops into position. Suitable clips may be used in lieu of wires, at the CONTRACTOR’s discretion.

E. When any waterstop is installed in the concrete on one side of a joint, while the other half or portion of the waterstop remains exposed to the atmosphere for more than 2 days, suitable precautions shall be taken to shade and protect the exposed waterstop from direct rays of the sun during the entire exposure and until the exposed portion of the waterstop is embedded in concrete.

3.4 SPLICES IN WATERSTOPS

A. Splices in waterstops shall be performed by heat sealing the adjacent waterstop sections in accordance with the manufacturer's printed recommendations and the following requirements:

1. The material shall not be damaged by heat sealing. Care shall be taken during the heating process to not burn or char the waterstop material. Charred areas in a spliced joint are unacceptable.

2. The splices shall have a tensile strength of not less than 60 percent of the unspliced materials tensile strength.

3. The continuity of the waterstop ribs and of its tubular center axis shall be maintained.

4. Splicing of waterstops shall be performed using a Teflon-covered heating iron operating at a temperature of 400 degrees F. Waterstops shall be cut with a saw absolutely straight so that no gaps will exist between the edges after they are spliced together. The heating iron shall be placed between the spliced ends and remain there until at least a 1/8 inch melted bead is produced. The edges shall be quickly held together until cooled. The newly spliced joint shall not be moved for at least 5 minutes after joining. Alternate methods of splicing may be submitted to the ENGINEER for review.

B. Butt joints of the ends of two identical waterstop sections may be made while the material is in the forms.

C. All joints with waterstops involving more than 2 ends to be jointed together, and all joints which involve an angle cut, alignment change, or the joining of 2 dissimilar waterstop sections shall be prefabricated by the CONTRACTOR prior to placement in the forms, allowing not less than 24-inch long strips of waterstop material beyond the joint. Upon being inspected and accepted, such prefabricated waterstop joint assemblies shall be installed in the forms and the ends of the 24-inch strips shall be butt welded to the straight run portions of waterstop in place in the forms.

3.5 JOINT CONSTRUCTION A. Setting Waterstops:

1. In order to eliminate faulty installation that may result in joint leakage, particular care shall be taken of the correct positioning of the waterstops during installation. Adequate provisions shall be made to support the waterstops during the progress of the Work and to insure the proper embedment in the concrete. The symmetrical halves of the waterstops shall be equally divided between the concrete pours at the joints. The center axis of the waterstops shall be coincident with the joint openings. Maximum density and imperviousness of the concrete shall be insured by thoroughly working it in the vicinity of all joints

2. In placing flat-strip waterstops in the forms, means shall be provided to prevent them from being folded over by the concrete as it is placed. Unless otherwise shown, all waterstops shall be held in place with light wire ties on 24-inch centers which shall be passed through the edge of the waterstop and tied to the curtain of reinforcing steel. Horizontal waterstops, with their flat face in a vertical plane, shall be held in place with continuous supports to which the top edge of the waterstop shall be tied. In placing concrete around horizontal waterstops, with their flat face in a horizontal plane, concrete shall be worked under the waterstops by hand so as to avoid the formation of air and rock pockets.

3. Adequate means shall be provided for anchoring the waterstop in concrete. Waterstops shall be positioned so that they are equally embedded in the concrete on each side of the joint.

B. Joint Location:

1. Construction joints, and other types of joints, shall be provided where shown. When not shown, construction joints shall be provided at 25-foot maximum spacing for all concrete construction, unless noted otherwise. Where joints are shown spaced greater than 25 feet apart, additional joints shall be provided to maintain the 25-foot maximum spacing. The location of all joints, of any type, shall be submitted for acceptance by the ENGINEER.

C. Joint Preparation:

1. Special care shall be used in preparing concrete surfaces at joints where bonding between two sections of concrete is required. Unless otherwise shown, such bonding will be required at all horizontal joints in walls. Surfaces shall be prepared in accordance with the requirements of Section 03300, Cast-in-Place Concrete. Except on horizontal wall construction joints, wall to slab joints or where otherwise shown or specified, at all joints where waterstops are required, the joint face of the first pour shall be coated with a bond breaker as specified herein.

D. Construction Joint Sealant:

1. Construction joints in water-bearing floor slabs, and elsewhere as shown, shall be provided with tapered grooves which will be filled with construction joint sealant. The material used for forming the tapered grooves shall be left in the grooves until just before the grooves are cleaned and filled with joint sealant. After removing the forms from the grooves, all laitance and fins shall be removed, and the grooves shall be sand-blasted. The grooves shall be allowed to become thoroughly dry, after which they shall be blown out; immediately thereafter, they shall be primed and filled with the construction joint sealant. The primer used shall be supplied by the same manufacturer supplying the sealant. No sealant will be permitted to be used without a primer. Care shall be used to completely fill the sealant grooves. Areas designated to receive a sealant filler shall be thoroughly cleaned, as outlined for the tapered grooves, prior to application of the sealant.

2. Expansion joint filler shall be held in place by glue. Nails shall not be driven through the filler material.

3. Sealant application shall be in accordance with the manufacturer's printed instructions. The surfaces of the groove for the sealant shall not be coated. Concrete next to waterstops shall be placed in accordance with the requirements of Section 03300, Cast-in-Place Concrete.

4. The primer and sealant shall be placed strictly in accordance with the printed recommendations of the manufacturer, taking special care to properly mix the sealant prior to application. All sealant shall cure at least 7 days before the structure is filled with water.

5. All sealant shall be installed by a competent waterproofing specialty CONTRACTOR who has a successful record of performance in similar installations. Before work is commenced, the crew doing the Work shall be instructed as to the proper method of application by a representative of the sealant manufacturer.

6. Any joint sealant which after the manufacturer's recommended curing time for the job conditions of the Work hereunder, fails to fully and properly cure shall be completely removed; the groove shall be thoroughly sandblasted to remove all traces of the uncured or partially cured sealant and primer, and shall be re-sealed with the specified joint sealant. All costs of such removal, joint treatment, re-sealing, and appurtenant work shall be at the expense of the CONTRACTOR.

E. Bentonite Waterstop:

1. Where a bentonite waterstop is called for in the Contract Documents, it shall be installed with the manufacturer's instructions and recommendations; except, as modified herein.

2. When requested by the ENGINEER, the CONTRACTOR shall arrange for the manufacturer to provide technical assistance in the field.

3. The bentonite waterstop shall be located as near as possible to the center of the joint and it shall be continuous around the entire joint.

4. Where a bentonite waterstop is used in combination with PVC waterstop, the bentonite waterstop shall overlap the PVC waterstop for a minimum of 6 inches and shall be placed in contact with the PVC waterstop.

5. The bentonite waterstop shall not be placed when the temperature of the waterstop material is below 40 degrees F. The waterstop material may be warmed so that it shall remain above 40 degrees F during placement; however, means used to warm the material shall in no way harm the material or its properties. The waterstop shall not be installed where the air temperature falls outside the manufacturer's recommended range.

6. The bentonite waterstop shall be secured in place with concrete nails and washers at 12-inch maximum spacing. This shall be in addition to the adhesive backing provided with the waterstop.