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  • 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


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