UNIVERSAL-90’s WALLS Above Grade Watertight by design©

Prefabricated Transitions

Universal-90’s Transitions and Terminations are patented, factory-fabricated, single-piece 90° units constructed from the same materials as the connecting precompressed expansion joint system. Bellows are constructed on both sides allowing a waterseal in an inner or outer 90° corner. This single unit achieves the greatest possible continuity of seal in transitions in planes, avoiding the limitations of field-made joins. Using Universal 90’s in your expansion joint design ensures continuity of seal. Installation time is reduced and the integrity of the seal is maintained. Universal-90’s are available for all coated EMSEAL products.

Some of the many applications: • Stadiums • Arenas• Parking decks • Floors• Deck-to-wall • Elevator tower perimeters• Deck-to-deck• Bridge expansion joints • Water tanks• Stair tower perimeters • Tunnels and enclosures

Continuity of Seal at Upturns, Downturns and Termination Points

US Patent: 9,200,437 Patent Pending

UNIVERSAL-90 Configurations

Horizontal-to- Vertical Downturn

Transitions

Horizontal-to- Vertical Upturn

Downturn-to- Vertical Overhang

Upturn-to-Vertical Rise

Terminations

EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581 PH: 508.836.0280 FX: 508.836.0281EMSEAL, LLC 120 Carrier Drive, Toronto, ON, Canada M9W 5R1 PH: 416.740.2090 FX: 416.740.0233

25

www.emseal.comToll Free 800-526-8365

Standard CAD details are available online at www.emseal.com. For application specific CAD details contact EMSEAL directly.

More Info @ Website

NEW Kickout Terminations direct water away from columns and elements.

c12) United States Patent Hensley et al.

(54) PRECOMPRESSED FOAM EXPANSION JOINT SYSTEM TRANSITION

(75) Inventors: Lester Hensley, Westborough, MA (US); Bill Witherspoon, Guelph (CA)

(73) Assignee: EMSEAL JOINT SYSTEMS LTD., Westborough, MA (US)

( *) Notice: Subject to any disclaimer, the term of this patent is extended or adjusted under 35 U.S.C. 154(b) by 80 days.

(21) Appl. No.: 12/635,062

(22) Filed: Dec.10,2009

Related U.S. Application Data

(60) Provisional application No. 61/121,590, filed on Dec. 11, 2008.

(51) Int. Cl. E04B 1168 (2006.01)

(52) U.S. Cl. CPC .................................... E04B 116812 (2013.01)

(58) Field of Classification Search CPC ......... EOlD 19/06; E04B 1/6812; E04B 1/68;

E04B 1/6815; E04B 1/948; E04D 11/02; E04D 13/151

USPC ........... 52/393, 396.04, 396.07, 586.1, 586.2, 52/741.4; 404/47, 68

See application file for complete search history.

(56) References Cited

U.S. PATENT DOCUMENTS

3,355,846 A 3,372,521 A 3,551,009 A * 3,670,470 A 3,672,707 A *

12/1967 Tillson 3/1968 Thorn

12/1970 Lester eta!. .................. 285/226 6/1972 Thorn 6/1972 Russo eta!. .................. 285/229

111111 1111111111111111111111111111111111111111111111111111111111111

CA DE

US009200437Bl

(10) Patent No.: (45) Date of Patent:

US 9,200,437 Bl Dec. 1, 2015

3,677,145 A 7/1972 Wattiez 3,934,905 A * 111976 Lockard ........................ 285/229 3,956,557 A 5/1976 Hurst 4,058,947 A 1111977 Earle eta!. 4,362,428 A 12/1982 Kerschner 4,401,716 A 8/1983 Tschudin-Mahrer 4,455,396 A * 6/1984 Al-Tabaqchall eta!. ....... 521154 4,566,242 A 111986 Dunsworth 4,637,085 A 111987 Hartkorn 4,773,791 A 9/1988 Hartkorn 4,781,003 A * 1111988 Rizza ......................... 52/396.07 4,916,878 A 4/1990 Nicholas 4,942,710 A 7/1990 Rumsey

(Continued)

FOREIGN PATENT DOCUMENTS

2640007 A1 3/2009 19809973 C1 7/1999

(Continued)

OTHER PUBLICATIONS

EMSeal, COLORSEAL, Jan. 2000, COLORSEAL TechData, p. 1-2.*

(Continued)

Primary Examiner- Elizabeth A Plummer (74) Attorney, Agent, or Firm- MKG LLC

(57) ABSTRACT

A water resistant expansion joint system for installation into a building joint in vertical and horizontal configurations is designed such that it can be used for either an inside or outside corner. The system comprises open celled foam having a water-based acrylic chemistry infused therein. A layer of an elastomer is disposed on the open celled foam and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The system is delivered to a job site in a pre-compressed state ready for installation into the building joint.

7 Claims, 6 Drawing Sheets

10

(56) References Cited

US 9,200,437 Bl Page 2

U.S. PATENT DOCUMENTS

2010/0275539 A1 2010/0319287 A1 2012/0117900 A1

1112010 Shaw 12/2010 Shaw

5/2012 Shaw

4,957,798 A * 5,094,057 A 5,115,603 A 5,130,176 A * 5,213,441 A * 5,249,404 A 5,327,693 A * 5,335,466 A 5,338,130 A 5,365,713 A 5,450,806 A * 5,508,321 A * 5,572,920 A 5,628,857 A 5,887,400 A 5,935,695 A * 6,014,848 A 6,128,874 A 6,460,214 B1 6,491,468 B1 * 6,499,265 B2 6,532,708 B1 * 6,860,074 B2 6,948,287 B2 7,114,899 B2 7,240,905 B1 7,748,310 B2 7,941,981 B2 8,171,590 B2 8,317,444 B1 8,341,908 B1 8,365,495 B1

2003/0110723 A1 * 2006/0030227 A1 * 2008/0193738 A1 *

9/1990 3/1992 5/1992 7/1992 5/1993

10/1993 7/1994 8/1994 8/1994

1111994 9/1995 4/1996

1111996 5/1997 3/1999 8/1999 112000

10/2000 10/2002 12/2002 12/2002 3/2003 3/2005 9/2005

10/2006 7/2007 7/2010 5/2011 5/2012

1112012 112013 212013 6/2003 2/2006 8/2008

Bogdany ......................... 428/95 Morris Blair Baerveldt . . . . . . . . . . . . . . . . . . . . . . 4 28/192 Baerveldt ........................ 404/66 Leek eta!. Schmid. Langohr Baerveldt Nicholas et a!.

52/396.D2

Jean . 114/74 A Brebner 523/179 Kennedy et a!. Baerveldt Bratek eta!. Baerveldt . . . . . . . . . . . . . . . . . . . . . . 4 28/218 Hilburn, Jr. Olson eta!. Chang Hagen ........................... 403/291 Shreiner Baerveldt . 52/396.05 Stanchfield Korn Gass eta!. Stahl, Sr. Kennedy Shaw Kim Hensley Hensley eta!. Witherspoon Baerveldt . 52/396.04 Hairston eta!. .............. 442/136 Hensley eta!. ............ 428/308.4

DE EP GB wo

FOREIGN PATENT DOCUMENTS

10200505437 5 A1 1118715 A1 2377379 A

2007024246 A1

5/2007 7/2001 112003 3/2007

OTHER PUBLICATIONS

EMSeal, COLORSEAL & SEISMIS COLORSEAL, May 1997, Install Data---COLORSEAL & SEISMIC COLORSEAL, p. 1-2.* Polyurethane Foam Field Joint Infill Systems, Sep. 23, 2007 (via Snagit), PIH, pp. 1-4. EMSeal Joint Systems, Drawing 010-0-00-00, Dec. 6, 2005. EMSeal Joint Systems, Techdata, Jun. 1997. Snagit Capture Polyurethane Foam Field Joint Infill Systems, Sep. 23, 2007. EMSeal Joint Systems, Drawing SJS-100-CHT-N, Nov. 20, 2007. EMSeal Technical Bulletin, Benchmarks of Performance for High­Movement Acrylic-Impregnated, Precompressed, Foam Sealants When Considering Substitutions, Jul. 3, 2012. EMSeal Material Safety Data Sheet, Apr. 2002. EMSeal, Is There a Gap in Your Air Barrier Wall Design?, Jul. 19, 2012. EMSeal, "Pre-cured-Caulk-And_Backerblock" Not New, Not Equal to EMSeal's COLORSEAL, Jul. 19,2012. Manfredi, Liliana; eta!. "Thermal degradation and fire resistance of unsaturated polyester, modified acrylic resins and their composites with natural fibres" Polymer Degradation and Stability 91; 2006; pp. 255-261. Stein, Daryl et a!. "Chlorinated Paraffins as Effective Low Cost Flame Retardants for Polyethylene" Dover Chemical Corporation.

* cited by examiner

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PRECOMPRESSED FOAM EXPANSION JOINT SYSTEM TRANSITION

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 61/121,590, filed on Dec. 11, 2008, the contents of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates generally to joint systems for use in concrete and other building systems and, more particu­larly, to expansion joints for accommodating thermal and/or seismic movements in such systems.

BACKGROUND OF THE INVENTION

Concrete structures and other building systems often incor­porate joints that accommodate movements due to thermal and/or seismic conditions. These joint systems may be posi­tioned to extend through both interior and exterior surfaces (e.g., walls, floors, and roofs) of a building or other structure.

In the case of an exterior joint in an exterior wall, roof, or floor exposed to external environmental conditions, the expansion joint system should also, to some degree, resist the effects of the external environment conditions. As such, most external expansion joints systems are designed to resist the effects of such conditions (particularly water). In vertical joints, such conditions will likely be in the form of rain, snow, or ice that is driven by wind. In horizontal joints, the condi­tions will likely be in the form of rain, standing water, snow, ice, and in some circumstances all of these at the same time. Additionally, some horizontal systems may be subjected to pedestrian and/or vehicular traffic.

Many expansion joint products do not fully consider the irregular nature ofbuilding expansion joints. It is common for an expansion joint to have several transition areas along the length thereof. These may be walls, parapets, columns, or other obstructions. As such, the expansion joint product, in some fashion or other, follows the joint as it traverses these obstructions. In many products, this is a point of weakness, as the homogeneous nature of the product is interrupted. Meth­ods of handling these transitions include stitching, gluing, and welding. In many situations, it is difficult or impossible to prefabricate these expansion joint transitions, as the exact details of the expansion joint and any transitions and/or dimensions may not be known at the time of manufacturing.

In cases of this type, job site modifications are frequently made to facilitate the function of the product with regard to the actual conditions encountered. Normally, one of two situ­ations occurs. In the first, the product is modified to suit the actual expansion joint conditions. In the second, the manu­facturer is made aware of issues pertaining to jobsite modifi­cations, and requests to modify the product are presented to the manufacturer in an effort to better accommodate the expansion joint conditions. In the first situation, there is a chance that a person installing the product does not possess the adequate tools or knowledge of the product to modifY it in a way such that the product still performs as designed or such that a transition that is commensurate with the performance expected thereof can be effectively carried out. This can lead

2 rework, or it is simply scrapped and re-manufactured. Both return to the manufacturer and scrapping andre-manufacture are costly, and both result in delays with regard to the building construction, which can in itself be extremely costly.

SUMMARY OF THE INVENTION

The present invention is directed to water resistant expan­sion joint systems for installation into building joints. In one

10 aspect, the present invention resides in a system for use in vertical or horizontal configurations and is designed such that it can be used for either an inside or outside corner. The system comprises open celled foam having a water-based acrylic chemistry infused therein. A layer of an elastomer is

15 disposed on the open celled foam and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The sys­tem is delivered to a job site in a pre-compressed state ready

20 for installation into the building joint.

In another aspect, the present invention resides in a vertical expansion joint system comprising a first section of open celled foam extending in a horizontal plane and a second section of open celled foam extending in a vertical plane. An insert piece of open celled foam is located between the first

25 and second sections, the insert piece being configured to transition the first section from the horizontal plane to the vertical plane of the second section. The foam is infused with a water-based acrylic chemistry. A layer of an elastomer is disposed on the foam to impart a substantially waterproof

30 property thereto. The vertical expansion joint system is pre­compressed and is installable between horizontal coplanar substrates and vertical coplanar substrates. Although the ver­tical expansion joint system is described as having an angle of transition from horizontal to vertical, it should be understood

35 that the transition of the angles is not limited to right angles as the vertical expansion joint system may be used to accommo­date any angle.

In another aspect, the present invention resides in a hori­zontal expansion joint system, the system being pre-com-

40 pressed and installable between horizontal coplanar sub­strates. The system comprises first and second sections of open celled foam extending in a horizontal plane, the sections being joined at a miter joint. The open celled foam is infused with a water-based acrylic chemistry. A layer of an elastomer

45 is disposed on the foam, the elastomer imparting a substan­tially waterproof property to the foam. Although the horizon­tal expansion joint system is described as transitioning right angles in the horizontal plane, it should be understood that the transition of the angles is not limited to right angles as the

50 system may be used to accommodate any angle and may also be used in planes that are not horizontal.

In any embodiment, the construction or assembly of the systems described herein is generally carried out off-site, but elements of the system may be trimmed to appropriate length

55 on-site. By constructing or assembling the systems of the present invention in a factory setting, on-site operations typi­cally carried out by an installer (who may not have the appro­priate tools or training for complex installation procedures) can be minimized. Accordingly, the opportunity for an

60 installer to effect a modification such that the product does not perform as designed or such that a transition does not meet performance expectations is also minimized.

BRIEF DESCRIPTION OF THE DRAWINGS to a premature failure at the point of modification, which may 65

result in subsequent damage to the property. In the second case, product is oftentimes returned to the manufacturer for

FIG. 1 is a perspective view of a vertical expansion joint system of the present invention.

US 9,200,437 Bl 3

FIG. 2 is an end view of the vertical expansion joint system taken along line 2-2 of FIG. 1.

FIG. 3 is an end view of the vertical expansion joint system installed between two substrates.

FIG. 4 is a perspective view of an assembly of foam lami­nations being prepared to produce the vertical expansion joint system of FIG. 1.

4 then compressed and held at such compression in a fixture. The fixture, referred to as a coating fixture, is at a width slightly greater than that which the expansion joint will expe­rience at the greatest possible movement thereof.

In the fixture, the assembled infused laminations 14 are coated with a waterproof elastomer 20. The elastomer 20 may comprise, for example, at least one polysulfide, silicone, acrylic, polyurethane, poly-epoxide, silyl-terminated poly­ether, combinations and formulations thereof, and the like.

FIG. 5 is a perspective view of the assembly of foam laminations being further prepared to produce the vertical expansion joint system of FIG. 1.

FIG. 6 is a perspective view offour sections of the vertical expansion joint system used in a building structure.

FIG. 7 is a perspective view of a horizontal expansion joint system of the present invention.

10 The preferred elastomer 20 for coating laminations 14 for a horizontal deck application where vehicular traffic is expected is PECORA 301 (available from Pecora Corpora­tion, Harleysville, Pa.) or DOW 888 (available from Dow Coming Corporation, Midland, Mich.), both of which are

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

15 traffic grade rated silicone pavement sealants. For vertical wall applications, the preferred elastomer 20 for coating the laminations 14 is DOW 790 (available from Dow Corning Corporation, Midland, Mich.), DOW 795 (also available from Dow Coming Corporation), or PECORA 890 (available The present invention provides a resilient water resistant

expansion joint system able to accommodate thermal, seis­mic, and other building movements while maintaining water resistance characteristics. The present invention is especially suited for use in concrete buildings and other concrete struc­tures including, but not limited to, parking garages, stadiums, tunnels, bridges, waste water treatment systems and plants, 25

potable water treatment systems and plants, and the like.

20 from Pecora Corporation, Harleysville, Pa.). A primer may be used depending on the nature of the adhesive characteristics of the elastomer 20.

Referring now to FIGS. 1-3, one embodiment of the present invention is an expansion joint system oriented in a vertical plane and configured to transition comers at right angles. This system is designated generally by the reference 30

number 10 and is hereinafter referred to as "vertical expan­sion joint system 10." It should be noted, however, that the vertical expansion joint system 10 is not limited to being configured at right angles, as the products and systems of the present invention can be configured to accommodate any 35

desired angle. The vertical expansion joint system 10 com­prises sections of open celled polyurethane foam 12 (herein­after "foam 12") that have been infused with a water-based acrylic chemistry. It should be understood, however, that although the present invention is described as comprising 40

polyurethane foam, the open celled foam can be any other suitable type of foam.

As is shown in FIG. 2, the foam 12 comprises individual laminations 14 offoam, one or more of which are infused with a suitable amount of the acrylic chemistry. It should be noted 45

that the present invention is not so limited as other manners of constructing the foam 12 are also possible. For example, the foam 12 of the present invention is not limited to individual laminations 14 assembled to construct the laminate, as the foam 12 may comprise a solid block of non-laminated foam 50

of fixed size depending upon the desired joint size, laminates comprising laminations oriented horizontally to adjacent laminations, or combinations of the foregoing.

Also as is shown in FIG. 3, the vertical expansion joint system 10 is positionable between opposing substrates 18 55

(which may comprise concrete, glass, wood, stone, metal, or the like) to accommodate the movement thereof. In particular, opposing vertical surfaces of the foam 12 are retained between the edges of the substrates 18. The compression of the foam 12 during the installation thereof between the sub- 60

strates 18 enables the vertical expansion system 10 to be held in place.

In any embodiment, when individual laminations 14 are used, several laminations, the number depending on the expansion joint size (e.g., the width, which depends on the 65

distance between opposing substrates 18 into which the ver­tical expansion system 10 is to be installed), are compiled and

During or after application of the elastomer 20 to the !ami­nations 14, the elastomer is tooled or otherwise configured to create a "bellows," "bullet," or other suitable profile such that the vertical expansion joint system 10 can be compressed in a uniform and aesthetic fashion while being maintained in a virtually tensionless environment. The elastomer 20 is then allowed to cure while being maintained in this position, securely bonding it to the infused foam lamination 14.

Referring now to FIGS. 4 and 5, when the elastomer 20 has cured in place, the infused foam lamination 14 is cut in a location at which a bend in the vertical expansion system 10 is desired to accommodate a comer. The cut, which is desig­nated by the reference number 24 and as shown in FIG. 4, is made from the outside of the desired location of the bend to the inside of the desired location of the bend using a saw or any other suitable device. The cut 24 is stopped such that a distance d is defined from the termination of the cut to the previously applied coating of the elastomer 20 on the inside of the desired location of the bend (e.g., approximately one half inch from the previously applied coating of elastomer 20 on the inside of the bend). Referring now to FIG. 5, the lamina­tion 14 is then bent to an appropriate angle A, thereby forming a gap G at the outside of the bend. Although a gap of 90 degrees is shown in FIG. 5, the present invention is not limited in this regard as other angles are possible.

Still referring to FIG. 5, a piece of infused foam lamination constructed in a manner similar to that described above is inserted into the gap Gas an insert piece 30 and held in place by the application of a similar coating of elastomer 20 as described above. In the alternative, the insert piece 30 may be held in place using a suitable adhesive. Accordingly, the angle A around the comer is made continuous via the insertion of the insert piece 30 located between a section of the open celled foam extending in the horizontal plane and a section of the open celled foam extending in the vertical plane. Once the gap has been filled and the insert piece 30 is securely in position, the entire vertical expansion system 10 including the insert piece 30 is inserted into a similar coating fixture with the previously applied elastomer 20 coated side facing down and the uncoated side facing upwards. The uncoated side is now coated with the same (or different) elastomer 20 as was used on the opposite face. Again, the elastomer 20 is then allowed to cure in position. Furthermore, the insert piece 30 inserted into the gap is not limited to being a lamination 14, as solid blocks or the like may be used.

US 9,200,437 Bl 5

After both sides have cured, the vertical expansion system 10 as the final uninstalled product is removed from the coat­ing fixture and packaged for shipment. In the packaging operation the vertical expansion system 10 is compressed using a hydraulic or mechanical press (or the like) to a size below the nominal size of the expansion joint at the job site. The vertical expansion system 10 is held at this size using a heat shrinkable poly film. The present invention is not limited in this regard, however, as other devices (ties or the like) may be used to hold the vertical expansion system 10 to the desired SIZe.

Referring now to FIG. 6, portions of the vertical expansion system 10 positioned to articulate right angle bends are shown

6 removed, the horizontal expansion system 110 will begin to expand, and the horizontal expansion system is inserted into the joint in the desired orientation. Once the horizontal expan­sian system 110 has expanded to suit the expansion joint, it will become locked in by the combination of the foam back pressure and the adhesive.

In any system of the present invention, but particularly with regard to the vertical expansion system 10, an adhesive may be pre-applied to the foam lamination. In this case, for instal-

10 lation, the foam lamination is removed from the packaging and simply inserted into the expansion joint where it is allowed to expand to meet the concrete (or other) substrate. Once this is done, the adhesive in combination with the back

as they would be positioned in a concrete expansion joint located in a tunnel, archway, or similar structure. Each por- 15

tion defines a foam laminate that is positioned in a comer of the joint. As is shown, the vertical expansion joint system 10

pressure of the foam will hold the foam in position. The vertical expansion system 10 is generally used where

there are vertical plane transitions in the expansion joint. For example, vertical plane transitions can occur where an expan­sion joint traverses a parking deck and then meets a sidewalk followed by a parapet wall. The expansion joint cuts through

is installed between horizontal coplanar substrates 18a and vertical coplanar substrates 18b.

Referring now to FIG. 7, an alternate embodiment of the invention is shown. In this embodiment, the infused foam, the elastomer coating on the top surface, and the elastomer coat­ing on the bottom surface are similar to the first embodiment. However, in FIG. 7, the expansion joint system designated generally by the reference number 110 is oriented in the horizontal plane rather than vertical plane and is hereinafter referred to as "horizontal expansion system 110." As with the vertical expansion system 10 described above, the horizontal expansion system 110 may be configured to transition right angles. The horizontal expansion system 110 is not limited to being configured to transition right angles, however, as it can be configured to accommodate any desired angle.

In the horizontal expansion system 110, the infused foam lamination is constructed in a similar fashion to that of the

20 both the sidewalk and the parapet wall. In situations of this type, the vertical expansion system 10 also transitions from the parking deck (horizontally) to the curb (vertical), to the sidewalk (horizontal), and then from the sidewalk to the para­pet (vertical) and in most cases across the parapet wall (hori-

25 zontal) and down the other side of the parapet wall (vertical). Prior to the present invention, this would result in an installer having to fabricate most or all of these transitions on site using straight pieces. This process was difficult, time consuming, and error prone, and often resulted in waste and sometimes in

30 sub-standard transitions.

vertical expansion system 10, namely, by constructing a foam 35

112 assembled from individual laminations 114 of foam

In one example of installing the vertical expansion system 10 in a structure having a sidewalk and a parapet, the installer uses several individual sections, each section being config­ured to transition an angle. The installer uses the straight run of expansion joint product, stopping within about 12 inches of the transition, then installs one section of the vertical expan-

material, one or more of which is infused with an acrylic chemistry. Although the horizontal expansion system 110 is described as being fabricated from individual laminations 114, the present invention is not so limited, and other manners of constructing the foam 112 are possible (e.g., solid blocks of foam material).

In fabricating the horizontal expansion system 110, two pieces of the foam 112 are mitered at appropriate angles B ( 45 degrees is shown in FIG. 7, although other angles are pos­sible). An elastomer, or other suitable adhesive, is applied to the mitered faces of the infused foam laminations. The indi­viduallaminations are then pushed together and held in place in a coating fixture at a width slightly greater than the largest joint movement anticipated. At this width the top is coated with an elastomer 20 and cured. Following this, the foam 112 is inverted and then the opposite side is likewise coated.

sion system 10 with legs measuring about 12 inches by about 6 inches. If desired, the installer trims the legs of the vertical expansion system 10 to accommodate the straight run and the

40 height of the sidewalk. Standard product is then installed across the sidewalk, stopping short of the transition to the parapet wall. Here another section of the vertical expansion system 10 is installed, which will take the product up the wall. Two further sections of the vertical expansion system 10 are

45 used at the top inside and top outside comers of the parapet wall. The sections of the vertical expansion system 10 are adhered to each other and to the straight run expansion joint product in a similar fashion as the straight run product is adhered to itself. In this manner, the vertical expansion sys-

50 tern 10 can be easily installed if the installer has been trained to install the standard straight run product. It should be noted, however, that the present invention is not limited to the instal­lation of product in any particular sequence as the pieces can After both coatings of elastomer 20 have cured, the hori­

zontal expansion system 110 is removed from the coating fixture and packaged for shipment. In the packaging opera- 55

tion, the horizontal expansion system 110 is compressed using a hydraulic or mechanical press (or the like) to a size below the nominal size of the expansion joint at the job site. The product is held at this size using a heat shrinkable poly film (or any other suitable device).

be installed in any suitable and/or desired order. In one example of installing the horizontal expansion sys-

tem 110, the system is installed where there are horizontal plane transitions in the expansion joint. This can happen when the expansion joint encounters obstructions such as supporting colunms or walls. The horizontal expansion sys-

60 tern 110 is configured to accommodate such obstructions. In the horizontal expansion system 110, the installation

thereof is accomplished by adhering the foam 112 to a sub­strate (e.g., concrete, glass, wood, stone, metal, or the like) using an adhesive such as epoxy. The epoxy or other adhesive is applied to the faces of the horizontal expansion system 110 prior to removing the horizontal expansion system from the packaging restraints thereof. Once the packaging has been

Prior to the present invention, the installer would have had to create field transitions to follow the expansion joint.

To extend the horizontal expansion system 110 around a typical support column, the installer uses four sections of the

65 horizontal expansion system. A straight run of expansion joint product is installed and stopped approximately 12 inches short of the horizontal transition. The first section of

US 9,200,437 Bl 7

the horizontal expansion system 110 is then installed to change directions, trimming as desired for the specific situa­tion. Three additional sections of horizontal expansion sys­tem 110 are then joined, inserting straight run pieces as desired, such that the horizontal expansion system 110 extends around the colunm continues the straight run expan­sion joint on the opposite side. As with the vertical expansion system 10, the sections may be installed in any sequence that is desired.

The present invention is not limited to products configured 10

at right angles, as any desired angle can be used for either a horizontal or vertical configuration. Also, the present inven­tion is not limited to foam laminates, as solid foam blocks and the like may alternatively or additionally be used.

Although this invention has been shown and described 15

with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular 20

situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within 25

the scope of the appended claims.

What is claimed is:

8 at an angle of about 90 degrees, wherein the precom­pressed foam of the first section, the second section and the insert piece are precompressed to a size below the size of an expansion joint, and are configured to expand and create a waterproof seal around a corner when installed in the expansion joint; and

a layer of the elastomer disposed on the foam, the elas-tomer imparting a substantially waterproof property to the foam, and wherein the layer of the elastomer is a continuous layer of the elastomer from the second plane to the first plane and the layer of elastomer is a continu-ous layer of the elastomer over the insert piece, and the insert piece is held in place by the continuous layer of the elastomer, and the expansion joint system, including the foam and the insert piece, is configured to accommodate thermal and seismic movement in the system by expand-ing and contracting while maintaining the continuous layer of the elastomer and the waterproof property thereof;

wherein the water resistant expansion joint system is installed between substrates by adhering the foam to the substrates, and creates the waterproof seal around the corner in the expansion joint upon expansion of the foam in the expansion joint.

2. The expansion joint system of claim 1, wherein the foam is open celled foam and comprises one or more individual laminations assembled to construct a laminate.

3. The expansion joint system of claim 1, wherein the foam is open celled polyurethane foam.

4. The expansion joint system of claim 1, wherein the elastomer disposed on the foam comprises a silicone.

1. A water resistant expansion joint system comprising: foam, which is cut and bent into a first section of precom­

pressed foam extending in a first plane; and a second 30

section of precompressed foam extending in a second plane, the first section being connected to the second section and forming an angle A therebetween of about

5. The expansion joint system of claim 1, wherein the elastomer disposed on the foam is selected from the group consisting of polysulfides, acrylics, polyurethanes, poly-ep-

35 oxides, silyl-terminated poly ethers, and combinations of one or more of the foregoing.

90 degrees, wherein a gap G is located in the foam opposite the angle A and configured to receive an insert piece of precompressed foam to transition between the first section and the second section;

the insert piece of precompressed foam located in the gap G between the first section of foam extending in the first plane and the second section of foam extending in the 40

second plane, the insert piece being configured to tran­sition the first section of the foam from the first plane to the second plane of the second section of the foam also

6. The expansion joint system of claim 1, wherein a water­based acrylic chemistry is infused into at least one of the first section and the second section of the foam.

7. The expansion joint system of claim 1, wherein the expansion joint system is a vertical expansion joint system or a horizontal expansion joint system.

* * * * *

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Copyright © 2015 by EMSEAL JOINT SYSTEMS, LTD. All Rights Reserved.

EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581 USAEMSEAL, LLC 120 Carrier Drive, Toronto, ON, M9W5R1 Canada

www.emseal.comEMSHIELD DFR2 SYSTEM TECH DATA

NOVEMBER 2015, PAGE 1 OF 4

ProductDescriptionEMSHIELD DFR2 is a UL-certified 2-hour fire-rated, watertight sound suppressing, expansion joint.

EMSHIELD DFR2 features a traffic-grade silicone sealing surface on both the upper and lower faces, adhered to a fire-retardant impregnated foam backing.

The system is installed into epoxy adhesive field-applied onto the joint faces. A field-injected silicone sealant band seals the bellows to the substrate at the traffic surface. (NOTE: DFR2 was tested and passed UL 2079 without installation of sealant bands from the underside and these are therefore NOT needed). Joins between each stick are executed using a field-applied silicone sealant at the top and bottom of the join and field-applied intumescent sealant on the adjoining foam faces.

Traffic Durable, Watertight, 2-Hour Fire-Rated Expansion JointEMSHIELD DFR2 is a watertight, fire-rated, traffic-durable, sound-attenuating primary seal for both retrofit and new structural expansion joints in horizontal-plane applications. It eliminates the need for additional fire blankets, mineral wools, liquid sealants, cover plates, or other fire stopping materials.

For joints from 1/2-inch (12mm) up to 4-inches (100mm) where +50% and -50% (total 100%), of nominal material size, joint movement is expected.

EMSHIELD DFR2 (Deck, Fire-Rated 2-Hours) is part of a comprehensive line of breakthrough, multifunction, structural expansion joint materials manufactured by EMSEAL. Tested and certified by Underwriters Laboratories (UL), to the rigors of UL 2079, additional versions for walls and floors (including DFR3, a 3-hour fire-rated version) are now available — consult EMSEAL.

Fire-retardant-impregnated foam is factory pre-coated on both the upper and lower facing surfaces with a traffic-grade silicone coating. The resulting composite is then factory compressed to less than its nominal size for installation into structural or other openings.

EMSHIELD DFR2 provides a watertight, clean handling, UV stable, nonstaining, low-temperature-flexible, high-temperature-stable, watertight, traffic durable, sound-suppressing, and fire-rated joint seal in a single installation process.

DATA

TECH

UsesFor expansion joints in decks and floors where watertightness and/or a fire-rating and/or traffic durability are required. Applications examples are:

• Stadiums • Arenas• Parking decks • Floors• Stair tower perimeters • Elevator tower perimeters• Deck-to-deck • Deck-to-wall

Can be used alone or under any other expansion joint cover, plate or filler where depth of substrate allows.

FeaturesWatertight – EMSHIELD DFR2 is installed with the tensionless traffic-grade, fuel-resistant bellows ensuring that watertightness is achieved.

Fire-Rated – The fire-retardant-impregnated foam ensures a 2-hour fire protection in accordance with UL-2079.

Sound Attenuation – EMSHIELD DFR2 minimizes sound transfer which often occurs at the expansion joint gap. Tested results of EMSHIELD foam products in a 1 1/2” gap in a STC 68/OITC 51 assembly are an STC of 64 and an OITC of 52.

Non-Invasive Anchoring – There are no hard metal-to-substrate connections with EMSHIELD DFR2. This includes embedded pins, anchors, screws, bolts or tracks, trays or rails, flanges or coverplates. The system is locked to the joint faces by means of the 1) backpressure of the foam, 2) the epoxy adhesive, and 3) the injected sealant bands at the joint face.

Movement Capability – +50% and -50% (100% total) of nominal material size.

Versatility – The standard EMSHIELD DFR2 top surface and lower side color is gray (other colors are optional). At the designer’s option, a different color of (non-trafficable) silicone coating can be applied to the underside.

Joint-Size Variation – Uniform bellows appearance, and the ability to handle variations in joint size through size-switching, are among other system features.

Factory-Fabricated Terminations and Transitions – as in all EMSEAL expansion joint systems, continuity of seal through changes in plane and direction is an essential performance differentiator.

EMSHIELD DFR2 is manufactured in straight-run sticks which can be joined in the field to EMSEAL’s patented factory-fabricated “Universal-90” Transitions and Terminations. (see page 4) These are factory-fabricated single-piece 90° units which are coated on both sides with silicone coating allowing them to be installed as an upturn termination or as a downturn termination. Each has a 12-inch long horizontal leg and a 6-inch vertical leg. Terminations end in a 45° sealed and mitered end. Transitions end in an uncoated 90° cut to be adhered to another transition piece as used in treads and risers, parapets, curbs and other short-rise applications.

EMSHIELD DFR2 SYSTEMWater / Fire / Traffic / Movement / Sound

US Patent: 8,739,495 Patent Pending

EMSHIELD DFR2 sample shown here is displayed in substrate mock-up

Rev 12-23-15

Continued on back

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Copyright © 2015 by EMSEAL JOINT SYSTEMS, LTD. All Rights Reserved.

EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581 USAEMSEAL, LLC 120 Carrier Drive, Toronto, ON, M9W5R1 Canada

www.emseal.comEMSHIELD DFR2 SYSTEM TECH DATA

NOVEMBER 2015, PAGE 2 OF 4

In addition to guaranteeing watertightness, EMSEAL’s “Universal-90 terminations and transitions” allow for much faster and secure installation by eliminating field cutting at angles.

EMSHIELD DFR2 builds on EMSEAL’s track record of over 30 years of innovation in sealing structural expansion joints with impregnated foam sealants.

PerformanceCapable of movements of +50%, -50% (100% total) of nominal material size.

Standard sizes from 1/2” (12mm) to 4” (100mm).

Depth of Seal for all sizes = 4” (100mm). Note: Typical thickness of concrete for a 2-hour rating = 4” (100mm).

Substrates must be solid, parallel and plumb.

Performance Limitations – For applications in larger joints (3-inches and above) where full extension movement and high point load, small-diameter-wheel conditions (shopping cart, luggage carts, etc.) exist, the designer should consider use of a cover plate over the DFR2 or instead specify the SJS-FR system.

Testing and StandardsEMSHIELD DFR2 has been tested and certified under UL 2079 and as a result meets the requirements of ASTM E1966, ASTM E119 and ASTM E1399.

UL 2079, like ASTM E1966, was developed to encompass the fire testing of ASTM E119 and the movement cycling regime of ASTM E1399.

Laminations – EMSHIELD DFR2 has passed UL 2079 when configured with either vertical, compression-bonded laminations OR with horizontal, adhesive-bonded laminations. The orientation or presence of laminations in any form is inconsequential to the performance of the product under the UL2079 testing criteria.

Design/System/Construction/AssemblyThis material has been tested to UL/ULC 2079 and is manufactured under UL’s Follow-Up Service. The material is being supplied as a fire-rated component of a wall or floor assembly. It has been tested to UL 2079 in assemblies as depicted in EMSEAL’s various listings in the UL Online Certifications Directory. Use of this material in assembly configurations other than depicted in the named UL listings will not encumber or lower the resistance of the

deck or wall assembly but is done so at the designers’ discretion and responsibility for designing substrates as part of a fire rated assembly that meet applicable standards for the project. Similarly, the published information in the UL Listings cannot always address every construction nuance encountered in the field. Authorities Having Jurisdiction should be consulted in all cases as to the particular requirements covering the installation and use of UL Listed or Classified products or materials. Authorities Having Jurisdiction should be consulted before construction to ensure that specific adjacent substrates and assemblies are detailed and constructed to meet local fire-rating requirements.

ColorsStandard traffic surface color is gray (consult EMSEAL for options). Alternate colors for the bottom coatings are available as an option — consult EMSEAL.

WarrantyStandard or project-specific warranties are available from EMSEAL on request. Each product can only perform its designed function if it, and the joint-gap into which it is installed, is sized to suit anticipated joint movements in consideration of the movement capability of the product and in consideration of the temperature at time of installation, and if it is installed in strict accordance with EMSEAL’s installation instructions.

Availability & PriceEMSHIELD DFR2 is available for shipment internationally. Prices are available from local representatives and/or directly from the manufacturer. The product range is continually being updated, and accordingly EMSEAL reserves the right to modify or withdraw any product without prior notice.

Fire-Retardant Impregnated Foam

Highway-Grade Silicone Trafficable Bellows

EMSHIELD DFR2

Highway-Grade Silicone Trafficable Bellows

Sizing

Product Code* Nominal Material Size

(Joint Size @ Mean Temp.)

Depth of Seal

DFR2-0050 1/2 " (12mm) 4 “ (100mm)

DFR2-0065 5/8” (15mm) 4 “ (100mm)

DFR2-0075 3/4” (20mm) 4 “ (100mm)

DFR2-0100 1 “ (20mm) 4 “ (100mm)

DFR2-0125 1 1/4” (30mm) 4 “ (100mm)

DFR2-0150 1 1/2” (40mm) 4 “ (100mm)

DFR2-0175 1 3/4” (45mm) 4 “ (100mm)

DFR2-0200 2 “ (50mm) 4 “ (100mm)

DFR2-0225 2 1/4" (55mm) 4 “ (100mm)

DFR2-0250 2 1/2” (65mm) 4 “ (100mm)

DFR2-0275 2 3/4” (70mm) 4 “ (100mm)

DFR2-0300 3 “ (75mm) 4 “ (100mm)

DFR2-0325 3 1/4” (85mm) 4 “ (100mm)

DFR2-0350 3 1/2” (90mm) 4 “ (100mm)

DFR2-0375 3 3/4” (95mm) 4 “ (100mm)

DFR2-0400 4 “ (100mm) 4 “ (100mm)

*NOTE: Product Code begins with DFR2 designation. [e.g. DFR2-0100 = 1-inch (25mm) DFR2]

Features, continued

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Copyright © 2015 by EMSEAL JOINT SYSTEMS, LTD. All Rights Reserved.

EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581 USAEMSEAL, LLC 120 Carrier Drive, Toronto, ON, M9W5R1 Canada

EMSHIELD DFRUL 2079 Testing and Certification(This page shows the original testing of EMSHIELD DFR2.)

Manufacture UL certification begins with certification of the manufacturing process. UL personnel observe the entire manufacturing process from impregnation to coating to packaging.

Installation Next, an installation to include a join between standard lengths, using the tools and procedures that will be used in the field is observed by UL. Specifically, 4-inch nominal DFR2 was installed into 4-inch thick concrete slabs (4-inches of concrete are required for the concrete itself to provide 2-hours of fire resistance). Once the epoxy-adhesive and liquid sealants used in the installation were cured, the slabs were ready for cycling.

EMSHIELD DFR2 was tested both with just the intumescent bellows on the bottom side as well as with the intumescent bellows on the bottom side coated with a silicone bellows*.

Joint Cycling Before any fire testing can commence, the product must pass UL’s cycling requirement through the extremes of the offered movement range (+25%, -25% from nominal). Joint movement under UL 2079 occurs at two levels. The first, 400 cycles @ 10 cycles/minute. This test is designed to simulate thermal and wind-sway cycling. The second, an additional 100 cycles @ 30 cycles per minute, is more rapid and is designed to simulate seismic movement. EMSHIELD DFR2 passed cycling at both levels.

Fire Resistance Within 96 hours of the cycling tests the fire testing must occur. The concrete slabs are installed over the test oven.

The joint gap is set at the maximum offered opening for the material size tested (4-inch nominal material at +25% movement claim = 5-inches).

Thermocouples are placed on the top side of the material. For the DFR2, the thermocouples were placed directly on the material--in the middle of the product, at the substrate interface, and directly over the field-join.

The oven is ignited and the temperature rises rapidly to near 1650°F (899°C) over 30 minutes. After two hours the internal temperature of the oven reaches 1850°F (1010°C).

The data from the thermocouples is monitored throughout the 2 hour duration of the test. To pass, no single thermo couple can read in excess of 356°F (180°C) at any point during the duration of the test.

Final ResultsAfter two hours, no single thermocouple on the EMSHIELD DFR2 read in excess of 248°F (120°C).

The successful conclusion of the test earns the EMSHIELD DFR2 the certification by UL of this product in sizes from 4-inches and smaller at depths of 4-inches and with a movement capability of +25% and -25% (total 50%) to be fire-rated for up to 2 hours.

* UL-certified DFR2 is now manufactured with silicone bellows on the bottom without intumescent bellows. Lower intumescent bellows are incorporated in the design of EMSHIELD DFR3 (DFR 3-hour fire rated

www.emseal.comEMSHIELD DFR2 SYSTEM TECH DATA

NOVEMBER 2015, PAGE 3 OF 4

Joint gap at maximum expansion (+50% of nominal size.)

Thermocouples are placed in predeter-mined locations on top of the expansion joint to effectively measure heat transfer.

Testing oven below the EMSHIELD DFR2 reaches a maximum temperature of 1850°F (1010°C).

Thermocouples register no more than 248°F (120°C)

PH: 508.836.0280 FX: 508.836.0281PH: 416.740.2090 FX: 416.740.0233

Copyright © 2015 by EMSEAL JOINT SYSTEMS, LTD. All Rights Reserved.

EMSEAL JOINT SYSTEMS, LTD 25 Bridle Lane, Westborough, MA 01581 USAEMSEAL, LLC 120 Carrier Drive, Toronto, ON, M9W5R1 Canada

www.emseal.comEMSHIELD DFR2 SYSTEM TECH DATA

NOVEMBER 2015, PAGE 4 OF 4

DFR2 Universal-90 Terminations and Transitions

Upturn Termination to Vertical Rise

Downturn Termination to Vertical Overhang

Horizontal to Vertical Upturn Transition

Horizontal to Vertical Downturn Transition

EMSHIELD DFR fire-retardant impregnated foam

Factory-applied and cured traffic-grade silicone facing

EMSHIELD DFR fire-retardant impregnated foam

Factory-applied and cured traffic-grade silicone facing

EMSHIELD DFR fire-retardant impregnated foam

Factory-applied and cured traffic-grade silicone facing

EMSHIELD DFR fire-retardant impregnated foam

Factory-applied and cured traffic-grade silicone facing

DFR2 In Deck Applications

Deck to Deck Deck to Wall

EMSHIELD DFR fire-retardant impregnated foam

Factory-applied and cured traffic-grade silicone facing

Epoxy adhesive both sides of gap (by EMSEAL)

EMSHIELD DFR fire-retardant impregnated foam

Factory-applied and cured traffic-grade silicone facing

Epoxy adhesive both sides of gap (by EMSEAL)

Factory-applied and cured traffic-grade silicone facing Factory-applied and cured

traffic-grade silicone facing

US Patent: 9,200,437 Patent Pending