Epoxy.com ^TM Product #63
Watertight Expansion Joint System
Guide Specification

PART 1 – GENERAL

1. 01 WORK INCLUDED

• A. Install a watertight, wear resistant expansion joint system, including all necessary preparation, in accordance with the drawings and specifications.

1.02 RELATED WORK

• A. Section ( :) (Cast In Place Concrete)

  B. Section ( :) ( )

1.03 SUBMITTALS

• A. The Contractor shall deliver the required submittals to the Engineer at the address listed on the cover of the Project Manual. Submittals shall be made promptly and in such a sequence as to cause no delay in the work.

  B. The Contractor shall submit the following in duplicate.

  • l. Technical data sheets from the manufacturer and/or distributor for each product that he intends to use, showing that they meet the requirements of the specifications. The technical data shall include the following.
    • a. Expansion Joint Filler:
      • l. Intended use of product .

        2. Density, modulus, recovery, extrusion, water absorption, ultra violet resistance and weathering resistance per AASHTO T42 – 49(1974).

        3. Recommended installation procedures.

      b. Epoxy Bonder:

      • l. General Description of the intended use of product.

        2.Concrete bond strength by ASTM C-882 (7 days).

        3.Compressive Strength by ASTM D-695

        4.Gel Time .

        5.Final Cure Time

        6.Shrinkage by ASTM C-882

        7.Listing of the ASTM type, grade, and class

        8.Mix Ratio

        9.Viscosity (mixed) by ASTM D-2393

        10.Packaging

        11.Recommended application procedures

      c. Epoxy Mortar Resin:

      • l. General Description of intended use of product

        2. Tensile strength by ASTM D-638

        3. Compressive strength by ASTM D-695

        4. Flexural Strength by ASTM D-790

        5. Elongation by ASTM D-638

        6.Viscosity (mixed) by ASTM D-2393

        7. Consistency

        8. Initial Cure

        9. Final Cure

        10. Packaging

        11. Recommended application procedures .

1.04 MATERIAL DELIVERY, HANDLING AND STORAGE

• A. Materials shall be delivered in the manufacturer's undamaged, unopened containers. Each container shall be clearly marked with the following:
  • l. Product name

    2. Manufacturer's name

    3. Batch number.

    4. Component designation ("A" or "B")

    5. Ratio of component mixtures

.

• B. Provide equipment and personnel to handle the material by methods which prevent damage.

  C. Promptly inspect shipments to assure that material comply with requirements, quantities are correct and materials are undamaged.

  D. The Contractor shall be responsible for all materials furnished by him, and he shall replace, at his own expense, all such material that is found to be defective in manufacturing or that has become damaged in handling.

  E. Store materials in accordance with. the manufacturer's instructions with seals and labels intact and legible. Maintain temperatures within the required ranges.

1.05 JOB CONDITIONS

• A. The Contractor shall visit the site and examine the condition of the joint surfaces to receive the expansion joint system. He shall follow the manufacturer's recommendations with regard to the various moisture and temperature limitations of the materials.

PART 2 – PRODUCTS

2.01 MATERIALS

• A. Expansion Joint Filler
  • 1. General Requirements:
    • a. Ability to remain flexible in all weather conditions .

      b. Ability to resist penetration of moisture, salts and de-icing chemicals, efflorescence and petroleum products .

      c. Ability to resist embedment of dirt and debris into joint.

      d. Ability to perform within range of all anticipated movements.

    2. Specific Requirements:

    • a. Material shall be Epoxy.com  Product #63 - cross linked, closed cell ethylene vinyl acetate low-density expanded foam.

      b. Color: (white) (grey)

      c. Material shall be tested per AASHTO standards in accordance with T42-49 (1974) and comply with the following:

      • l. Density: 2.5 – 3.5 pcf .

        2. Modulus of Elasticity: 30-40 p.s.i.

        3. Elongation/Tension: Minimum 190% @ 120 p.s.i .

        4. Recovery: Minimum 99%.

        5. Extrusion: Maximum 0.15% @ 1" thickness.

        6. Water Absorption: Maximum 1.5% @ 1" – 3" thickness.

        7. Weathering: Exhibit no deterioration from effects of freeze -thaw cycles .

        8. Ultra Violet: Exhibit no deterioration or degradation of the cell structure.

  B. Epoxy Bonder

  • 1. General Requirements:
    • a. Compatible with the expansion joint filler material and the substrate .

      b. Chemical resistant

      c. Abrasive resistant

    2. Specific Requirements (@ 77 F):

    • a. Material shall be Epoxy.com ™ Product # 6

      b. 100% solids by weight

      c. Two component

      d. Viscosity - Mixed (ASTM D-2393): 548,000 cps.

      e. Consistency - No Sag

      f. Capable of application to frost free and dry surfaces at 40 degrees F or above.

      g. Concrete bond strength (ASTM C-882): Minimum 2,250 p.s.i.

      h. Compressive strength (ASTM D-695): Minimum 10,480 p.s.i.

      i. Shrinkage (ASTM D-2566): Passed.

      j. Initial cure (80% of ultimate strength) - 24 hours

      k. Final Cure - 7 days

      l. Packaging 1 gal. cans, 5 gal. pails, drums

  C. Epoxy Mortar Grout:

  • 1. General Requirements:
    • a. Compatible with the in place concrete, expansion joint filler material and the epoxy bonder.

      b. Material to be impervious to moisture.

      c. Chemical resistant

      d. Abrasive resistant

    2. Specific Requirements:

    • a. Epoxy Mortar Resin (@ 77 F)
      • 1. Epoxy Mortar Material Shall be Epoxy.com ™ Product #11.

        2.Two component epoxy resin which meets or exceeds requirements of epoxy resin Type III, Grade 1, Class B, per ASTM C-881.

        3.100% solids by weight.

        4.Capable of application to frost free and dry surfaces at 40 degrees F. or above.

        5.Concrete Bond Strength (ASTM C-883) - 2,290 p.s.i.

        6.Compressive Strength (ASTM C-695) (neat) 10,600 p.s.i.

        7.Tensile Strength (ASTM D-638) 2,800 p.s.i.

        8.Flexural Strength (ASTM D-790) 2,800 p.s.i.

        9.Elongation (ASTM D-638) 38%

        10.Gel Time - 41 minutes

        11.Color - Gray

        12.Viscosity (mixed) (ASTM D-2393) 600 cps.

        13.Consistency - No bead formed

        14.Initial Cure 24 hours

        15.Final Cure- 7 days

        16.Packaging 1 gal. cans, 5 gal. pails, drums

      b. Select Aggregates for Grout .

      • 1. Fine aggregate shall be clean, dry, bagged and within the following gradations:
        • Screen Number Percent Passing

          # 4 95 – 100%
          # 8 80 – 100%
          #16 50 – 85%
          #30 25 – 60%
          #50 5 – 10%
          #80 0%

2.02 ACCEPTABLE MATERIALS AND MANUFACTURERS

• A. The expansion joint material shall be Epoxy.com Product #63, as distributed by Epoxy.com 352-489-1666.

  B. The epoxy bonder shall be Epoxy.com Product #6 manufactured by Epoxy.com a division of Epoxy Systems, Inc. 352-489-1666.

  C. The epoxy mortar resin shall be Epoxy.com Product #10 as manufactured by Epoxy.com a division of Epoxy Systems, Inc. 352-489-1666.

PART 3 EXECUTION

3.01 PREPARATION

• A. New Construction:
  • 1. The concrete adjacent to the joint shall be formed to the proper lines, grades and elevations detailed on the plans.

    2. The Contractor installing the joint system (and/or the Engineer) shall inspect and approve each area for the joint installation. Areas determined to be inadequate shall be repaired prior to installation.

    3. The joint surfaces shall be cleaned by sandblasting, high pressure water-blasting, or other pre-approved abrasive cleaning as necessary to remove surface laitenance, debris and other contaminants which may impair adhesion of the system.

  B. Rehabilitation of Existing Joints:

  • 1. The installation Contractor (and/or the Engineer) shall lay out the limits of concrete removal as detailed on the drawings and in accordance with the system manufacturer's recommendation.

    2. Provide a 1" deep saw cut along the limits of removal.

    3. Remove concrete adjacent to the joint to the proper lines and grades as detailed on the plans (and/or approved drawings). Hammers used during the removal operation shall not exceed a 30# rating.

    4. The Contractor installing the joint system (and/or the Engineer) shall inspect and approve each area prior to the joint installation.

    5. The joint surfaces shall be cleaned by sandblasting or high pressure water-blasting to remove surface laitenance, debris and other contaminants which may impair adhesion of the system.

3. 02 INSTALLATION OF EPOXY MORTAR NOSINGS

• A. Install an appropriate form over the center of the joint. The bond breaker used on the form shall be as recommended by the system manufacturer.

  B. Prime the concrete joint surfaces with a 5-10 mil coating of the neat epoxy mortar resin just prior to installing the epoxy mortar grout.

  C. Mix and install the epoxy mortar grout in accordance with the manufacturer's recommendations. The ratio of the aggregate to epoxy mortar resin, by volume, shall be not, less than 4 parts aggregate to 1 part epoxy resin.

  D. Place and compact the epoxy mortar grout. Strike off and finish to the proper grade and elevation. The leading edges of the epoxy mortar grout shall have a minimum of a 1/4" radius installed during the final finishing.

  E. Remove form work when the epoxy mortar grout is tack free.

3.03 INSTALLATION OF EXPANSION JOINT MATERIAL

• A. The expansion joint material shall be furnished in one continuous piece for each joint, wherever possible. If field splicing is required, the material shall be heat spliced in accordance with the manufacturer's recommendations.

  B. Apply approximately 6 mils of the epoxy bonder to the vertical interface of the (epoxy mortar nosing) (concrete substrate) and the sides of the expansion joint material. Tape shall be place on the top of the (epoxy mortar nosing ) (adjacent concrete surfaces) to prevent spreading of epoxy bonder on same. Remove tape prior to the curing of the epoxy bonder.

  C. Compress and install the expansion joint material. Remove excess epoxy bonder from the top surface of the joint material prior to the curing of same.

  D. Final position of the joint material shall be (1/8"below) (flush with) ( ) the adjacent horizontal surfaces.

PART 4 METHOD OF PAYMENT

4.01 The expansion joint system shall be paid for by the lineal foot of joint installed, including all necessary materials, labor and equipment required to prepare the joint opening (install the epoxy mortar NOSINGS) and install the expansion joint material.

END OF SECTION

This information is presented in good faith to assist in determining whether our products are suitable for application. No warranty or representation, however, is intended or made, nor is protection from any law or patent to be inferred, and all patent rights are reserved. 950512ll