CONSTRUCTION AND SEALING OF CONSTRUCTION AND SEALING OF JOINTS IN CONCRETE PAVEMENTJOINTS IN CONCRETE PAVEMENT

ByBy

Mr.ThaMr.Tha KyawKyaw ZanZan&&

Mr.TirthaMr.Tirtha ChandanChandan PatraPatra

NEED FOR JOINTSNEED FOR JOINTS

TOTO CONTROLCONTROL CRACKINGCRACKING

TO FACILITATE A BREAK IN CONSTRUCTIONTO FACILITATE A BREAK IN CONSTRUCTION

TO ALLOW CONSTRUCTION OF PAVEMENT IN TO ALLOW CONSTRUCTION OF PAVEMENT IN LANES OF CONVENIENT WIDTHLANES OF CONVENIENT WIDTHLANES OF CONVENIENT WIDTHLANES OF CONVENIENT WIDTH

IMPORTANCE OF JOINTSIMPORTANCE OF JOINTS

RIDING QUALITYRIDING QUALITY

DURABILITY & PERFORMANCE OF PAVEMENTDURABILITY & PERFORMANCE OF PAVEMENT

Defects in Pavement JointsDefects in Pavement Joints

SPALLED JOINT WITH SPALLED JOINT WITH DEPLETED SEALANTDEPLETED SEALANTSPALLED EDGESPALLED EDGE DEPLETED SEALANTDEPLETED SEALANT

SPALLED SPALLED POLYSULPHIDE JOINTPOLYSULPHIDE JOINT CORNER SPALLINGCORNER SPALLING

SPALLED EDGESPALLED EDGE

Defects in Pavement JointsDefects in Pavement Joints

FUNCTIONAL REQUIREMENT OF JOINTSFUNCTIONAL REQUIREMENT OF JOINTS

A joint must be waterproof at all times.A joint must be waterproof at all times.

Free movement of the slabs at the joint must be Free movement of the slabs at the joint must be permitted at all times.permitted at all times.

Joints should not form a deterrent to the Riding Joints should not form a deterrent to the Riding Joints should not form a deterrent to the Riding Joints should not form a deterrent to the Riding Quality of a road carriageway.Quality of a road carriageway.

A joint should not be the cause of an unexpected A joint should not be the cause of an unexpected structural weakness in a pavement.structural weakness in a pavement.

Joints should interfere as little a possible with the Joints should interfere as little a possible with the placing of the concrete pavementplacing of the concrete pavement

LONGITUDINAL / WARPING JOINT

NO LONGITUDINAL JOINTS UPTO NO LONGITUDINAL JOINTS UPTO 4.5M PAVEMENT WIDTH.4.5M PAVEMENT WIDTH.

LONGITUDINAL JOINTS SHOULD LONGITUDINAL JOINTS SHOULD COINCIDE WITH PAVEMENT LANE COINCIDE WITH PAVEMENT LANE LINES & SHOULD BE ALWAYS LINES & SHOULD BE ALWAYS AVOIDED ALONG WHEEL TRACKS.AVOIDED ALONG WHEEL TRACKS.

TIE BARSTIE BARS

PREVENTS LANE SEPARATION AND/OR FAULTING.PREVENTS LANE SEPARATION AND/OR FAULTING.

MAXIMUM TENSION IN THE TIE BAR ACROSS ANY JOINT IS MAXIMUM TENSION IN THE TIE BAR ACROSS ANY JOINT IS EQUAL TO THE FORCE REQUIRED TO OVERCOME THE EQUAL TO THE FORCE REQUIRED TO OVERCOME THE FRICTION BETWEEN PAVEMENT AND SUBGRADE/SUBFRICTION BETWEEN PAVEMENT AND SUBGRADE/SUB--BASE BASE FROM THE JOINT UNDRE CONSIDERATION, TO THE NEAREST FROM THE JOINT UNDRE CONSIDERATION, TO THE NEAREST JOINT OR FREE EDGEJOINT OR FREE EDGE

AATT = (D X F X W)/W= (D X F X W)/WSS

WHERE AWHERE ATT = AREA OF STEEL REQUIRED PER/M LENGTH OF JOINT = AREA OF STEEL REQUIRED PER/M LENGTH OF JOINT IN SQ.CMIN SQ.CM

D = DISTANCE BETWEEN THE JOINTS OR JOINT AND FREE D = DISTANCE BETWEEN THE JOINTS OR JOINT AND FREE EDGE IN M.EDGE IN M.

F = COEFFICIENT OF FRICTION BETWEEN SLAB AND F = COEFFICIENT OF FRICTION BETWEEN SLAB AND SUBGRADESUBGRADE

WWSS = WEIGHT OF PAVEMENT SLAB IN KG/SQ.M.PER CM = WEIGHT OF PAVEMENT SLAB IN KG/SQ.M.PER CM THICKNESSTHICKNESS

LENGTHLENGTH OFOF TIETIE BARBAR::

ITIT SHOULDSHOULD BEBE ATAT LEASTLEAST TWICETWICE THATTHAT REQUIREDREQUIRED TOTODEVELOPDEVELOP BONDBOND STRENGTHSTRENGTH EQUALEQUAL TOTO THETHE WORKINGWORKINGSTRESSSTRESS OFOF THETHE STEELSTEEL..

L = (2 X WL = (2 X Wss X AX ATT) / (B) / (BSS X P)X P)

WHERE ,WHERE ,WHERE ,WHERE ,

L = LENGTH OF TIE BAR IN CM.L = LENGTH OF TIE BAR IN CM.

WWSS = ALLOWABLE WORKING STRESS IN STEEL KG/SQ.CM= ALLOWABLE WORKING STRESS IN STEEL KG/SQ.CM

AATT = CROSS= CROSS--SECTIONAL AREA OF ONE TIE BAR IN SQ.CM.SECTIONAL AREA OF ONE TIE BAR IN SQ.CM.

BBSS = PERMISSIBLE BOND STRESS IN KG/SQ.CM.= PERMISSIBLE BOND STRESS IN KG/SQ.CM.

P = PERIMETER OF TIE BAR IN CMP = PERIMETER OF TIE BAR IN CM

CONTRACTION JOINT

EXPECTEDEXPECTED CHANGECHANGE ININ SLABSLAB LENGTH,LENGTH,CC == FLFL ((TTEE XX SSEE))

WHEREWHERE F = BASE/SLAB FRICTIONAL RESTRAINTF = BASE/SLAB FRICTIONAL RESTRAINT

L = SLAB LENGTHL = SLAB LENGTH

= PCC COEFFCIENT OF THERMAL EXPANSION= PCC COEFFCIENT OF THERMAL EXPANSION

TTEE = MAXIMUM TEMPERATURE RANGE.= MAXIMUM TEMPERATURE RANGE.

SSEE = SHRINKAGE COEFFICIENT OF CONCRETE= SHRINKAGE COEFFICIENT OF CONCRETE

SPACING OF SPACING OF JOINTSJOINTS

JOINT WIDTHJOINT WIDTH

4.5 m (15)4.5 m (15) 10 mm10 mm

6.1 m (20)6.1 m (20) 12 mm12 mm

9.1 m (30)9.1 m (30) 12 mm12 mm

12.2 m (40)12.2 m (40) 16 mm16 mm

Dowel BarsDesigned so that maximum bearing stress between the concrete and dowel (Smax) should be less than the allowable bearing stress in concrete (Cb).

Smax = K Pt (2 + z) / (4 3 E I)

K = the modulus of dowel/concrete interaction in kg/cm2/cm Pt = the load transferred by a dowel bar = the relative stiffness of the bar embedded in concrete

= 4 (K b / 4 E I)= 4 (K b / 4 E I)E = the modulus elasticity of dowel in kg/cm2I = the moment of inertia of the dowel in cm4b = the diameter of dowel in cmz = the joint width in cm

Cb = Fck (10.16 b) / 9.525

Fck = the characteristic compressive strength of the concrete in kg/cm2b = the diameter of dowel in cm

Dowel requirement based on pavement Dowel requirement based on pavement thickness / truck trafficthickness / truck traffic

Concrete pavement thickness in MM

Truck Traffic

Trucks / day

Dowel Diameter in MM

< 175 80 Not < 175 80 Not necessary

175-200 80 -100 Left to engineers decision

200 - 250 100 32 mm

>250 > 100 >32mm

DOWEL BAR DETAILSDOWEL BAR DETAILS

Slab ThicknessSlab Thickness DiameterDiameter LengthLength SpacingSpacing

250 mm250 mm 32 mm32 mm 450 mm450 mm 300 mm300 mm

300 mm300 mm 38 mm38 mm 450 mm450 mm 300 mm300 mm

350 mm350 mm 44 mm44 mm 500 mm500 mm 300 mm300 mm

EXPANSION JOINT

Provided when concrete surface joins with fixed structures i.e., Bridge AbutmentsAbutments

CONSTRUCTION JOINT

Good construction planning ensures construction joint is either a contraction or expansion joint

CONSTRUCTION OF JOINTSCONSTRUCTION OF JOINTS

Placement of Concrete and Formation of JointsPlacement of Concrete and Formation of Joints Longitudinal joints, Contraction joints & Expansion joint locations Longitudinal joints, Contraction joints & Expansion joint locations

duly marked at site.duly marked at site. Dowels should be thinly coated with grease. Dowels should be thinly coated with grease. Adequate compaction of the concrete in the area of the jointsAdequate compaction of the concrete in the area of the joints When paving fullWhen paving full--depth fulldepth full--width, a mechanical prewidth, a mechanical pre--spreader and spreader and

finishing machine in the paving train can be used to reduce drag and finishing machine in the paving train can be used to reduce drag and shear forces on the dowels. shear forces on the dowels.

Sawing of JointsSawing of Joints TwoTwo--stage operation. Initial sawing is intended to cause the stage operation. Initial sawing is intended to cause the

pavement to crack at the intended joint. Second sawing provides the pavement to crack at the intended joint. Second sawing provides the necessary shape factor for the sealant material. necessary shape factor for the sealant material.

Timing of sawing: Premature sawing will cause Timing of sawing: Premature sawing will cause spallingspalling and and raveling raveling of concrete, and if sawing is late, of concrete, and if sawing is late, shrinkage cracks shrinkage cracks will appear. will appear.

For joints, an initial sawing depth of one 3rd of slab thickness is For joints, an initial sawing depth of one 3rd of slab thickness is adopted. adopted.

When a lengthy period is anticipated between the initial sawing of When a lengthy period is anticipated between the initial sawing of the joint and the final sawing and sealing, then the joint should be the joint and the final sawing and sealing, then the joint should be filled with a temporary filler.filled with a temporary filler.

Joint Fillers and Seals:Joint Fillers and Seals:

FieldField--mouldedmoulded sealants and Preformed sealants. sealants and Preformed sealants. Filler boards are used to provide the gaps for expansion Filler boards are used to provide the gaps for expansion

Causes of the Joint failureCauses of the Joint failure

Failure of Joint Seals Failure of Joint Seals Failure of Joint Seals Failure of Joint Seals Failure to transfer load by dowel rods. Failure to transfer load by dowel rods. Failure to expand / contract in the provided joint widthFailure to expand / contract in the provided joint width

Performance and life of JointsPerformance and life of Joints

Correct Design of JointsCorrect Design of JointsPhysical properties of sealant materialsPhysical properties of sealant materials

Properties of sealant materialsProperties of sealant materials be impermeable.be impermeable. deform to accommodate the total movement and rate of movement deform to accommodate the total movement and rate of movement

occurring at the joint.occurring at the joint. sufficiently recover their original properties and shape after cyclical sufficiently recover their original properties and shape after cyclical

deformations. deformations. remain in contact with the joint faces.remain in contact with the joint faces. not rupture internally.not rupture internally. not undergo unacceptable softening at high service temperatures.not undergo unacceptable softening at high service temperatures. not become unacceptable brittle at low service temperatures and remain not become unacceptable brittle at low service temperatures and remain

elastic.elastic.elastic.elastic. not to be affected to the durability and service factors by ageing, weathering not to be affected to the durability and service factors by ageing, weathering

and other environmental conditions that may occur.and other environmental conditions that may occur. not become sticky or cause staining under hotter climatic conditions. not become sticky or cause staining under hotter climatic conditions. have resistance to indentation and intrusion of solids. have resistance to indentation and intrusion of solids. have high resistance to hardening with age. have high resistance to hardening with age. have high bonding property with adjoining concrete with or without the have high bonding property with adjoining concrete with or without the

application of a primer. application of a primer. not shrink after they have been poured. not shrink after they have been poured. satisfy to the standard tests like bond strength, retest for bond, flow satisfy to the standard tests like bond strength, retest for bond, flow

penetration and etc. (BS 5212 penetration and etc. (BS 5212 --1990)1990)

Sealing Details of Contraction and Construction Joint GrooveSealing Details of Contraction and Construction Joint Groove

Sealing Details of Expansion Joint Groove Sealing Details of Expansion Joint Groove

Sealing Details of Longitudinal Joint GrooveSealing Details of Longitudinal Joint Groove

Sealing Details of Longitudinal Joint Between Sealing Details of Longitudinal Joint Between Cement Concrete Slabs and Bituminous ShoulderCement Concrete Slabs and Bituminous Shoulder

Materials required for Joint SealingMaterials required for Joint Sealing1. Primer (Low Viscosity type)1. Primer (Low Viscosity type)

2. Sealant Materials2. Sealant Materials

Hot poured elastic type of sealantsHot poured elastic type of sealants Hot poured rubberized asphalts (Thermoplastic type)Hot poured rubberized asphalts (Thermoplastic type) ColdCold--applied thermosetting type of sealantsapplied thermosetting type of sealants Preformed compression sealsPreformed compression seals

3. Storage of sealing material3. Storage of sealing material

4. Back4. Back--up materialup material

Polyethylene closed cell foamPolyethylene closed cell foam Polyurethane closed cell foamPolyurethane closed cell foam Sponge rubber closed cellSponge rubber closed cell Neoprene foam rod Neoprene foam rod Preformed gasketsPreformed gaskets

Effect of Debonding Paper on Free Movement of SealantEffect of Debonding Paper on Free Movement of Sealant

Effect of Compressible Backup Material on releasing Effect of Compressible Backup Material on releasing Extrusion PressureExtrusion Pressure

Sealing of JointsSealing of Joints Grooves be prepared, cleaned and primed.Grooves be prepared, cleaned and primed.

BackBack--up material or bond breaker shall be placed in joint groove.up material or bond breaker shall be placed in joint groove.

Debonding strip paper back (1 to 2 mm) thick is placed between Debonding strip paper back (1 to 2 mm) thick is placed between the sealant and the backthe sealant and the back--up material.up material.

Joint edges are protected with the masking tape. Joint edges are protected with the masking tape.

Placement of the sealant to a depth of at least 12 mm. The Placement of the sealant to a depth of at least 12 mm. The surface of which should be recessed by not less than 3 mm and surface of which should be recessed by not less than 3 mm and surface of which should be recessed by not less than 3 mm and surface of which should be recessed by not less than 3 mm and not more than 6 mm below pavement surface. not more than 6 mm below pavement surface.

The time lapse between priming of joint sides and placement of The time lapse between priming of joint sides and placement of sealant should be accordance with the sealant manufacturers sealant should be accordance with the sealant manufacturers written instruction.written instruction.

The traffic should not be opened to the freshly joint sealed The traffic should not be opened to the freshly joint sealed pavement until the sealant has adequately cool or cured not to pavement until the sealant has adequately cool or cured not to

pick up on vehicle tirespick up on vehicle tires

Sealing of JointsSealing of Joints

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONSCase I: Sealant not adhering to JointCase I: Sealant not adhering to Joint

Causes of ProblemsCauses of Problems SolutionsSolutions

Joint not clean enough during Joint not clean enough during preparationpreparation

Clean the joint surface and resealClean the joint surface and reseal

Apply on the wet joint surfacesApply on the wet joint surfaces Allow the joint surface to dry before Allow the joint surface to dry before the applicationthe application

In hot applied sealants type due to low In hot applied sealants type due to low Heat up the sealant materials in the Heat up the sealant materials in the In hot applied sealants type due to low In hot applied sealants type due to low sealant application temperaturesealant application temperature

Heat up the sealant materials in the Heat up the sealant materials in the melter melter pourer to the correct pourer to the correct temperature or verify the temperature temperature or verify the temperature gauges in the melter gauges in the melter pourer machinepourer machine

In cold ambient temperatureIn cold ambient temperature Allow the ambient temperature to raise Allow the ambient temperature to raise up for pouring the sealant into the jointup for pouring the sealant into the joint

Insufficient space in joint width for Insufficient space in joint width for cold applied sealants and after the road cold applied sealants and after the road is opening to the traffic, the traffic is opening to the traffic, the traffic tires are pulling out the sealanttires are pulling out the sealant

Keep the sufficient space for joint Keep the sufficient space for joint widthwidth

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONSCase II: Sealant pickCase II: Sealant pick--up or pullup or pull--out when opened to trafficout when opened to traffic

Causes of ProblemsCauses of Problems SolutionsSolutions

Opened to traffic too soon Opened to traffic too soon after applicationafter application

Refer to the sealant manufacturers written instructions Refer to the sealant manufacturers written instructions about the full setting time of the sealant after about the full setting time of the sealant after application. Traffic should be opened only after the full application. Traffic should be opened only after the full setting time of the sealant setting time of the sealant

Sealing operation has done in Sealing operation has done in high ambient temperature high ambient temperature

Joint sealing operation should be done in cooler Joint sealing operation should be done in cooler ambient temperature. Refer to manufacturers written ambient temperature. Refer to manufacturers written high ambient temperature high ambient temperature ambient temperature. Refer to manufacturers written ambient temperature. Refer to manufacturers written instructions about the application ambient temperature instructions about the application ambient temperature

Excessive sealant application Excessive sealant application without space under the without space under the concrete top surface in the concrete top surface in the joints joints

Sealant should be applied with a specified space in a Sealant should be applied with a specified space in a joint joint

Type of sealant is too soft for Type of sealant is too soft for the particular climate the particular climate

Use the stiffer type of sealant to resist the extremely hot Use the stiffer type of sealant to resist the extremely hot climate temperature climate temperature

Due to overheated or under Due to overheated or under heated temperature sealant heated temperature sealant was applied was applied

Apply the sealant at correct temperature as per Apply the sealant at correct temperature as per manufacturers written instructions. The temperature manufacturers written instructions. The temperature gauge on melter machine should also be verified gauge on melter machine should also be verified

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONS

Case III: Sealant gelling in Case III: Sealant gelling in meltermelter

Causes of ProblemsCauses of Problems SolutionsSolutions

Sealant overheated in Sealant overheated in melter melter

Check and verify the temperature gauges in melter Check and verify the temperature gauges in melter

Sealant reheated too many Sealant reheated too many times times

Use the fresh sealant Use the fresh sealant times times

Using sealant with short Using sealant with short pot life pot life

Change the type of sealant with longer pot life Change the type of sealant with longer pot life

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONS

Case IV: Sealant cracking or debonding in winterCase IV: Sealant cracking or debonding in winter

Causes of ProblemsCauses of Problems SolutionsSolutions

Applied sealant is too stiff Applied sealant is too stiff at low temperature at low temperature

Use the type of sealant which is more extendible Use the type of sealant which is more extendible at low temperature. at low temperature.

Poor cleaning the joint Poor cleaning the joint during sealant installation during sealant installation

Improve the joint cleaning during preparation Improve the joint cleaning during preparation

Sealing operation has done Sealing operation has done Avoid executing the sealing operation during the Avoid executing the sealing operation during the Sealing operation has done Sealing operation has done during hot summer when during hot summer when the joint widths are at their the joint widths are at their narrowest gaps narrowest gaps

Avoid executing the sealing operation during the Avoid executing the sealing operation during the extremely hot temperatures extremely hot temperatures

Joint width is too narrow Joint width is too narrow for the movement for the movement experienced in concrete experienced in concrete pavement pavement

Provide wider joints width Provide wider joints width

Joints spacing are too long Joints spacing are too long Provide the closer joint spacing Provide the closer joint spacing

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONSCase V: Voids or bubbles formed in cured sealantCase V: Voids or bubbles formed in cured sealant

Causes of ProblemsCauses of Problems SolutionsSolutions

Due to high temperature and Due to high temperature and moisture in the pavement moisture in the pavement when sealing operation has when sealing operation has done done

Sealing work should be done in cooler periods and Sealing work should be done in cooler periods and allow the concrete pavement sufficient time to dry or allow the concrete pavement sufficient time to dry or cure before the sealing operation cure before the sealing operation

Damaging of backer material Damaging of backer material It may be melting with the hot applied sealants. Use the It may be melting with the hot applied sealants. Use the heat resistant backer material and check for proper heat resistant backer material and check for proper sealant temperature during the sealing operation sealant temperature during the sealing operation

Backer rod punctured and Backer rod punctured and damaged during installation damaged during installation

Install the backer rod cautiously without damaging Install the backer rod cautiously without damaging

Due to top to down sealing Due to top to down sealing sequence which can trap air at sequence which can trap air at the bottom the bottom

Apply the sealant from bottom to up sequence which Apply the sealant from bottom to up sequence which will avoid from trapping air at the bottom will avoid from trapping air at the bottom

Air entering the sealant Air entering the sealant pumping pipe lines pumping pipe lines

Tighten all the connections at the pipe lines or bleed off Tighten all the connections at the pipe lines or bleed off the entrapped air the entrapped air

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONS

Case VI: Sink holes in sealantsCase VI: Sink holes in sealants

Causes of ProblemsCauses of Problems SolutionsSolutions

Sealant material flowing Sealant material flowing through the gaps formed through the gaps formed in backer material in backer material

Use the larger backer material, reapply the Use the larger backer material, reapply the sealant at the top surface to correct the level sealant at the top surface to correct the level or use the nonor use the non--sag type sealant sag type sealant

Backer material fixed in Backer material fixed in Use the heatUse the heat--resistant type backer material resistant type backer material Backer material fixed in Backer material fixed in the joint is melting when the joint is melting when pouring the hotpouring the hot--applied applied sealants sealants

Use the heatUse the heat--resistant type backer material resistant type backer material

COMMON PROBLEMS AND SOLUTIONSCOMMON PROBLEMS AND SOLUTIONS

Case VII: ColdCase VII: Cold--applied sealants not setting upapplied sealants not setting up

Causes of ProblemsCauses of Problems SolutionsSolutions

Sealant material shelf Sealant material shelf life is expired life is expired

Use the fresh manufactured date sealant Use the fresh manufactured date sealant material material

Incorrect proportion Incorrect proportion Correct the proportion of mixing the two Correct the proportion of mixing the two mixing of two mixing of two component sealants component sealants

component sealants and the mixing system. component sealants and the mixing system. Refer to the sealant manufacturers written Refer to the sealant manufacturers written instructions instructions

Bond Breakage due to inadequate Bond Breakage due to inadequate

Deficiencies in application of joint sealantsDeficiencies in application of joint sealants

Faulty sealing procedure has resulted Faulty sealing procedure has resulted Bond Breakage due to inadequate Bond Breakage due to inadequate quantity of sealant quantity of sealant

Faulty sealing procedure has resulted Faulty sealing procedure has resulted in air bobble embedded in the sealant in air bobble embedded in the sealant

Without a debonding strip the Without a debonding strip the lower fiber has started to crack lower fiber has started to crack

Harder variety of sealant has Harder variety of sealant has cracked in cold season cracked in cold season

Deficiencies in application of joint sealantsDeficiencies in application of joint sealants

Sealant filled Sealant filled uptoupto brim is bulging brim is bulging Overfilled sealant has caused Overfilled sealant has caused

bumpy joint bumpy joint Sealant filled Sealant filled uptoupto brim is bulging brim is bulging

out during expansion of slabs out during expansion of slabs bumpy joint bumpy joint

Improper placement of debonding Improper placement of debonding tape has resulted in leakage of tape has resulted in leakage of

sealant inside the groovesealant inside the groove

Embedded stone is causing Embedded stone is causing spallingspalling of concreteof concrete

THANK YOUTHANK YOU