Safer, dust-free installation of pre-compressed expansion joint seal systems

Abstract

A safer, dust-free method for installing an expansion joint seal system without mechanically abrading the substrate to improve adhesion is disclosed. The method includes installing a substrate forming a gap between opposing surfaces of the substrate, preparing the surface by solvent wiping, and applying a mounting strip of sealant to the surface. The method includes placing a seal system in the gap adjacent to or within the mounting strip, and maintaining the seal system in the gap until the system expands toward the surface, embeds within the mounting strip, and secures the seal system in place between the opposing surfaces. The method also includes removing the existing system by severing the sealant between the existing joint seal system and the substrate prior to preparing the surface, wiping the surface with solvent, and leaving any deformed or embedded residue from the removed seal system on or embedded in the surface of the substrate.

Description

[Technical field]

[0001] The present disclosure generally relates to a joint seal system and a safer, dust-free installation or replacement and reinstallation or retrofit method thereof. More particularly, the present disclosure relates to an expansion joint seal system and a process for installing the same in joints between substrates forming building or structural components. Substrates include, for example, concrete and other building or structural systems designed to accommodate movement due to, for example, heat, wind and / or earthquake shaking, shear and / or load forces, or other building or structural movements. The present disclosure also applies to sealing solutions for many other gaps or joints between substrates of building or structural systems that do not experience significant movement, but are still required to resist or prevent water ingress, contain heat, flame and / or smoke from fire for a period of time, and provide thermal and other improved sealing properties. These gaps or joints between substrates forming building components include, for example, control joints in masonry (brick or concrete block (CMU)), joints in building or structure facades or exterior insulated floor systems (EIFS), window surround joints, joints in precast concrete or metal panel construction, and others in structures including, but not limited to, buildings, parking structures, stadiums, tunnels, bridges, etc. [Background technology]

[0002] Most buildings include expansion joints, control joints, and other gaps between substrates forming the building or structural components that are designed to accommodate the movement of the structure. Expansion joints are generally about 0.375 inches (0.9525 cm) wide across the joint and are designed to accommodate the movement of the building or structural components caused by thermal expansion and contraction as well as wind, earthquake, shear, and load. Control joints are used to allow substrates made of materials including, for example, concrete or brick to shrink during curing, eliminating tension forces across the joint and thus preventing cracking of the substrate material. Window perimeter joints are present to accommodate and tolerate imprecision in construction and to prevent any forces from being transmitted to the window itself. References below to expansion joints and / or construction joints should be understood to be any of these various gaps or joints between substrates forming the building or structural components.

[0003] Systems designed to seal expansion and / or construction joints may be positioned to extend through both the interior and exterior surfaces of substrates of a building or structure, such as walls, floors, ceilings, and roofs. For exterior joints between substrates forming exterior walls, floors, or roofs that are exposed to exterior environmental conditions, the expansion joint seal system must contain and / or resist to some extent the effects of the exterior environmental conditions on the joint. Thus, most exterior expansion joint seal systems are designed to contain and / or resist the effects of water penetrating the structure. Seal systems installed on vertically oriented exterior joints between substrates are designed to resist the penetration of water in the form of rain, snow, ice, or the intrusion of foreign bodies caused by wind. Seal systems installed on horizontally oriented exterior joints between substrates are designed to resist water in the form of rain, puddles, snow, ice, etc., foreign bodies such as sand, chemicals used to treat snow and / or ice covered surfaces, and all of these simultaneously, depending on the circumstances. Additionally, some seal systems installed in horizontal joints may be exposed to pedestrian and / or vehicular traffic and are designed to withstand such traffic while providing and maintaining a seal.

[0004] Water-resistant or watertight joint seal systems can exist in different forms, but are generally composed of materials designed to resist water penetration and adapt to the physical cycles resulting from thermal expansion and / or contraction, wind and / or seismic shaking, and movement of a building or structure in response to load and / or shear forces.

[0005] Several devices have been used to attempt to provide a watertight expansion joint sealing system. One such sealing system, known as a "caulk and backing bar" system, requires on-site assembly by a skilled installer to provide a finished, functional joint sealing system. These systems can have numerous deficiencies related to both the installation method and the technology itself. Installation issues include difficulties in inserting the backing bar and difficulty in setting the backing bar at the proper depth. Technical issues include closed cell compression set of the backing bar, the possibility of poor or no adhesion between the backing bar and the overcoated caulk, tension in the caulk, caulk curing under ambient or non-ideal conditions and caulk curing while movement occurs. Furthermore, these issues are generally exacerbated when the system is installed or is expected to be installed in a moving joint that is nominally greater than about 1 inch (2.54 cm) wide across the joint and that operates by accommodating movement of more than about + or -10 to 15 percent (±10 to 15%). Such aforementioned factors can result in less than desirable results, such as shorter system life and poor migration capabilities, which can ultimately result in water intrusion and associated problems. The field assembly nature of the caulk and backing bar system can contribute to high installation labor costs, offsetting much of the cost benefit realized with less expensive components.

[0006] U.S. Patent No. 5,130,176 describes a sealing system designed to address some of these problems. The described sealing system may eliminate the need for on-site assembly and improve productivity. The described system is particularly effective in joints between substrates that have a width across the joint of more than about 1.5 inches (3.81 cm), and may be used in joints as large as about 12 inches (30.48 cm) across, for example.

[0007] The trend in the building industry is toward fewer and larger / wider expansion joints. The trend toward fewer joints is due in part to the fact that expansion joints are typically placed in areas of water infiltration and fire containment deficiencies. Additionally, the trend toward larger / wider joints is due to building codes that mandate that greater wind and / or seismic movement be considered during design and construction.

[0008] It has been generally recognized that architectural joint seal systems are inadequate with respect to fire resistance. In some cases, movement due to construction or expansion joints can result in cracks or gaps in joint seal solutions for joints between substrates, which can create a chimney effect, which has been shown to be critical with respect to fire containment. This often results in the destruction of fire-resistant elements that may be incorporated into the design and construction of the building or structure. This problem is particularly acute in large, high-rise buildings, parking structures, and stadiums, where fires can spread quickly and do not allow for safe and adequate evacuation from the structure.

[0009] Early designs of fire-resistant joint seal systems included monolithic blocks of mineral wool or other inorganic materials in either monolithic or composite configurations, with or without in-situ liquid sealants. Generally, these designs were suitable for non-moving or controlled joints where the movement was small. Where the movement was large and the material compressed significantly in response to cycles of normal thermal expansion and contraction, wind and / or earthquake shaking, load and / or shear forces, or other movements of the building, these designs generally did not function as intended. In fact, many designs simply lacked the resilience or recovery characteristics required to maintain adequate coverage / seal across the entire joint width over normal thermal cycles (expansion and contraction) and other movements experienced by buildings and other structures. Many of these designs are tested according to accepted testing standards, such as ASTM International's "Standard Test Methods for Fire Tests of Building Construction and Materials" (ASTM E-119), which provide for fire exposure testing of building components under static conditions and do not consider the dynamic nature of the expansion joint seal system. As discussed above, this dynamic behavior can contribute to compromising the water and / or fire resistance properties of some building designs.

[0010] The Underwriters Laboratories has developed test standard 2079, "Tests for Fire Resistance of Building Joint Systems" (UL 2079), which is a further refinement of the ASTM E-119 fire resistance requirements by adding a cyclic joint movement regime to the UL 2079 test standard. The UL 2079 cyclic joint movement regime is substantially similar to a second ASTM International test standard, "Standard Test Method for Cyclic Movement and Measuring the Minimum and Maximum Joint Widths of Architectural Joint Systems" (ASTM E-1399). In addition, the UL 2079 standard specifies that designs are tested at the maximum joint size. The UL 2079 test standard is considered more reflective of real-world conditions, and therefore architects and engineers have begun to specify expansion joint seal products that meet it. Many designs that pass ASTM E-119 without the cyclic movement regime will not pass the UL 2079 test standard. This may be appropriate for non-moving construction joints between substrates as described above, however, most construction expansion joint systems are designed to accommodate some degree of movement as a result of thermal action (e.g., expansion into the joint and contraction away from the joint), wind and / or seismic sway, load and / or shear forces. Co-owned U.S. Patent No. 8,365,495 and other co-owned patents describe an expansion joint seal solution that addresses both the water and fire resistance aspects in a single expansion joint seal system that passes the fire resistance and movement cyclic tests provided by the UL 2079 test standard.

[0011] Additionally, in the field of joint sealing in architectural environments, there remains a need to maintain construction or expansion joint seals by first sealing, then removing the old system, and installing a replacement joint sealant. Porous substrates between which construction and expansion joints are formed range from natural stone, concrete, masonry (e.g., brick, CMU), EIFS, stucco, and the like. The surfaces of these substrates need to be prepared and / or repaired prior to installation of the expansion joint seal system into the gap or joint formed between the substrate surfaces. Substrate surface preparation and / or repair may be required to make the surface receptive to adhesives or other sealants that aid in bonding and adhesion between the expansion joint seal system and the substrate. Preparation and repair may include, for example, cleaning, scraping, grinding, sanding, polishing, or other treatments to remove dirt, old sealant residue, or other materials that may prevent the formation of a good bond and adhesion between the substrate and the expansion joint seal system. Preparation and / or repair may also include smoothing the surface to remove high spots or fill voids. As can be appreciated, scraping, grinding, sanding and / or polishing of substrates and materials on the substrate surface can release dust or other contaminants as airborne particles. The airborne particles can be harmful to personnel installing the expansion joint seal system and anyone in the vicinity of the work area. For example, it is known that scraping, grinding, sanding or polishing of some materials commonly used as substrates in construction can release particles including silica. Silica is known to be a health hazard to humans when inhaled.

[0012] Safety and other building and health agencies, for example, in the United States, the Occupational Safety and Health Administration (OSHA) and state and local building and health departments implement regulations that set requirements to protect workers and building occupants from the inhalation of free silica and other contaminants. Compliance with these regulations requires installers to use dust collection equipment attached to all cutting, scraping, grinding, sanding and polishing tools. Dust collection accessories generally make the equipment heavier and more difficult to maneuver. In addition, installers are generally required to use personal protective equipment (PPE), including, for example, self-contained breathing apparatus (SCBA), to meet OSHA requirements to prevent or at least substantially minimize inhalation risks. Although desirable for health and safety reasons, the combined use of PPE and dust collection equipment can increase the cost of installation, reduce productivity, and create additional burdens or introduce other health and safety risks to the installer. Summary of the Invention [Problem to be solved by the invention]

[0013] Thus, a need remains for an expansion joint seal system and installation method that eliminates the need for scraping, grinding, sanding and abrading the surfaces of the substrate that will form the expansion joint to prepare the surface to receive an adhesive or other sealant that will aid in the bond between the expansion joint seal system and the substrate. [Means for solving the problem]

[0014] Thus, according to embodiments herein, a system and installation method is provided that resists or prevents water ingress, holds back heat, flames and / or smoke from a fire over a period of time, and provides improved thermal and other sealing properties while accommodating structural movement and sealing joints more safely, among other advantages. The embodiments disclosed herein overcome the technical problems of previous construction joint seal designs, such as caulking and backing bars, and improve upon the teachings of prior art systems and installation methods.

[0015] According to one aspect, a relatively safer, dust-free method for installing a pre-compressed expansion joint seal system is provided. The method includes installing a first substrate and a second substrate within a target structure, where the second substrate is disposed flush with the first substrate and spaced from the first substrate by a gap formed between the opposing surfaces of the first substrate and the second substrate. The method includes preparing the opposing surfaces of the first substrate and the second substrate without the need to mechanically polish or grind the substrates by wiping the opposing surfaces with a solvent and applying a mounting strip of liquid sealant to the opposing surfaces of the first substrate and the second substrate while leaving any surface deformations and residues. The method also includes placing the expansion joint seal system in the gap by installing the pre-compressed expansion joint seal system between the opposing surfaces and at least one of adjacent to or within the mounting strip of liquid sealant applied to the opposing surfaces of the first substrate and the second substrate. The method includes maintaining the pre-compressed expansion joint seal system in position within the gap until the pre-compressed expansion joint seal system expands outwardly toward the opposing surfaces, embeds within a mounting strip of sealant, and secures the expansion joint seal system in position between the opposing surfaces of the first and second substrates.

[0016] In one embodiment, the safer, dust-free method for installing the pre-compressed expansion joint seal system further includes applying a bead of liquid sealant to and between a portion of the top surface of the pre-compressed expansion joint seal system and the opposing surfaces of the first and second substrates.

[0017] In yet another embodiment, a safer, dust-free method for installing a pre-compressed expansion joint seal system further includes, prior to preparing the opposing surfaces of the first and second substrates, installing an existing joint seal system installed in the gap between the first and second substrates, and removing the existing joint seal system by severing the sealant between the existing joint seal system and the first and second substrates. In this embodiment, preparing the opposing surfaces of the first and second substrates by wiping further includes wiping the opposing surfaces with a solvent and either preparing the substrates or removing the residue of the previously installed and removed joint seal system without having to mechanically sand or grind the substrates, while leaving any embedded residue of remaining sealant from the existing and now removed joint seal system remaining embedded on or in the opposing surfaces of the first and second substrates.

[0018] In one embodiment, a safer, dust-free method for installing a pre-compressed expansion joint seal system includes installing a water-resistant and / or fire-resistant pre-compressed expansion joint seal system. In one embodiment, the water-resistant and / or fire-resistant pre-compressed expansion joint seal system includes a fire-retardant material introduced into a core of the expansion joint seal system, and the core with the fire-retardant material therein has a fire resistance of about 160 kg / m 3 ~about 800kg / m 3 and the expansion joint seal system is configured to pass the tests provided by UL 2079. In one embodiment, the pre-compressed expansion joint seal system further includes a water-resistant or waterproof coating applied to a surface of the pre-compressed expansion joint seal system. In one embodiment, the water-resistant or waterproof coating is paintable.

[0019] Referring now to the drawings, which are exemplary embodiments, like elements are numbered likewise. [Brief description of the drawings]

[0020] [Figure 1A] FIG. 2 is a schematic partial cross-sectional view of a coated pre-compressed expansion joint seal system according to one embodiment. [Figure 1B] FIG. 1B is a schematic partial cross-sectional view of the expansion joint seal system of FIG. 1A after compression and forming an arch-shaped top profile, according to one embodiment. [Figure 1C] FIG. 1B is a schematic partial cross-sectional view of the expansion joint seal system of FIG. 1A after being compressed, consolidated into multiple laminae, and forming a bellows-shaped top surface profile, according to one embodiment. [Figure 2A] FIG. 1C is a schematic diagram of the compressed and arched expansion joint seal system of FIG. 1B wound on a spool for shipping. [Figure 2B] 2B is a cross-sectional view of FIG. 2A taken along section BB of FIG. 2A. [Figure 2C] FIG. 1D is a schematic diagram of an end view of the compressed, bellows-shaped expansion joint seal system of FIG. 1C packaged for shipment. [Figure 2D] FIG. 1D is a schematic diagram of a perspective view of the compressed, bellows-shaped expansion joint seal system of FIG. 1C packaged for shipment. [Figure 3A] FIG. 2 is a schematic partial cross-sectional view of an expansion joint seal system including layers and after compression to form an arch-shaped top profile, according to one embodiment. [Figure 3B] 1 is a schematic partial cross-sectional view of an expansion joint seal system including layers and after compressing, consolidating into a plurality of lamina, and forming a bellows-shaped top surface profile, according to one embodiment. [Figure 4] 1 illustrates a safer, dust-free method for installing an expansion joint seal system, according to an embodiment. [Figure 5A] 5A-5C are schematic partial cross-sectional views of the method steps of FIG. 4 according to one embodiment. [Figure 5B] 5A-5C are schematic partial cross-sectional views of the method steps of FIG. 4 according to one embodiment. [Figure 5C] 5A-5C are schematic partial cross-sectional views of the method steps of FIG. 4 according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to a resilient water-resistant and / or fire-resistant expansion joint seal system and its safer, dust-free installation method by compressing the system within a gap or joint between substrates forming building or structural components of structures including, but not limited to, buildings, parking lots, stadiums, tunnels, bridges, etc. When installed under compression, the water-resistant and / or fire-resistant expansion joint seal system accommodates thermal expansion and contraction and movement of building or structural components caused by wind, earthquake, shear and loads as needed, while maintaining water resistance, fire resistance and / or other desired properties as the system seals the gap or joint. Although other methods and materials may be used for the construction described herein, particularly suitable and preferred methods and materials are described herein. Unless otherwise specified, any technical or scientific term used has the meaning as understood by one of ordinary skill in the art to which the invention pertains.

[0022] The expansion joint seal system described herein according to embodiments is best understood by reference to the accompanying drawings. Referring to FIG. 1A, there is disclosed a partial cross-sectional view of one embodiment of an expansion joint seal system 10 manufactured, installed, and operative in accordance with aspects of the present invention. As shown in FIGS. 1A-1C, the expansion joint seal system 10 includes a core 11, which is comprised of one or more strips or lamina 16 or blocks of, for example, open-cell polyurethane foam material, which is treated with at least one and / or combination of water-resistant chemicals 12, such as acrylics or waxes, fire-resistant materials 14, ultraviolet (UV) stabilizers, and / or polymeric materials, impregnated, saturated, dispersed, permeated, loaded, contained, or otherwise introduced to at least partially or entirely fill or coat the exterior or interior of the cells and / or matrix of the material of the core 11. In one embodiment, the core 11 is described above as being composed of a foam, such as an open-cell polyurethane foam, but it should be understood that this material is merely an example of one suitable material for the core 11. Other examples of materials for the core 11 include, but are not limited to, polyurethane foam and / or polyether foam, and may be open-cell or dense closed-cell structures. Further examples of materials for the core 11 include paper-based products, cardboard, metal, plastics, thermoplastics, dense closed-cell foams, such as polyurethane and polyether open or closed-cell foams, crosslinked foams, neoprene foam rubber, urethane, ethyl vinyl acetate (EVA), silicone, core chemistries (e.g., foam chemistries) that impart inherently hydrophobic and / or fire-resistant properties to the core 11; and / or composite materials. Any combination of the above-mentioned materials or other suitable materials may also be used to construct the core 11. It is further noted that while foam is primarily referred to herein as a material for the core 11, the description of foam may also be applied to other materials for the core, such as those described above.

[0023] In one embodiment, the strips or lamina 16 are fabricated from large sheets of core 11 material, typically about 1.5 inches (1.5 in.; 3.81 cm) thick by 20 inches (20 in.; 50.8 cm) wide by 10 feet (10 ft.; 3.048 m) long. Other dimensions may be used as needed depending on the circumstances. The sheets or blocks of core 11 material are preferentially treated by being impregnated, saturated, dispersed, permeated, loaded, contained or otherwise introduced with suitable water-resistant chemicals 12, such as, for example, water-based acrylics, ultraviolet (UV) stabilizers, polymeric materials, fire-resistant materials 14, individually and / or in combination. In one embodiment, the weight ratio of core material to chemicals (including particles) may be in the range of about 1:1 to about 1:5 by volume, the ratio being determined in part by the permeability of the core material, with the amount of chemicals and particles relative to the core 11 material generally being greater the greater the permeability. Similarly, more chemicals and core materials may be used and the core material is more porous, i.e., has a larger bubble size, as this often results in higher permeability. Alternatively or in addition, larger particles may be used and the core material is more porous, i.e., has a larger bubble size.

[0024] In one embodiment, the fire resistant material 14 is preferentially impregnated, saturated, dispersed, infiltrated, encased, included or otherwise introduced into the sheet or block of material of the core 11 in a ratio of about 3.5:1 to 4:1 by weight relative to the untreated material of the core 11 itself. The resulting uncompressed material of the core 11, whether comprising a solid block or multiple lamellae, has a compressibility of about 130 kg / m according to the embodiment. 3 ~Approx. 150kg / m 3 range, specifically 140kg / m 3 Another suitable density of the resulting uncompressed material of the core 11 may be about 50 kg / m 3 ~about 250kg / m 3 , for example more particularly about 80 kg / m 3 ~Approx. 180kg / m3 Or about 100 kg / m 3 ~Approx. 180kg / m 3 10 to 150 kg / m2, which can provide the desired water and / or waterproofing and fire resistance to the structure. According to embodiments, the materials of the core 11, including the water resistant chemicals 12, ultraviolet (UV) stabilizers, polymeric materials, and / or fire resistant materials 14, can be constructed to ensure that substantially the same density of the water resistant chemicals 12 and / or fire resistant materials 14 is present in the expansion joint seal system regardless of the final size of the system. As a non-limiting example, according to embodiments, when compressed, the processed materials of the core 11 generally have a density of at least about 160 to about 800 kg / m2. 3 It should be understood that the present invention is not limited to processing within the uncompressed density ranges described above and / or may cycle within the compressed density ranges described above. For example, depending on the embodiment, installation, and compression ratio, the core 11 may have a density outside the density ranges described herein, such as from about 50 to about 250 kg / m uncompressed. 3 and when compressed, the density is about 160 to about 800 kg / m 3 A density of 100 nm can be achieved.

[0025] In embodiments described herein, the treated material of the core 11 can be configured to provide an amount of flame retardant material 14 incorporated into the core 11 such that the resulting treated material of the core 11, regardless of the final size of the product, will pass, e.g., comply with, Underwriters Laboratories' UL 2079 travel cycle and fire resistance test program. For example, according to various embodiments, the amount of flame retardant material 14 incorporated into the core 11 is such that the resulting material will withstand and endure travel cycles by repeating the intended range of travel (expansion and contraction) and subsequently meet the prescribed fire resistance test approval requirements. As known to those skilled in the art, travel cycle testing is defined in Section 9 of UL 2079, while fire resistance testing is defined under Section 11. As required by the test standard, the expansion joint seal system 10 described herein passes the UL 2079 fire resistance test by being able to resist, withstand, and withstand exposure to one or more times and temperatures set forth in the UL 2079 time-temperature curve, such as a temperature of about 538°C for about 5 minutes, a temperature of about 927°C for about 1 hour, a temperature of about 1010°C for about 2 hours, a temperature of about 1052°C for about 3 hours, a temperature of about 1093°C for about 4 hours, and a temperature of up to about 1260°C for about 8 hours, without significant loss of integrity of the joint seal system. Optionally, and depending on the intended use of the expansion joint seal system undergoing UL 2079 testing, for example, the joint seal system intended for installation and use in vertical applications (wall mounted systems) versus horizontal applications (floor mounted systems), the core 11 may pass other tests set forth in UL 2079, such as the hose stream test as defined in sections 17 and 18 of UL 2079.

[0026] Furthermore, in all of the embodiments described herein and as shown in Figures 3A and 3B, the fire retardant material 14 introduced into the core 11 material may be in the form of a layer 19 disposed between the core 11 material or portions of the core 11 material. The layer 19 containing the fire retardant material 14 may be located within the body of the core 11 material, for example as an inner layer, or a thin layer of the fire retardant material 14 is introduced with a higher ratio or density than the remainder of the core 11 material. It should be understood that the present invention is not limited to the exact or precise location or placement of the layer 19 within the core 11 material shown in Figures 3A and 3B, as the layer 19 may be included at various depths within the core 11 material without departing from the scope of the present invention. It is further noted that the layer 19 may extend within the core 11 material in any direction relative to the width of the construction or expansion joint. For example, the layer 19 may be oriented parallel to the direction in which the joint width extends, perpendicular to the direction in which the joint width extends, or a combination of the above. Layer 19 acts as a fire resistant barrier layer within the material or body of core 11. Thus, layer 19 may comprise, for example, any suitable material that provides fire retardant properties.

[0027] Further, it should be understood that the present invention is not limited to the uncompressed and compressed densities and / or layered or non-layered embodiments described herein that may be used to provide water and / or fire resistance and / or other properties without adversely affecting the ability of the expansion joint seal system to repeatedly (expand and contract) to accommodate movements of the substrate (between which the system is compressed) during installation and operation in order to maintain a seal. For example, acceptable or favorable performance of an expansion joint seal system 10 designed and operated in accordance with the present invention requires a balance between the back pressure (e.g., stored strain energy due to compression that provides a restoring or returning force) provided by the organic structure of the raw material of the core 11 (e.g., the organic cellular structure of the raw core without the incorporation of one or more water-resistant chemicals 12, ultraviolet (UV) stabilizers, polymeric materials and / or fire-resistant materials 14) and the amount of component (liquid or solid) introduced (e.g., by impregnating, saturating, dispersing, penetrating, placing, containing or other equivalent process) into the organic structure, because the amount of component introduced into the structure of the core 11, whether it be the water-resistant chemicals 12, the fire-retardant materials 14 or other compositions, affects the degree to which the back pressure of the raw material of the core 11 is attenuated or inhibited by the introduced component or components. Thus, the amount of a component introduced, saturated, impregnated, dispersed or infiltrated or placed in must not adversely affect, for example, the ability of the system to cycle (expand and contract) to accommodate movements of the substrate (between which the system is compressed) in order to maintain the seal provided by the expansion joint seal system during operation, and, in the case of fire resistant expansion joint seal systems, the ability of the system to pass by complying with at least the cycle of movement and fire resistance test program of the UL 2079 standard.

[0028] One type of flame retardant material that may be used is aqueous aluminum trihydrate, also known as aluminum trihydroxide (ATH). However, the present invention is not limited in this regard, as other flame retardant materials may be used. Such materials include, but are not limited to, expanded graphite and / or other carbon-based derivatives that may impart fire resistance or flame retardancy, metal oxides and other metal hydroxides, aluminum oxides, antimony oxides and hydroxides, iron compounds such as ferrocene, molybdenum trioxide, nitrogen-based compounds, phosphorus-based compounds, halogen-based compounds, halogens such as fluorine, chlorine, bromine, iodine, astatine, compounds that may inhibit combustion and smoke formation, and combinations of any of the above-mentioned materials. However, the present invention is not limited in this regard, as other flame retardant materials may be used.

[0029] In one embodiment, a process by which chemicals (e.g., water-resistant chemicals 12, ultraviolet (UV) stabilizers, polymeric materials, and / or fire-resistant materials 14) may be impregnated, saturated, dispersed, loaded, contained, or otherwise introduced into the cellular structure of the core 11 material includes suspending the chemicals in a solution (e.g., in water or another solvent) and then passing a sheet of the core 11 cellular material through an apparatus floating in a bath of solution, which compresses and releases the core 11 material, causing the core 11 to draw the solution (and thus the chemicals) into the bubbles of the core 11 material, resulting in a cellular structure that is completely coated and at least partially or entirely filled. The solvent is then driven off by a drying process, leaving the chemicals dispersed throughout the cellular structure of the core 11 material. It should be understood that alternative processes, as known to those skilled in the art, may be used to impregnate, soak, disperse, permeate, place, include or otherwise introduce water-resistant chemicals 12, ultraviolet (UV) stabilizers, polymeric materials and / or fire-resistant materials 14 to at least partially or entirely fill or coat the exterior or interior of the cells and / or matrix of core 11.

[0030] After the chemicals (e.g., water-resistant chemicals 12, ultraviolet (UV) stabilizers, polymeric materials, and / or fire-resistant materials 14) have been impregnated, saturated, dispersed, loaded, contained, or otherwise introduced into the material of the core 11, and the chemicals and treated core 11 have been properly cured, the sheet may be coated with a suitable water-resistant or waterproof material 20, such as, for example, an elastomeric sealant coating, which is applied to the surface of the core 11. As described below, the sealant coating should not only provide water-resistant and / or waterproof properties, but also provide excellent bonding when used in installation, eliminating the need for scraping, sanding, and grinding the surfaces of the substrates that form the expansion joints in which the expansion joint seal system is to be used. In one embodiment, the coating of water-resistant or waterproof material 20 is applied to the exterior surface of the core 11 to a thickness of approximately 0.032 inches (0.032 in; 1 mm). The coating is cured per manufacturer's instructions.

[0031] In one embodiment, the water-resistant or waterproof material 20 is composed of a moisture-curable composition, in particular a moisture-curable composition based on isocyanate-terminated polymers or silane-terminated polymers. In particular, preference is given to moisture-curable compositions based on isocyanate-terminated polyurethane polymers and / or silane-terminated polyurethane polymers, which are suitable as sealants or elastic adhesives. Examples of such compositions are commercially available under the brand names Sikaflex® or SikaHyflex® from Sika Corporation, USA. One particularly suitable such composition is, for example, SikaHyflex®-150 LM (Low Modulus) sealant from Sika Corporation, Lyndhurst, New Jersey USA. In one embodiment, the moisture-curable composition that may be used as a sealant coating is paintable and is adapted to receive a topical application of another coating, such as a color, a sealant repair or a protective coating, and to coat the surface of the structure to which the expansion joint seal system 10 is to be attached. Thus, a localized application of paint or other coating may be applied to an entire facade or other surface of a building or structure without the need to mask the joints or interrupt the paint or other coating application process (e.g., spraying or rolling the surface) at the joints. It is recognized that the advantage of eliminating a masking step or providing a continuous application process is increased efficiency in performing this subsequent localized application. In one embodiment where such a subsequent localized application is applied, the moisture-curable composition used as the sealant coating may be provided in a neutral color.

[0032] For example, providing a paintable sealant coating such as the moisture curable composition described above is an improvement over conventional expansion joint sealant systems, and it should be understood that silicone-based coatings are known to attract dirt and other environmental contaminants more easily than acrylic coatings, and are considered less preferred as they would preclude the use of other than silicone-based coatings in future repainting of the expansion joint sealant system should that become necessary. Additionally, providing a uniformly applied coating to a structural surface, such as a building wall or deck, can provide aesthetic benefits, the same color or protective coating.

[0033] Although described in one embodiment as an elastomeric sealant coating, it should be understood that it is within the scope of the present invention to use any suitable water-resistant or waterproof coating or layer, etc., on the surface of the core 11 or within the material to enhance the water-resistant or waterproof properties of the embodiment, according to the embodiment. In some embodiments, this water-resistant or waterproof material 20 can be a combination of one or more of the above-mentioned materials, or mixtures, blends, or other combinations of one or more of the above, with or without polysulfides, silicones, acrylics, polyurethanes, poly-epoxides, silyl-terminated polyurethanes, silyl-terminated polyethers, other elastomeric components, or similar suitable elastomeric coatings or liquid sealant materials. One example of another elastomeric sealant coating for horizontal deck applications where vehicular traffic is expected is Sikasil® WS-295 sealant, which is a silicone sealant available from Sika Corporation of Lyndhurst, New Jersey. Another elastomeric sealant coating is Pecora 301, a silicone pavement sealant available from Pecora Corporation, Harleysville, Pennsylvania. Yet another elastomeric sealant coating is Dow Corning 888, a silicone joint sealant available from Dow Corning Corporation, Midland, Michigan. Each of the above elastomeric sealant coatings is a traffic grade rated sealant. For vertically oriented expansion joints, exemplary preferred elastomeric coatings include Sikasil WS-295, Pecora 890, Dow Corning 790, and Dow Corning 795. Depending on the nature of the adhesive properties of the water-resistant or waterproof material 20, a primer may be applied to the inner or outer surface of the material of the core 11 prior to coating the core 11. Applying such a primer may promote adhesion of the water-resistant or waterproof material 20 to the core 11.Those skilled in the art should understand that the term liquid sealant as used herein describes a sealant that is dispensed in a wet or liquid state, shaped or tooled on-site during installation, and then cured to a final finished shape. The wet state is maintained as a result of the liquid sealant being confined within its product packaging until it is dispensed and cured, for example, at ambient conditions. It should also be appreciated that, according to one aspect of the present invention, the water-resistant or waterproof material 20 is comprised of a moisture-curable sealant composition that includes at least one organic polymer containing silane groups. In one embodiment, the at least one organic polymer is a polyurethane, polyolefin, polyester, polycarbonate, polyamide, poly(meth)acrylate or polyether, or a blended form of these polymers, preferably a polyurethane polymer.

[0034] In one embodiment, the processed coated sheets of core 11 material as described above are slit into strips or lamina appropriate for the width of the construction and / or expansion joint to be sealed. The resulting strips are generally rectangular in shape and coated on at least one side with water-resistant or waterproof material 20. After slitting, the single strips or lamina are manually or mechanically compressed laterally to increase back pressure on the core 11 (e.g., stored strain energy due to compression). At the same time, the water-resistant or waterproof material 20 is formed into an "arch", "dome", or other shape, generally shown at 30 in FIG. 1B. The arched or dome profile of the water-resistant or waterproof material 20 is advantageous in designs to contribute to compression forces while maintaining a tension-free surface as described below. For example, other sealing products may exist in the art, such as sealants and tie bars or sealing tape solutions, but do not include pre-compressed self-expanding arched elements where the arch is perpendicular to the compression direction. The pre-compressed arched shape acts as a resilient spring, providing a compressive force against the substrate when the expansion joint system is installed between the substrates forming the joint, which provides and contributes to the creation and maintenance of a substantially watertight seal of the construction and / or expansion joint. In the case of a moving expansion joint, the compressive force of the arched elastomer and the back pressure of the lower compressed core 11 enable the expansion joint seal system 10 to maintain a weathertight seal through areas of joint movement (e.g., expansion and contraction). As will be appreciated, the inherent compressive force reduces or substantially eliminates the need for strong bonds between the sealant and substrate that are typical of conventional sealant and backing bar type systems, which experience tensile stresses at the bond line during movement and often contribute to joint failure.

[0035] 2A and 2B, in one embodiment, after compression and shaping, the expansion joint seal system 10 is wound around a spool 40 of suitable material, such as, for example, cardboard or plastic. Although the spool 40 is primarily referred to herein, it should be noted that other suitable substrates and / or devices, such as open or solid bars, may be used in place of the spool 40 to hold and / or contain the expansion joint seal system 10 in a rolled form, for example, for shipment to the site. The compression and shaping may be maintained at each wrap around the spool 40 by using a relatively inextensible liner 42, as shown diagrammatically in FIG. 2B. The liner 42 may be constructed of, for example, a plastic film or other suitable material. The liner 42 may also include a pressure sensitive adhesive that is wound against the material of the compressed core 11 and the water resistant material 20 disposed on the core 11. The pressure sensitive adhesive may be used as an installation aid. As the compressed material of the core 11 is wrapped around the periphery of the spool 40, the core overlaps itself multiple times depending on its overall length. The liner 42 keeps each turn separate and prevents adhesion between the turns. At the end of the winding process, the liner 42 is secured to itself, as generally shown at 46 (FIG. 2A), for example by adhesive tape. Advantageously, an inexpensive liner 42 is used to maintain the compressed shape and size of the expansion joint seal system 10 in coil form around the periphery of the spool 40, since more expensive packaging options to maintain the desired shape and compression level are less desirable.

[0036] In one embodiment, the treated coated sheet of material of the core 11 as described above is slit into two or more strips or lamina, the number and width of cuts depending on the desired size of the expansion joint seal system. After slitting, the two or more strips or lamina 16 are brought together and then laterally compressed and, according to an embodiment, held in such compression as a unitary structure in a suitable fixture to maintain the back pressure stored therein. Similarly, the core 11 comprising a solid block of material is compressed and held in such compression in a suitable fixture to maintain the back pressure stored therein. The fixture is set to a width slightly wider than the maximum possible movement expected to be experienced by the expansion joint between adjacent surfaces. According to an embodiment, at this width, the treated material of the core 11 (as a lamina or block) is coated on one or more outer surfaces with a water-resistant or waterproof material 20. In one embodiment shown in FIG. 1C, a coating of water-resistant or waterproof material 20 is tooled or otherwise configured to provide a "bellows" shape 32, including a series of "arches," "domes," and the like shapes or other suitable profiles, which may be uniformly and aesthetically compressed while maintained in a substantially tension-free environment.

[0037] In one embodiment, a second or more coatings are applied to the treated material of the core 11. For example, additional coatings of water-resistant material 20, intumescent material and / or barrier coatings are applied to the material of the core 11 held in compression within the fixture and similarly formed into an arched or domed profile as shown in FIG. 1B or a bellows shape 32 as shown in FIG. 1C. As described in commonly owned U.S. Pat. No. 8,365,495 and other commonly owned patents, one type of intumescent material suitable for use in the expansion joint sealing system 10 described herein is a caulking material having fire retardant properties. Caulking materials are generally silicone, polyurethane, polysulfide, silyl-terminated polyether or polyurethane and acrylic sealants in a latex or elastomer base. Fire retardant properties are generally imparted to the caulking material by incorporating one or more flame retardants. One preferred intumescent material is 3M CP25WB+, a fire-resistant caulking available from 3M, St. Paul, Minnesota. In one embodiment, a pry-resistant or pry-resistant elastomeric coating may be applied to one or more surfaces of the material of the core 11. Examples of pry-resistant coatings include, for example, Pecora Dynaflex SC or equivalent.

[0038] After the coating on one or more surfaces of the material of the treated core 11 has cured in place and while the treated core 11 is held at a predetermined compressed width, the expansion joint seal system 10 is removed from the fixture and packaged for shipment to the site. Optionally, prior to removal of the fixture, the expansion joint seal system 10 is further compressed to less than the nominal width of the construction and expansion joint to which the system is intended to be installed. This further compressed expansion joint seal system 10 is then removed from the fixture and packaged for shipment to the site. As mentioned above, packaging includes wrapping the expansion joint seal system 10 shown in FIG. 1B around the periphery of a spool 40, as shown in FIGS. 2A and 2B. 2C and 2D, for the expansion joint seal system 10 shown in FIG. 1C, packaging involves compressing the expansion joint seal system 10 cut to a predetermined length L, e.g., 10 feet (10 ft.), placing the system 10 between two relatively rigid hardboards 50, and then enclosing the system 10 and hardboards 50 with a packaging wrapper 52, e.g., shrink wrap plastic film or the like. As described below in the installation method, the packaging is designed to prevent the expansion joint seal system 10 from prematurely expanding outward (due to the release of built-up back pressure) prior to installation into the intended construction and / or expansion joint.

[0039] As discussed in the Background section of this disclosure, a typical installation of a new expansion joint seal system, whether during initial construction or during subsequent maintenance operations, requires preparation of the surface of the building and / or expansion joint forming substrate to which the expansion joint seal system is to be installed. Preparation and / or repair of the substrate surface may be required to make the surface receptive to an adhesive or other sealant that aids in the bond between the expansion joint seal system and the substrate. Preparation and repair traditionally includes, for example, cleaning, scraping, grinding, sanding, polishing or other treatment to remove dirt, old sealant residue or other materials that may prevent the formation of a good bond and adhesion between the substrate and the expansion joint seal system. As can be appreciated, scraping, grinding, sanding and / or polishing of the substrate and materials on the substrate surface may release harmful dust or other contaminants, such as silica, as airborne particles. To minimize exposure to such harmful dusts and contaminants, federal, state and local safety agencies and other building and health agencies have established regulations requiring installers to use dust collection equipment attached to all cutting, scraping, sanding and polishing tools and requiring installers to use personal protective equipment (PPE). As noted in the background section, the use of dust collection equipment and PPE has cost and other health and safety disadvantages. The expansion joint seal system 10 and installation method described herein is deemed to substantially minimize, if not eliminate, exposure to such harmful dusts and contaminants while minimizing the health and safety disadvantages of using safety equipment, for example, by eliminating the need to scrape, grind, sand and polish the surface of the substrate on which the expansion joint is formed to prepare the surface to accept an adhesive or other sealant that aids in the bonding and adhesion between the expansion joint seal system and the substrate on which the joint is formed.

[0040] 4 and 5A-5C, a safer, dust-free method 100 of installation of an expansion joint seal system, such as the water-resistant and / or fire-resistant expansion joint seal system 10 described above, into a gap or construction or expansion joint 200 formed between substrates, for example, where a previous system was installed and is to be removed to install a new seal system, includes the following steps: At step 110, the method includes cutting the sealant 204 to remove the existing expansion joint seal system 202 held in position between the surfaces 212 and 222 of the opposing faces of the substrates 210 and 220 forming the joint 200 (FIG. 5A). Cutting the sealant 204 in the joint 200 is performed, for example, by a knife, saw, reciprocating saw or cutter or similar device (not shown) as close to the substrates 210 and 220 as achievable. Cutting the sealant 204 allows for removal of the existing expansion joint seal system 202 while leaving any embedded residue 206 of the sealant 204 from the existing system 202 on the surfaces 212 and 222 of the substrates 210 and 220. For example, traditional steps of mechanically abrading, scraping or grinding the surfaces of the substrate to prepare the substrate or to remove residue of a previously installed and removed joint seal system are not required. In step 120, the surfaces 212 and 222 may be wiped with, for example, a lint-free wipe or rag with a solvent such as water, acetone or similar solvent to remove any particulate matter of sealant, dirt or other materials that may interfere with the adhesive bond from the surfaces 212 and 222 of the substrates 210 and 220. It should be appreciated that this cleaning step leaves any surface modifications or remaining residues 206 of the previously applied sealant 204 remaining on or embedded in the surfaces 212 and 222 of the substrates 210 and 220. In step 130, an attachment band 230 of a liquid sealant, such as, for example, SikaHyflex®-150 LM sealant, is applied to the surfaces 212 and 222 of the substrates 210 and 220 (FIG. 5B).In step 140, the shipping package containing the compressed water-resistant and / or fire-resistant expansion joint seal system 10 is brought near the installation location and the shipping package is removed by cutting the liner 42 (FIGS. 2A and 2B) or packaging material 52 (FIGS. 2C and 2D). Once the liner 42 or packaging material 52 is removed, the compressed water-resistant and / or fire-resistant expansion joint seal system 10 begins to slowly expand outward. Optionally, additional liquid sealant attachment strips can be applied to the surface of the expansion joint seal system 10. In step 150, the compressed self-expanding expansion joint seal system 10 is installed in the expansion joint 200 in a position immediately adjacent to and overlying the wetted attachment strips 230 applied to the surfaces 212 and 222 (FIG. 5C). The stored strain energy of the compression or back pressure of the expansion joint seal system 10 continues to cause the material of the core 11 to expand outward (in the direction indicated by arrow 10A) to embed the expansion joint seal system 10 within the attachment zone 230 of the liquid sealant and securely attach it to the substrates 210 and 220, completing the installation by securing the system 10 in place between the substrates 210 and 220. It should be appreciated that once installed in position between the surfaces 212 and 222, the back pressure alone and together with the attachment zone 230 of the liquid sealant is sufficient to support the expansion joint seal system 10 within the expansion joint 200. Optionally, an additional bead 232 (e.g., a corner bead) of liquid sealant is applied to and between a portion of the top surface of the water-resistant or waterproof material 20 and the surfaces 212 and 222 of the substrates 210 and 220 to strengthen the bond line therebetween and / or contain any dust and contaminants exposed to the surfaces 212 and 222. When the attachment strip 230 of liquid sealant cures, the bond line between the expansion joint seal system 10 and the attachment strip 230 and optionally the bead 232 is never in tension. Similarly, the bond between the attachment strip 230 of sealant and any residue of sealant embedded in the surfaces 212 and 222 of the substrates 210 and 220 is never in tension.Any joint movement in the sealant joint due to heat, wind, earthquake or other building movement is absorbed and tension-free in the water-resistant or waterproof material 20 (whether a single arched piece of material or a series of bellows-shaped pieces of material) and the core 11 of the expansion joint seal system 10. For example, the water-resistant material 20 and the core 11 of the prefabricated, pre-compressed expansion joint seal system 10 appear to simply fold and unfold (e.g., expand and contract) to accommodate movement of the substrates 210 and 220 that form the joint 200.

[0041] 4, 5B and 5C, the safer, dust-free installation method 100 of the above-described water and / or fire resistant expansion joint seal system 10 to a building or expansion joint 200 in, for example, a newly constructed structure where no system has been previously installed, is completed by performing steps 120-150. It should be understood that when an expansion joint seal system is installed in a newly constructed structure, the opposing surfaces of the substrates that will form the expansion joint, for example surfaces 212 and 222 of substrates 210 and 220 that will form joint 200 as shown in FIG. 5A, will typically be prepared to receive the expansion joint seal system in a conventional manner by scraping, grinding, sanding, polishing or other treatment to smooth out surface deformations and / or remove dirt, residue or other material that may prevent the formation of a good bond and adhesion between the substrate and the expansion joint seal system. As will also be appreciated, in accordance with the present invention, the above-described safer, dust-free installation method 100 of a water-resistant and / or fire-resistant expansion joint seal system 10, either as new or to replace an existing system already installed in a building or expansion joint 200, eliminates the need for scraping, grinding, sanding and polishing of the surfaces 212 and 222 of the substrates 210 and 220 forming the expansion joint 200 to prepare the surfaces 212 and 222 to receive an adhesive or other sealant 230 that aids in bonding and adhesion between the newly installed expansion joint seal system 10 and the substrates 210 and 220 forming the joint 200. As discussed above, the elimination or at least substantial minimization of dust and airborne contaminants eliminates or at least makes optional the need for the installer to use dust collection equipment and PPE.

[0042] The embodiments disclosed herein, particularly the designs described above, address shortcomings of previous designs, resolve issues associated with caulking and backing bar designs, eliminate installation steps that generate airborne particles and / or particulate matter that are harmful to workers, tenants, and public health and safety if inhaled, eliminate or make optional the need for PPE and / or special equipment to capture harmful airborne particles and / or particulate matter, and cost-effectively improve upon the teachings of prior art systems and methods of installation. Furthermore, in a spooled or coiled packaging format, expensive and wasteful packaging materials can be replaced with inexpensive plastic liners and inexpensive cardboard spools. The coiled form also significantly reduces other packaging materials, such as boxes and skids. The coiled form also makes on-site handling and installation much more efficient and simple.

[0043] Although the present invention has been shown and described with respect to its detailed embodiments, those skilled in the art will understand that various modifications may be made without departing from the scope of the invention, and that its elements may be substituted with equivalents. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its essential scope. Therefore, the present invention is not limited to the specific embodiments disclosed in the above detailed description, but the present invention is intended to include all embodiments that are within the scope of the detailed description and the appended claims that will be understood by those skilled in the art. Thus, the various embodiments described herein and in the above-mentioned priority application, including configurations, may be combined in any combination and in any order.

Claims

1. A safer, dust-free installation method for a pre-compressed expansion joint seal system, said method comprising: identifying the location of a first substrate and a second substrate, wherein the second substrate is disposed coplanar with the first substrate and spaced apart from the first substrate by a gap formed between opposing surfaces of the first substrate and the second substrate; locating an existing joint seal system installed in the gap between the first substrate and the second substrate; removing the existing joint seal system by cutting sealant between the existing joint seal system and the first substrate and the second substrate; preparing the opposing surfaces of the first and second substrates without mechanical abrasion, grinding, or scraping by wiping the opposing surfaces with a solvent while leaving any surface deformations and embedded residues of remaining sealant from the removed joint sealing system on or embedded in the opposing surfaces of the first and second substrates, wherein the substrates are not prepared by mechanical abrasion, scraping, or grinding, nor are residues of the previously installed and removed joint sealing system removed by mechanical abrasion, scraping, or grinding of the substrates; applying mounting strips of liquid sealant to the opposing surfaces of the first substrate and the second substrate; Positioning the expansion joint seal system in the gap by placing a pre-compressed expansion joint seal system between the opposing surfaces and at least one of adjacent to and within the attachment strips of the liquid sealant applied to the opposing surfaces of the first substrate and the second substrate; and maintaining the pre-compressed expansion joint seal system in said position within the gap until the pre-compressed expansion joint seal system expands outwardly toward the opposing surfaces, embeds within the mounting strip of sealant, and secures the expansion joint seal system in said position between the opposing surfaces of the first substrate and the second substrate. A method comprising:

2. 10. The safer, dust-free installation method of claim 1, further comprising applying a bead of liquid sealant to and between a portion of an upper surface of the pre-compressed expansion joint seal system and the opposing surfaces of the first substrate and the second substrate.

3. 10. The safer, dust-free installation method of claim 1, wherein the installed pre-compressed expansion joint seal system is a water-resistant and / or fire-resistant pre-compressed expansion joint seal system.

4. The water and / or fire resistant pre-compressed expansion joint seal system includes a fire retardant material incorporated into a core of the expansion joint seal system, and the core has a fire resistance of about 160 kg / m ３ ~Approx. 800kg / m ３ and the expansion joint seal system is configured to pass the test provided by UL 2079.

5. 4. The safer, dust-free installation method of claim 3, wherein the installed pre-compressed expansion joint seal system further comprises a water-resistant or waterproof coating applied to a surface of the pre-compressed expansion joint seal system.

6. 6. A safer, dust-free installation method according to claim 5, wherein the water-resistant or waterproof coating is paintable.

7. A safer, dust-free installation method as described in claim 1, wherein the liquid sealant is based on an isocyanate-terminated polyurethane polymer and / or a silane-terminated polyurethane polymer.

Images