ic-qa-b318 - bonded metal-elastomer expansion joints

Edition 2 / Revision 1 TRANSPORT FOR NSW

June 2020

TRANSPORT FOR NSW (TfNSW)

QA SPECIFICATION B318

BONDED METAL-ELASTOMER EXPANSION JOINTS

NOTICE

This document is a Transport for NSW QA Specification. It has been developed for use with

roadworks and bridgeworks contracts let by Transport for NSW or by local councils in NSW. It is not

suitable for any other purpose and must not be used for any other purpose or in any other context.

Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev

Number

Clause

Number Description of Revision

Authorised

By Date

Ed 1/Rev 0 First Issued GM, RNIC 10.09.02

Ed 2/Rev 0 Updated to new AS 5100 standard

“Superintendent” changed to “Principal”

GM, IC (Warren

Stalder)

01.09.08

Ed 2/Rev 1 Global References to “Roads and Maritime

Services” or “RMS” changed to “Transport

for NSW” or “TfNSW” respectively.

DCS 22.06.20

Edition 2 / Revision 1 TRANSPORT FOR NSW

June 2020

QA SPECIFICATION B318

BONDED METAL-ELASTOMER

EXPANSION JOINTS

Copyright – Transport for NSW

IC-QA-B318

VERSION FOR:

DATE:

Bonded Metal-Elastomer Expansion Joints B318

Ed 2 / Rev 1 i

CONTENTS

CLAUSE PAGE

FOREWORD ............................................................................................................................................... II TfNSW Copyright and Use of this Document ............................................................................... ii Revisions to Previous Version ....................................................................................................... ii Project Specific Changes ............................................................................................................... ii

1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of the Specification ......................................................................................... 1 1.3 Proprietary Products ....................................................................................................... 1 1.4 Warranty ......................................................................................................................... 1

2 DESIGN ........................................................................................................................................... 2 2.1 General ........................................................................................................................... 2 2.2 Design Loads on Joint .................................................................................................... 2 2.3 Anchors .......................................................................................................................... 2 2.4 Design Certification ........................................................................................................ 3

3 MATERIALS .................................................................................................................................... 3 3.1 Elastomer ........................................................................................................................ 3 3.2 Metal ............................................................................................................................... 4 3.3 Corrosion Protection ....................................................................................................... 4

4 NOISE ............................................................................................................................................. 5

5 CONFORMITY ................................................................................................................................. 5

6 INSTALLATION ............................................................................................................................... 5

ANNEXURES B318/A TO B318/B – (NOT USED) ...................................................................................... 7

ANNEXURE B318/C – SCHEDULES OF HOLD POINTS AND IDENTIFIED RECORDS .................................... 7 C1 Schedule of Hold Points ................................................................................................. 7 C2 Schedule of Identified Records....................................................................................... 7

ANNEXURES B318/D TO B318/L – (NOT USED) ...................................................................................... 7

ANNEXURE B318/M – REFERENCED DOCUMENTS .................................................................................. 8

LAST PAGE OF THIS DOCUMENT IS ............................................................................................................ 8

B318 Bonded Metal-Elastomer Expansion Joints

ii Ed 2 / Rev 1

FOREWORD

TFNSW COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Transport for NSW.

When this document forms part of a contract

This document should be read with all the documents forming the Contract.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy

controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW

Internet website: http://www.rms.nsw.gov.au/business-industry/partners-

suppliers/specifications/index.html

REVISIONS TO PREVIOUS VERSION

This document has been revised from Specification TfNSW B318 Edition 2 Revision 0.

All revisions to the previous version (other than minor editorial and project specific changes) are

indicated by a vertical line in the margin as shown here, except when it is a new edition and the text

has been extensively rewritten.

PROJECT SPECIFIC CHANGES

Any project specific changes are indicated in the following manner:

(a) Text which is additional to the base document and which is included in the Specification is

shown in bold italics e.g. Additional Text.

(b) Text which has been deleted from the base document and which is not included in the

Specification is shown struck out e.g. Deleted Text.

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

http://www.rms.nsw.gov.au/business-industry/partners-suppliers/specifications/index.html

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Ed 2 / Rev 1 1

TfNSW QA SPECIFICATION B318

BONDED METAL-ELASTOMER EXPANSION JOINTS

1 GENERAL

1.1 SCOPE

This Specification sets out the requirements for the supply and installation of bonded metal-elastomer

expansion joints which comprise reinforced elastomeric units, sealants and anchorage systems.

This type of expansion joint consists of a metal reinforced elastomeric pad that spans the joint gap and

is rigidly attached on each side of the gap. The joint movements are accommodated by deformation of

the elastomer. The metal reinforcement embedded in the elastomer supports traffic crossing the gap.

1.2 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 Schedules of HOLD POINTS and Identified Records

The schedules in Annexure B315/C list the HOLD POINTS that must be observed. Refer to

Specification TfNSW Q for the definition of HOLD POINTS.

The records listed in Annexure B318/C are Identified Records for the purposes of TfNSW Q

Annexure Q/E.

1.2.2 Referenced Documents

Unless specified otherwise, the applicable issue of a referenced document, other than a TfNSW

Specification, is the issue current at the date one week before the closing date for tenders, or where no

issue is current at that date, the most recent issue.

For convenience standards, specifications and test methods are referred to in an abbreviated form (e.g.

AS 1234). Their full titles are given in Annexure B318/M – Referenced Documents.

1.3 PROPRIETARY PRODUCTS

Where the Drawings nominate a particular proprietary bonded metal-elastomer expansion joint, a joint

other than the nominated joint must not be used without the prior authorisation of the Principal, in

accordance with the Conditions of Contract.

1.4 WARRANTY

Proprietary bonded metal-elastomer expansion joints must be supplied with a warranty in the name of

Transport for NSW. The warranty from the joint supplier must cover defective workmanship, material

and serviceability of the joint for a minimum period of five years from the date of installation.

Serviceability must include watertightness of the joint. Any joints becoming defective within this

period must be rectified by the supplier at no cost to the Principal.



2 Ed 2 / Rev 1

2 DESIGN

2.1 GENERAL

Design bonded metal-elastomer expansion joints to possess the necessary properties of extension,

compression and deformation to give the required range of movement, as shown on the Drawings and

in accordance with AS 5100.4. The wearing surface of the joint must be of metal which is wear and

skid resistant.

The required profile of the bonded metal-elastomer joint to match the bridge cross section may be

obtained by sealing together straight lengths of joint by means of a sealant recommended by the

manufacturer of the expansion joint.

The maximum transverse movement of the joint in service must be not more than 1/12 of the total

maximum movement range.

2.2 DESIGN LOADS ON JOINT

Design the joint to withstand the following loads:

(a) A vertical live load from an A160 individual heavy axle in accordance with AS 5100.2; and

(b) A concurrent longitudinal live load that is a minimum of 35% of the vertical load acting at road

level parallel to the direction of traffic.

Apply the design lanes at any location on the deck joint to give the worst loading case.

The dynamic load allowance must be 0.6.

Multiply the design load with the dynamic load allowance by a factor of 1.8 for ultimate limit state

effects, 1.0 for serviceability limit state effects and 0.6 for fatigue.

2.3 ANCHORS

The supplier must comply with AS/NZS ISO 9001 Clause 7.3 with respect to the design of the

anchors. Design the anchors to meet the requirements of AS 5100.4 and the following additional

requirements:

(a) The forces in the anchors must be calculated in accordance with the laws of statics, assuming

that the concrete above the line joining the points of connection between the anchors and the

member is ineffective;

(b) Anchors must have a minimum thickness of 12 mm if rectangular bars and must not be less than

20 mm in diameter if round bars;

(c) Bars used as anchorages must form a loop of sufficient size to be permit anchoring into the

concrete with the contribution of the transverse and other reinforcement;

(d) Any welding of anchorage bars must develop the full strength of the bar and accommodate an

infinite number of fatigue cycles;

(e) Stud welded shear connectors used as anchors must be at least 16 mm diameter and 150 mm in

length and welded only by resistance welding using a welding gun. Do not weld steel stud

shear connectors to aluminium;

(f) Anchors must be designed to allow easy replacement of the joint.



Ed 2 / Rev 1 3

2.4 DESIGN CERTIFICATION

Submit details of the proposed design and a certificate from an Engineer who is eligible for

membership of the Engineers Australia certifying that the proposed joint has been designed to meet all

the requirements of AS 5100.4 and this Specification.

HOLD POINT

Process Held: Supply of the bonded metal-elastomer expansion joint.

Submission Details: (a) Calculated loads on the joint and distribution to anchors (see Clause 2.2

and Clause 2.3(a));

(b) Calculated stress in the anchors (see Clause 2.3 (a));

(c) Method of replacing the joint (see Clause 2.3 (f));

(d) Design details and certification (see Clause 2.4).

Release of Hold Point: The Principal will consider the submitted documents prior to authorising the

release of the Hold Point.

3 MATERIALS

3.1 ELASTOMER

The elastomeric material in the joint must be entirely uniform and homogeneous throughout. Any

section showing imperfections, surface splits or indentations must be rejected.

The elastomeric components of the joint must be made from vulcanized compound having

polymerized chloroprene as the only base polymer.

Provide documentary evidence to the Principal to verify that the elastomer used in the manufacture of

the joint has been tested by a laboratory with appropriate NATA registration and that it complies with

the requirements specified in Table B318.1.



4 Ed 2 / Rev 1

Table B318.1 – Elastomer Material Requirements

Property Requirement Test Method

1. General

a) Tensile Strength 12.0 MPa minimum AS 1683.11 (Dumb-bell test pieces)

b) Elongation at Break 350% minimum AS 1683.11 (Dumb-bell test pieces)

c) Hardness IRHD 59+5 AS 1683.15.1

2. Accelerated Ageing AS 1683.26 (Method A for 72 hours at 100C)

a) Tensile Strength Change -15% to +15% AS 1683.11 (Dumb-bell test pieces)

b) Elongation at Break Change -40% to 0 AS 1683.11 (Dumb-bell test pieces)

c) Hardness Change IRHD -15 to +15 AS 1683.15.1

3. Resistance to Ozone No visible cracking AS 1683.24 (Ozone concentration 50 pphm in

air, 20% strain, 72 hours at 40C)

4. Change in Volume in Oil +30% maximum AS 1683.23 (Using Oil No. 3, after 72 hours at

100oC)

5. Compression Set 40% maximum AS 1683.13 (72 hours at 100oC)

6. Brittleness Not brittle ASTM D746 (B) (At –30oC)

The Principal may waive the requirement for testing to Table B318.1 provided that:

(a) the supplier of the elastomer for the manufacture of the joint has a third party certified quality

management system to AS/NZS ISO 9001 for the manufacture and supply of elastomer; and

(b) (i) test certificates are supplied to prove that the elastomer meets the properties specified in

Table B318.1 in Type Tests not more than six months old; and

(ii) day to day batch quality control on the manufacture of the elastomer is exercised by

performing a test which accurately measures the cure characteristics of the elastomer and

highlights variations resulting from incorrect ingredients or levels thereof; and

(c) the manufacturer establishes control points and limits on batches which have been Type Tested

and uses these control points and limits for subsequent quality control purposes.

3.2 METAL

Structural steel embedded in the elastomer must conform to AS 3679.1 Grade 250 unless noted

otherwise on the Drawings or in the Specification.

Other embedded metal must conform to the relevant Australian Standard for the strength grade

specified in the design.

3.3 CORROSION PROTECTION

The anchors must be hot dipped galvanized in accordance with AS 4680 or AS 1214, unless shown

otherwise on the Drawings.



Ed 2 / Rev 1 5

4 NOISE

It is possible that the centre portion of the expansion joint, in a compressed condition, lifts off the

support, forming a convex profile. As vehicles travel across the joint a thumping noise may emanate.

If required by the Principal, provide field performance of noise levels under similar site and

temperature conditions and state the measures implemented to eliminate noise resulting from the

lifting of the joint.

5 CONFORMITY

Provide a certificate from the supplier of the joint verifying its conformity with the Drawings and this

Specification.

HOLD POINT

Process Held: Dispatch of the bonded metal-elastomer expansion joint to site.

Submission Details: Certificate from the supplier of the joint verifying its conformity with the

Drawings and this Specification.

Release of Hold Point: The Principal will consider the submitted details prior to authorising the


6 INSTALLATION

The method of placing the joint must be in accordance with the manufacturer’s recommendations.

The joint must not be inserted into the blockout until at least three days after all deck concreting in the

adjacent spans or abutments is completed.

The top surface of the expansion joint must be set 4 mm 1 mm below the deck wearing surface.

Submit the procedure for the installation of the expansion joint including the following information:

(a) Deck preparation, including blockout reinforcement, dimensions and tolerances required;

(b) Anchor locations and presetting required to suit the bridge deck temperature at the time of joint

installation;

(c) Preparation of the blockout base to ensure a true and even surface on which to bed the joint

units;

(d) Methods of sealing joint units at kerbs, gutters and horizontal directional changes in the bridge

deck profile;

(e) Sequence of installation of the units;

(f) Method of achieving a watertight seal at the interfaces between the concrete blockout and the

joint units;

(g) Method of joining adjacent joint units to ensure a watertight seal;



6 Ed 2 / Rev 1

(h) Torque requirements for anchors and the method of sealing bolt hole cavities;

(i) Filling for the gap between the edges of the unit and the adjacent road surfaces;

(j) Time after completion of installation when traffic is allowed on the road; and

(k) Method for testing of the installed joint for watertightness.

HOLD POINT

Process Held: Installation of the bonded metal-elastomer expansion joint.

Submission Details: Procedure for the installation of the expansion joint required in Clause 6.

Release of Hold Point: The Principal will consider the submitted details, prior to authorising the




Ed 2 / Rev 1 7

ANNEXURES B318/A TO B318/B – (NOT USED)

ANNEXURE B318/C – SCHEDULES OF HOLD POINTS AND

IDENTIFIED RECORDS

Refer to Clause 1.2.1.

C1 SCHEDULE OF HOLD POINTS

Clause Description

2.4 Supply of the bonded metal-elastomer expansion joint

5 Dispatch of the bonded metal-elastomer expansion joint to site

6 Installation of the bonded metal-elastomer expansion joint

C2 SCHEDULE OF IDENTIFIED RECORDS

The records listed below are Identified Records for the purposes of TfNSW Q Annexure Q/E.

Clause Description of Identified Record

1.4 Warranty on the joint by the supplier against defective workmanship, material and

process on the serviceability of the joint for a minimum period of five years

2.4 Method for replacement of joint

2.4 Design details of the proposed joint with Engineer’s Certification

3.1 Documentary evidence that the elastomer complies with the specified requirements

4 Field performance of joint noise levels with measures implemented to reduce noise

resulting from the lifting of the joint (if required)

5 Certificate from the supplier of the joint verifying its conformity with the requirements

of the Drawings and this Specification

6 Procedure for installation of the joint including field jointing and testing of the installed

joint for watertightness

ANNEXURES B318/D TO B318/L – (NOT USED)



8 Ed 2 / Rev 1

ANNEXURE B318/M – REFERENCED DOCUMENTS

Refer to Clause 1.2.2.

TfNSW Specifications

TfNSW Q Quality Management System

Australian Standards

AS 1214 Hot-dip galvanized coatings on threaded fasteners (ISO metric coarse thread

series)

AS 1683 Methods of tests for elastomers

AS 1683.11 Tension testing of vulcanized or thermoplastic rubber

AS 1683.13 Compression set of vulcanized rubber under constant deflection

AS 1683.15.1 International rubber hardness

AS 1683.23 Rubber – Vulcanized – Determination of resistance to liquids

AS 1683.24 Methods of test for rubber – Determination of the resistance of vulcanized or

thermoplastic rubbers to ozone cracking – Static strain test

AS 1683.26 Rubber, vulcanized or thermoplastic - Accelerated ageing and heat resistance

tests

AS 3679.1 Structural steel - Hot-rolled bars and sections

AS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles

AS 5100 Bridge design

AS 5100.2 Part 2 – Design loads

AS 5100.4 Part 4 – Bearings and deck joints

American Society for Testing Materials Standards

ASTM D746 Standard Test Method for Brittleness Temperatures of Plastics and Elastomers

by Impact