IRC:57-2006 RECOMMENDED PRACTICE FOR ! SEALING OF JOINTS IN CONCRETE PAVEMENTS (First Revision) ——————— CONTROLLED (Swi) Published by THE INDIAN ROADS CONGRESS Kama Koti Marg, Sector 6, R.K. Puram, New Delhi — 110 022 2006 Price Rs. 100/- (Packing & Postage Extra)IRC:57-2006 First Published: Augusi, 1974 Reprinted September, 2002 Reprinted April, 2005 First Revision: October, 2006 (The Rights of Publication and of Translation are reserved) (he official amendments to this document weuld de published by the IRC in its periodical, Indian Highways", which shall be considered as effective and as part of the code/guidelines/manual, etc. from the Date specified therein) Printed at Gopsons Papers Lud., Noida (1000 copies)eX AY ew CONTENT; Personnel of the Highways Specifications and Standards Committee Introduction Scope General Shape of the Joint Sealing Groove ‘Type of Joints Sealing Details Preformed Seals Resealing Old Joints IRC:57-2006 ti) & Gi) a sty 1313, 14 15, 7, 18. 19. 23. 24. 25 IRC:57-2006 PERSONNEL OF THE HIGHWAYS SPECIFICATIONS AND Yelayutham, V. (Convenor) Sharan, G. (Co-Convenor) Dhodapkar, A.N. (Member-Secreiary) Bahadur, A.P. Datta, PK. Desai, J.P. Dhingra, 8.L., Dr Gupta, DP. Gupta, 8.6. fain, RK, Jain, S.S., Dr. Kadi | LAR. Dr. Katare, Prabha Kant Mathur, J.B. Meena, HL, Momin, 8.8. Pawar, A.B. Ranjan, Gopal, Dr, Rathore, 8.8. Saha, Arghya Pradip Sharma, $.C. Nanda, PX., Dr. Singh. C.K., Br. Singh, Nirmal Jit ‘Sinha, ALY. Sinha, N.K STANDARDS COMMITTEE, (As on 08.10.2005) Addl. Director General, Ministry of Shipping, Road ‘Transport é& Highways, New Delhi Member (Tech), NHAI, New Delhi Chief Bngineer (R) S&R, Minisiry of Shipping, Road Transport & Highways, New Delhi Members Chief Engineer, Ministry of Shipping, Road Transport 8 Highways, New Deli Executive Director, Consulting Engg. Services (1) Pvt. Ltd., New Delhi St. Vice-President (Tech. Ser.), Gujarat Ambuja ‘Cements Lid., Ahmedabad Professor, Indian Institute of Technology, Mumbai DG (RD) & AS, MOST (Retd.), New Delhi Chief Engineer, Utaranchal PWD, Almora Chief Engineer (Rete), Haryana PWD, Sonepat Professor & Coordinator (COTE), Indian Institute of Technology, Roorkee Chie? Executive, LR. Kadiyali & Associates, New Delhi Joint Director, National Rural Roads Dev. Agency, New Delhi Chic! Engineer (Retd.), MoSRTH, Noida Chief Engineer-cum-Addl, Secy. to the Govt. of Rajasthan, PWD, Jaipur ‘Member, Maharashtra Public Service Commission, Mumbai Secretary (Works) (Retd.), Maharashtra PWD, Pune Director, College of Engg... Roorkee Secretary to the Govt. of Gujarat, R&B Department, Gandhinagar Sr. Consultant, New Delhi DG (RD) & AS, MORTRI (Retd.), New Delhi Director, Centrat Road Research Institute, New Delhi Engineer-in-Chief-cum-Addl. Comm-cum-Sp] Secy.(Retd,), Ranchi Member (Tech.}, National Highways Authority of India, New Delhi Chief General Maager, National Highways Authority of India, New Delhi DG (RD)&SS, MOSRTA&H (Retd.), New Delhi @IRC:57-2006 27. Sinha, VK. 28, Sarin, KK, 29, Velayudhan, TP, 30, Verma, V.C., Maj. 31. ‘The Chief Engineer (NH) 32. ‘The Chief Engineer (Plg,) 33. ‘The Chief Engineer (Mech.) 34, ‘The Chief Engineer (Mech.) ‘The Chief Engineer (NH) ‘The Bngineer-in-Chief 37. ‘The Chief Engineer 38. President Indian Roads Congress 39, Director General (Road Development) 40. Secretary General Indian Roads Congress 1. Agrawal, MK. . Justo, CE.G, Dr, 3. Khattar, M.D. - Madhathil, Sunny C. 5. Merani, N.V. Chief Engineer, Ministry of Shipping, Road Transport & Highways, New Delhi DG (RD) & AS, MOST (Retd.), New Delhi Addl, D.G, Directorate General Border Roads, New Delhi Executive Director (Marketing), Oriental Structural Engrs. Pet, Lid., New Delhi R&B Department, Hyderabad (S.B. Basu), Ministry of Shipping, Road Transport & Highways, New Deli (V.K. Sachdev), Ministry of Shipping, Road Transport & Highways, New Delhi PWD, Kolkata (B.C, Pradhan) Sachivalaya Marg, Bhubaneshwar (Tribhuwan Ram) U.P. PWD, Lucknow National Highways, PWD, Bangalore Ex-Officio Members (V.B. Borge), Secretary (Roads), Maharashtra PWD, Mumbai (Indu Prakash), Ministry of Shipping, Road ‘Transport & Highways, New Delhi (R.S. Sharma), Indian Roads Congress, New Delhi Corresponding Members Enginccr-in-Chief, Haryana PWD (Retd.), Panchkula Emeritus Fellow, Bangalore University, Bangalore Executive Director, Hindustan Construction Co. Ltd, Mumbai Director (Project), Bhagheeratha Engg. Ltd... Kochi Principal Secretary, Maharashtra PWD (Retd.), Membai’ (ii)RECOMME) IDED PRACTICE FOR SEALING OF JOIN’ IRC:57-2006 CONCRETE PAVEMENTS 1 INTRODUCTION The IRC:57, “Recommended Practice for Scaling of Joints in Concrete Pavements” was. published by the Indian Roads Congress in 1974, Revision of the document was taken up by the Rigid Pavements Committee (personne! given below), Rigid Pavement Committee (H-5) Kadiyali, L.R., Dr. CE (R)S&R, MORT&H (Jain, N.S.) Yenkatesha, M.C. Convenor Co-Convenor Mamber-Secretary Members Chahial, HLS. A Rep. of MSRDC Chary, MLN. (Kulkarni, PD.) Indoria, RP. A Rep. of DGBR Jain, RK. (MLS, Sodhi) Pandey, B.B.Dr A Rep. of NCC&BM Phull, ¥.R (Wason, RC) Rastogi, S. A Rep. of CRRI Sabnis, S.M. (Saiandar, Kumar) Sharia, 8.C. Director, HRS Singh, Brajendra Sinha, VK. Vasan, RM. Dr, (Thangarasa, K.) Corresponding Members Bhaumik, KB. Krishna Rao, K.V., Prof. De, DC. Ravi Shankar, A.U Vandana, ‘Tare, Dr. (Mrs.) Ex-Officio Members President, IRC DGRD) (Borge, V.B.) (Prakash, Indu) Sceretary General, IRC (Sharma, R.S.) ‘The Rigid Pavement Committee discussed and finalised the revised drufi of IRC:57 “Recommended Practice for Sealing of Joints in Concrete Pavements” in their meeting held on 27th December, 2004. The Highways Specifications & Standards Committee in their meeting held on 8th October, 2005 considered the revised draft of IRC:57 and approved subject to some modifications to be carried out by De LR. Kadiyali (Convenor, Rigid Pavement Committee). Accordingly, Dr. Kadiyali modified the draft document, and the same was pliced before the Executive Commitee of IRC in its meeting held on the 20th October, 2005 and before the Council in its meeting held on 12th November, 2005 at Bhubaneshwar (Orissa), The Council approved the document with cenain modifications as per comments, suggestions of the members. 2. SCOPE Scaling of joints in a concrete pavement is done either using field-moulded sealants ot pre-formed compression seal. 3. GENERAL, 3.1. Cement concrete pavemenis (roads, streets, airport apcon, taxi-ways and runways, etc.) are subjected to volumetric changes (expansion and contraction) caused by changes in their moisture content and/or temperature which leads to initial drying, shrinkage and ineversible creep. ‘These changes cause ‘movements of slabs. If contraction movements are excessively restrained, they will result in cracking of the pavement, On the other hand, the restraint of expansion movements may result in development of compressive stresses that are bome by abutting faces of the slab. Transverse joints are provided to accommodate these movements and thereby prevent development of distress in the pavement, Longitudinal joints are provided to relieve stresses due to warping andIRC:57-2006 dividing, the pavement into convenient lanes. Joints are also required to facilitate construction without serying any stuctural purpose. ‘This document outlines the recommended practice for sealing these joints. 32, Detwils of different types of joints in concrete pavements are outlined in IRC:15, “Stanklad Specification and Code of Pructice for Construction of Conerete Roads”. The present standard is intended w augment the provisions contained in IRCHL5. 33. The introduction of joints openings in the slab which must be sealed in ordey (0 prevent ingress of rain water to the sub-basc/subgrede or other unwanted substances, like, grit into the openings, Foreign solid matter which is incompressible must be prevented from collecting in the joints, otherwise the joints cannot close freely later. Should the joints get clogged with foreign solid ‘atter, malfunetioning of the joints may occur and high stress may be generated in the slub leading to spalling of concrete and development of cracks. Scaling of these joints is done using cither field-moulded sealants or preformed compression seal. creates, 3.4, The performance and life of a sealing compound depend not only on the properties of the sealing compound and the mode of application but also on the design of the joints. The types of joints normally formed in conercte pavements are described below. 4, SHAPE OF THE JOINT SEALING GROOVE ‘Shape of field-moulded sealant is important as the sealant is subjecied to compression and tension during expansion and coniraetion phases ‘of concrete slab, 'The sealants which are solid at service temperatures are likely 10 change in their shape but their volume will remain same during opening of these sealants. The shape of the sealant is important as strains developed in them during expansion and contraction should not exceed the permissible limit. The stresses generated in sealants during expansion and contraction phases are shown in Fig, ‘The shape of the joint groove inlencled as a reservoir of sealant largely depends upon the type of sealant used, Shape factor of a sealant is defined as : Depth of seaiane Shape Facwe= Ron ‘Width of sealant i Sean ‘SEALANT \covpressve StRESs WHEN SLAB EXPANDS: 1d-Moulded Sealants due to Temperature Changes WHEN SLAB CONTRACTS TENSLE STRESS AT SEALANT BEND. STRESS Al" INTERFACE: DEELING STRESS AT EDGE TTeNsiue STRESS IN FACE MATERAL- Fig. 1. Stresses Generated in SS BG SOs Re R SS RS ES 'SIRESS FREE CONDITION i . RSs INITIAL CONDITION OF SLABShape factors normally recommended for various sealants are as under: Hot-poured sealant 2 10-125 Cold poured sealant like polysulphide 10-125 Silicone 2 0.75 Shape factor for expansion joints can be 0.5. Although theoretically the above shape factors are desirable, some authorities feel that a ratio of 3:2 is to be preferred, Therefore, a compromise has to be maul in deciding the shape factor based on the field experience so that the stress produced within sealant body is within the allowable limit specified by the manufacturers, 5. ‘TYPE OF JOINTS S.1. In cement conerete pavements, the following types of joints are commonly provided: (a) Contraction joints (b) Expansion joints (ec) Construction joints (©) Longitudinal joints A typical pavement layout generally adopted in a two-lane road is shown in Fig. 2 z ai SUPTE-EEEELLLE HEE = Loneindona soir [HAHAH FREE H+ Fig, 2. Payement Configuration of Two ‘Lane Road IRC:57-2006 5.2, Contraction Joints These are purposely made weakened planes which relieve the tensile stresses in the concrete caused due to changes in moisture content (drying shrinkage) and/or temperature and prevent the formation of imegular cracks duc to restraint in free contraction of concrete. They also relieve stresses due 0 warping, Details of the contraction joints are given in IRC:15, They are formed initially by sawing @ groove of 3-5 mm with up to about one- fourth to one-third the slab thickness as shown in Fig, 6. This facilitates the formation of a natural crack at this location extending to the full depth. In order to seal the joint, the top 10-20 mm of this grooye is widened to 6-10 mm as shown in Figs. 3, 4 and 5. For heavy duty roads, these joints are provided with steel dowel ars to improve the continuity of slab and improved performance of jeinis, including load transfer. Typical cross-section of a contraction joint is given in Fig. 6(2). 5.3. Longitudinal Joints Longitudinal joints are provided in multi- Jane payements and also when the pavement is, more than’ 5 m wide, They relieve stresses ue to warping. Initially joint is cut to a depth 1/3 to 1/2 of the slab, Tie bars are provided at the joints not for load transference but for keeping the adjoining slabs together. The _Getails of such joints are given in IRC:15. The ‘top 15-20 mm of the joint is sawn toa width of 6-8 mm for sealing. Typical cross-section of a joint is given in Fig. 6(b). S.4, Expansion Joints ‘There are full-depth joints provided transversely into which pavement can expand, thus relieving compressive stresses due to expansion of concrete slabs, and preventing any tendency towards distortion, buckling, blow-up and spalling. The current practice is to provide these joints only when conerete slab abuts with bridge or culvert. Details of these joims are given in IRC:15. They are about 20-25 mm in width,IRC:57-2006 CouPReSSELE Next ResisTaNT ge ote —{ srcxereroor BACK UPROD Desonie SRE CONTRACTION JOINT ve }— SEALANT steps fer nae LONGITUDINAL JOINT Sen i re ra Po 2onm SEALANT ae DEDONDNG re Seoreineia nunaowe—| EXPANSION JOINT ores: "Whsoee cuca or cowenecain.r ocrownes IK Iie SEC=ssary THe STR SS NON AaSORaRIT TPE 2, JONTECAN BE SEALED BY ABCPTING ONE OF HE TWO ‘Derions OF DEDENDING STRIMONCKE OD Ad SHON, 6, DEMENDING UPONTHE SEALANT ANU FACTORER'S RECOMMENDAT ON, THE SIDES OF WIE GROOVE MY Fale 10 82 SAND ELAS EDAD PAPERED AND PRIMED. 4. THE GROOVE AND SEALANT IVENSICNS SHOWNARE ONLY FoR GUDANCE « BADKER RODBADCUPROD SHAU. RE EXPANDED (hase0.081 | POLYETHWENE FOME 4. eNDE OF THESUAING cROCVE SHALL BE PLUCCED SEPORE PCURINOBEALANT TOAVOID SPULAGE LATERALLY Fig. 3. Sealing Details of Joints (Grooyes Suitable for Hot Poured Rubberised Bitumen Sealant) 4IRC:57-2006 eee at fitiys 9. 4 TP clan son Fu aes de eorgs | | DEBONDING STRIP fb rackur eon enn 5a pi a t 1, t aE Pleo oh tom re DEBONONG TAPE a4 _— icnaiokn | ie wil aomm (eee ocr Sauer sa EXPANSION JOINT Notes: ‘NPAPCR BACKING OF COMPRESSIBLE DeROMOING STP SNOT NEGESSARY THE S731 NON ABSORBANT VTE: 2.J0INTS CANSE SEALED BY ADOPTING OME OF THE TWO ‘OPTIONS OF DEBONDING STRPEACKER-ROD Fs SHON, 3. DEFENLINS UPON THE SEALANT HAW FACTURER'S RECOMMENDATION, THE SIDES OF THE GROOV= VAY HAVE TC BE SAND BLASTEDISAND PAPERED AND PRIMED, |4cTHE GROCVE AND SEALANT OMERSONS SHOWIN ARE uly FoRcuIDANCE 5 BACKER ROD/GACK-LP ROD GALL BE EXPANDED) CLGSED-CSLL POLYEN-YLENE POM 6, SDS OF THe SEALING GRCOVE SHALL BE PLUGGED ‘BEFORE POURING SEALANT TO AVOD SPILLAGE LATERALLY, ‘TALLOMENSIONARE Wm Fig. 4. Sealing Details of Joints (Grooves Suitable for Cold Polysulphide Sealant) 5IRC:57-2006 ee ee j iF i 2 ep | SEALANT sc SiatesSite | DEBONDING STRIP =f Back.ur nop CONTRACTION JOINT 200 gy 48 fey fey ee . 1 ie Ste PT Tene % DeSONONG TAPE +4 | ance vero LONGITUDINAL JOINT eEONONGTHFE B .__J cowressacsnmetc—| Teta EXPANSION JOINT Notes: “PAPER BACKING OF COMPRESSIOLE OESONOING STRIP ISNT NECESSARY Tre STRIP IS NOWABSUREANT TYPE, ‘2 JOWTS CAN DE SEALED BYADOPTING ONE OF Te TWO. ‘OPTICNS OF CEBCNDING STRIPIEACKER-RCD AS SHOWN, DEFENDING UPON THE SEALANT MANU PACTURER'S RECOMENOATION, THE SES OF THE GRCOVENAY HAVE TO BE SAND BLASTEDISAND PAPERED AND PRED. 4.THE GROGVE AND SEALANT DIMENSIONS SHOWN ARE ONLY FOR GUIDANCE 5. BACKER RODIBACICUP ROD SHALL BE EXPANDED (CLOSED-CELL PoLYeTH¥. ENE FOAM 6: ENDS OF THE SEALING GROOVE SHALL 9€ PLUGGED BEFORE POURING SEALANT TOAYOID SPLLAGELATERALLY, ALL OMENSION ARE IN, Fig. 5. Sealing Details of Joints {Grooves Suitable for Cold Silicone Sealant) 6TOP OF THE GROOVE 15 WDENED FOR SEALING PURPOSE IRC:57-2006 __ is ROUND DOWEL BAR | ‘vet wa | i PLASTIC SHEATHING « “TOP OF THEGROOVE 1S WDENED FoR SEALING PURPOSE CONTRACTION JCINT VATH DOWEL BAR years ‘Yoto 2d = 2 os LENGTH PAINTED. WOH BITLAMINOIS PART LONGITUDINAL JOINT WHITH TIE - ROD BETWEEN TWO LANES cy) POWELCAP FILLED WT COMPRESSIBLE MATERIAL CONPRESSIBLEFILLER BOARD —+ i | a PLASTIC SHEATHING EXPANSION JOINT WITH DOWEL ; @ Fig. 6. ‘Typical Cross-Section of Joints A joint filler board of compressible material conforming to IRC: 15 is used to fill the gap between the adjacent slabs at the joint. The height of the filler board is such that its top is 23-25 mm below the surface of the pavement. The joint groove is filled by a sealant as shown in Figs. 3, 4 and 5, ‘Typical cross-section of an expansion joint is given in Fig. 6(c). 5.5. Construction Joints ‘The need for such joints arises when construction work is required to be stopped at a place other than the location of contraction or an expansion joint, due to some breakdown of the machinery or any other reason, Such joints are of butt type and extend to the full depth ofIRC:57-2006 the pavement. 'The sealing of sueh joints shall be done in the same manner as for eontraetion Joints, by cutting a groove 10-12 mm wide and 20-25mm deep. Generally, such joints are avoided in highways. The work is normally (erminated al a contraction or expansion joint. 5.6. sroove Dimensions The size of the joint groves is shown in Fig. 3, 42nd 5. The grooves shall not deviate from the specified size by + Imi hoth in depth and width, ‘All 6. SHALING DI 6.1. Steps involved in sealing operation of field-moulded sealant: * Widening of the first saw cut of 3-4 mm wo the required dimension as shown in Figs. 4 and 5, The grooves shall be checked for (olerance using width and depth gauges. * Sand blasting the groove face if the sealant manufacturer recommends it © Cleaning the groove with air compressor * Insertion of debonding sirip * Priming the sides of the sealant, if the sealant manufacturer recommends it © Pouring of seatant The sealants shall he applied only after the concrete slabs have been cuired to the specified duration, and there is no trace of moisture in the exposed faces of the joint groove. 62. jawing of Groove Lis recommended that all joints (except the expansion joint) be sawn. The sawing of joints should be a two-phase operation, In the initial phase, the sawing is done to. the required depth (one-fourth to one-third the depth) with a 3 mm blade soon after conerefe sets and is capable of taking the load of cuuing machine, This cut is intended to induce the full-lepth crack at the intended location, Since the next phase of sawing may be taken up after @ lapse of time, the joint should be filled with a temporary seat such as jute rope, This seal will Keep the incompressibles like stone pieves and dirt out of the joint and reduce the potential spalling. The second phase of saw cut is then made prior to the installation of the sealant. ‘This saw-cut widens the groove 10 the finally desired size and provitles a reservoir for the sealant material. When the second say-cut is made, the temporary seal is pushed into the bottom of the swidened groove se 28 to prevent all extraneous material from entering the joint including slurry generated during saving, process. Depth/iwieth gauges shall be used to control the dimension of the groove. If rough arises develop ‘when grooves are made, they shall be ground to provide a chamfer of 3 mm width, Ifthe groove is aan angle upto 10 degrees from the perpendicular to the surface, the overhanging edge of the sealing ‘groove shall be sawn or ground perpendicular. If spalling oveurs or the angle of the former is greater than 10 degrees, the joint sealing groove shall be sawn wider and perpendicular to the surface to encompass the defeets upto a maximum width, including any chamfer, of 35 mm for twansvese joints and 20 mm for longitudinal joins. Ifthe spalling cannot be eliminated then the artises shall be repaifed by an approved. thin bonded amis repair material using epoxy mortar, All grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil-free compressed air, If need arises, the cleaning may be done by pressurized water jets. Depending upon the requiement of the seslant manufacturer, the ides of the grooves may be sand blasted to increase the, bondage between the sealant and the conerete. Based on the recommendation of ‘manufacturer, the joint grooves shall be primed | before applying sealant, At the time of priming and sealing, the groove shall be clean andl dry, 63. Paper-Backed Debon g Strip Before sealing, the temporary seal provided for blocking the ingress of dirt, soil, ‘stone chips ete, shall be removed carefully. A debonding strip is then inserted in the groove to break the hond between the sealant and the bottom of the grocve and to plug the groove So that the sealant may not leak through the initial groove and ultimately into the cracks. ‘The details are given in Figs. 3, 4 and 5, The heat resisiant debonding strips are required for those cases where hol poured sealant ix used. In the case of compressible deboniting Strip 10 he used in contraction joint, normally the strip is provided with a paper-back so thatsealant is not absorbed by the debonding sttip. If the sirip is non-absorbant type no paper- hack is required. The width of the debonding strip shall be more than the width of joint groove so that it is held tightly in the groove, In the case of longitudinal joints there is no peed to install compressible debonding strip but a debonding tape of 1.0-2.0mm thickness is sufficient to plug the groove so that sealant does not flow downwards in the first cut groove, Heat resistant debonding strip, however, is to be used when hot-pouced sealant is used. 64. Debonding Strip and Backer Rod/Back- up Rod In the case of sealing of joint grooves with Field moulded technique, debonding strip or backer rods are required to prevent sealant flowing through bottom of the joint and prevent sealant adhesion to the bottom of the groove. ‘The debonding strip is normally of rectangular cross-section and of about 5 mm thickness and is provided with a paper backing 10 reduce the loss of sealant by absorption. The backer rod with round section is used without any paper backing as the closed cell foam used does not absorb sealant. ‘The types of materials used for debonding strip and backer rod ere: ® Polyethylene foam: This is a closed-cell foam that does not absorb water and is moderately compressible. As this material gets affected by heat, this is used for eold- poured joints. Cross linked polyethylene foam; This is compatible with hot-poured sealants. It is a closed-cell foam that Goes not absorb water and is moderately compressible, but will not melt in contact with hot-poured sealant Polyurethane foam : [Lis of open cell foam which can absorb moisture but does no: get affected by hot-pour sealant, It is very compressible and normally used with hot- pour sealunt, ‘The hacker/tack-up rods shall conform to ASTMC 5249-95 ar ASTMD 3575. IRC: 57-2006 65, Cleaning / Sand Blasting of sides of the Groove During the widening of the joint groove, water is fed to the diamond edged saw as coolant for grooving. The sluny preduced normally gers coated as a thin film on the sides of the groove which acts ay a barjer between sealant and concrete. Therefore, there is a need to clean the sides of the groove with sand blasting, water jet and subsequently, with an air jet as recommended by the manufacturer, As the surface of sides bocomes smoother during grooving/videning its generally necessary to sand blast the sides. The pitted surface of sides of the groove is helpful in improving the bond between sealant and concrete, 6.6, Priming A primer is used to improve the adhesive bond between sealing compound and conerete, to penetrate the pores of the concrete and to coat it with a thin film of yiscous sticky material. The primer must have a yery low viscosity s0 us to penetrate: the pores of the concrete. The primer to be used shall be as recommended by the sealant manufactures. ‘The primer shall be applied to the joint faces by spay or brush as soon as the surface is preparad, cleaned and dried as per specification. The primer shall be applied carefully co that the joint surfaces are evenly ‘coated. Pools of excess primer shall be avoided 9 these may be detrimental to the subsequent performance of the sealant. Some sealant manufacturers do not recommend use of primer with their product, but cleaning and sand blasting sides may be necessary, 6.7. ‘Types of Seatants ‘There are three main categories of materials for sealing of joints in cement concrete pavements, viz: aire © -hot-poured sealants * cold poured sealants Table | gives the brief details of various sealants in use.IRCS7-2006 Table 1, Common Joints Sealant Materials Sealant Type specification Properties Hot Poured Joint Sealants Rubberized Bitumen Sealant Polymeric Asphalt Based Is 1834 ASTM D34005 SS-S-1401.C ASTM DII90 Polymeric Sealant ASTM D3405 Low Modulus Modified Blastomeric Sealant Coal Tar, PVC ASTM D 3406 AASHTO MOI73 US Federal Highways Administration Specification US Federal Highways Administration Specification S8-S-1614, ASTM D 3405 Self leveling Self-leveling Self-leveling Self-leveling Self-leveling Self-leveling Self-leveling Self-leveling Self-loveling Cold Poured Sealants / Single Components Silicone Sealant ASTM 5893-96 Silicone Sealant ASTM 5893-96 Polysulphide Seatant BS 5212-1990 1995) Polyurethene Sealant BS 5212 IS 11433-1986 (Reaffirmed in Non sag, Toolable, Jow modulus Self-leveling (no tooling), Jow modulus Self-leveling (no tooling), | low modulus 6.8. Hot-Poured Sealants Rubberized-bitumen sealant is normally. heated in the range of 120°-180°C as per the recommendation of the manufacturer before using it. The relevant specifications for different hot poured seztants are given in Table 1 Inhol application, sealant should be heated in a melier and stutage vessel to the specified temperature, using oil jackets and thermometers for controlling the heat. A schematic view of a heating kettle is shown in Fig. 7. The sealant should be contimiously agitated (© avoid loval overheating throughout the heating and pouring operation. The temperature of the material should not be allowed to rise above that stated by the manufacturer nor should the material be maintained at application temperature for a longer period of time than indicated by the manufacturer. ‘The sealant shall be poured by means of a pouring kellie or using extruding machines which pump ‘the material into the sealing groove. The sealant shall be applied such that the tep surface of the cooled sealant is at the requited depth below the pavement surface, within a tolerance of 3 1 mm. ‘The minimum depth of the sealant shall not be less than that specified, On super-clevated portions: where the cross-full is greater them 2.5 per cent, measures should be taken to ensure that the sealant does not flow along the joint, by () placing tie material in thin layers and allowing each leyer 1o siffen before placing the next or (i) fooming dams at inte:vals along the joint wo check the flow. ‘The dams should be thereafter cut and replaced with sealant In order to avoid spillage of sealant ‘on the concrete surfive, care-board or tape should 10IRC:57-2006 |Site | Simremence Seseetoeseaine | Lad 8 unrrert— ' 1 SECTION ONAA %, Bio Siimcetneriver ‘eae PLAN Fig. 7. Schematic View of a Sealant Melter be sttick on both edges before pouring sealant, doie by sophisticated melter and pourer. The sealant may he pressed by a taol to have A kettle used tor sealing manually is shown in smooth surface, Sealing operation can be Fig. 8IRC:57-2006 175 i | mi 6.9. Cold Poured Sealants There are two main sealants under category which are used for pavements * Polysulphide conforming to 19:11433 (Part 1) or BS 5212 © Silicone conforming to ASTM:5893 Polyurethane conforming to BS:5212_ | They are poured at atmospheric’ temperature, and after being poured, undergo a chemical reaction and give a seal of the desired consistency. They allow for repeated larger extension of 30 per cent, as against 20 per cent in the case of hot poured bitumen- based sealants. Becuuse they do not need heating, the application is simple. At the same Gime, a great care is needed in selecting the product and applying them. They require greeter care in preparing the edges and the bottom of the groove (drying, cleaning and coating with primer). They ure costlier than hot applied sealants, but their higher cost is justified by longer life. 8. A Pouring Kettle for Hot-Poured Sealant 6.10. Movement Accommodation Factor (MAF) This is an important property of sealant which defines the capacity of the sealant to undergo expansion or contraction without any change int volume, The material will revert back to original shape on removal of load. It can be defined as: ‘Compressed Widhh ~ Original Width Orginal Wider Expanded Width Origin Wid Original Width MAI x 100 % 100 For highly clastic material. MAF value will be higher. Polysulphide sealants have MAF of more than +25%. The MAF of silicone sealants, is in the range of -50% w+ 100%. This sealant can be compressed to its 50% size whereas it can be stretched to 100% of its original length without any change in the volume of sealant, Polysulphide sealants are generally supplied in the form of wo components packed, separately, They are to be mixed immediatelybefore being used. They shall conform to BS 5212-Part IL. Sealing details of joints when polysulphide sealant is used are given in Fig. 4. Silicon sealants are single component type. They shall conform to ASTM Designation D 5893-96. This sealant hardens by absorbing moisture from the atmosphere. For it to harden in reasonable time, the sealant is placed in thin section ‘The cold application sealants are applied in the field either by hand-held guns/syringe or machine in accordance with the manufacturer's instructions. The surface of the sealant shall be recessed by not less than 2. mm nor more than 4 mm below the pavement surface. Sealants applied at contraction phase of the slabs would result in bulging of the sealant over and above the slab, Therefore, the right temperature and time shall he established for applying the sealant. A thermometer shalll be hung on a pole al the site for facilitating control during the sealing operation, Details of sealing grooves are given for guidance in Figs. 3, 4 and 5. The groove dimensions are different for silicone sealants as thin sections are preferred for early curing ‘Table 2. Requirem: IRC:57-2006 During the sealing operations, it shall be seen that no air bubbles are introduced into the sealant either by vapours or during the sealing process Manufacturer's certificate shall be produced for establishing that the sealant is not more than six months old or the shelf-life of the sealant, ‘The cold applied sealants shall be tooled so that the final surface of the sealant has a. parabolic shape in the surface cross-sectional area or as per the recommendation of the manufacturer Any sealant that pulls loose from the joints or shows excessive bubbling within one week after opening of the pavement to traffic shall be replaced by a fresh application. 7. PREFORMED SEALS ‘The pre-formed joint sealing material shall be a valcanised elastomeric compound using polychloroprene (Neoprene) as the base polymer, The Joint Seal shall conform to requirements of ASTM [2 2628 as given in Table 2 ents of ASTM D 2628 St DESCRIPTION REQUIREMENTS | ASTM TEST No. METHODS: [1 | Tensile Strengih. min, 13.8 MPa i 2_| Biongation at break min. 250% 3 | Hardness. Type A duometer 55-45 points D240 4 | Oven aging, 70 hat 100°C Tensile strength loss 20% max Ds 5__| Blongation toss 20% max 6 | Hardness Change Type A durometer (10 +10 poms Dan 7_| Oi Swoll, ASTM Oi1 3, 70 st 100°C Weight Chany 5% max Die 8] Ocone resistance 20% strain, 300 pphm inal. 70 b.at40°C] No cracks baat D 9 | Low temperature stiffening, 7 days at-10°C Harness (010 +15 points Change type A durometer 10__| Low temperature recavery, 22h at 10°C, 50% deflection | 88% min D 2628 Lt | Low temperature recovery, 22h af 29°C, 50% defiection | __83% min 2628 12_| High temperatne recovery, 709 at 100°C, 50% deflection] 854% min 12628 13. | Compression, deflection, ai $0% of normal width (min) | 613 Nim 2628 ‘The groove width und depth shall depend upon the manufacturers’ specifications. They shall be installed preferably by a machine, after cleaning the groove as described in para 6. 1BIRC:57-2006 8 RESEALING OLD JOINTS ‘When existing sealant has cracked or fas detached from the sides, the sealant shall be removed with a raker, and the surfaces are cleaned by brushing or using special tools or by sawing the groove afresh and air jet upto a depth of at least 20-25 mm. A raker normally used for cleaning the joints is shown in Fig. 9. ‘Temporary seal with a jute rope shall be ELEVATION inserted 10 protect the joints from ingress of dirt etc, before resealing joints. If the grooves are 100 narrow, widening by sawing may be necessary. Any spalled edges shall be repaired with a cementitions material (epoxy or polymer based fine concrete). Primer shall be applied to the cleaned surface in the manner described earlier, if recommended, and rescaling done as described earlier. SIDE VIEW