INSTALLATION INSTRUCTIONS FOR BALCO, INC. DURAFLEX TM FS SERIES - FLEX SEAL EXPANSION JOINT SYSTEMS

Transcription

1 2626 South Sheridan PO Box Wichita, Kansas Phone: (316) Fax: (316) INSTALLATION INSTRUCTIONS FOR BALCO, INC. DURAFLEX TM FS SERIES - FLEX SEAL EXPANSION JOINT SYSTEMS 2015, Balco, Inc. Document Control No. EJCI5005

2 INSTALLATION INSTRUCTIONS FOR BALCO, INC. DURAFLEX TM FS SERIES - FLEX SEAL SYSTEMS The following installation instructions are very important. Read them carefully, and be sure you understand them completely before you begin any work. STORAGE & HANDLING Upon receipt, these products should be stored in the horizontal position in a clean, dry location. Store these products in a protected area. Do not allow these products to freeze. Store these products at a temperature range of o F. EBA32 adhesive requires proper storage for maximum self life. Wear insulated gloves, Neoprene or other appropriate material, safety glasses, long sleeve shirts and long pants when installing these products. The work area shall be well ventilated. The recommended shelf life of Balco, Inc. EBA32 is nine (9) months from date of manufacture. All users should familiarize themselves with the MSDS information prior to the work. FS SERIES FOAM SEAL SYSTEMS PARTS LISTS FS-100 FS-150 FS-200 FS-250 FS-300 FS-400 A. Foam Seal FS100 FS150 FS200 FS250 FS300 FS400 B. Conditioner PC33 PC33 PC33 PC33 PC33 PC33 C. Epoxy Adhesive 1 EBA32 EBA32 EBA32 EBA32 EBA32 EBA32 D. Traffic Plate AL Plate AL Plate AL Plate AL Plate AL Plate E. Anchor TF TF TF TF TF EBA32 is a two component product. Part A and Part B are provided and are mixed by the installers at the job site. 2 Plate width varies according to joint size. 3 Anchors may differ from those listed above, depending upon substrate and system configuration. TOOLS REQUIRED This is a list of tools and materials recommended for use in the installation of these joint systems. Tools and materials in this list are not provided by Balco, Inc. Tools and materials marked with an asterisk (*) must be pre-approved by Balco, Inc. A. Tape Measure L. Drill Bit for Substrate (Concrete or Metal) B. Level M. Stiff-bristled Nylon Brush C. Concrete Saw N. Tape for masking substrate and seal D. Disc Grinder O. Putty Knives E. Diamond Grinding Disc P. Margin Trowel F. Concrete Patching Material* Q. Clean Plastic Sheet G. Sandblasting Equipment R. 18" Square Piece of Plywood (Clean!) H. Air Compressor (fitted with an oil trap) S. I. Markers for marking Concrete and Seal T. Phillips and Slotted Screw Drivers J. Utility Knife U. Miter Box K. Electric Drill 2

3 Figure 1 Figure 2 Figure 3 3

4 PRELIMINARY REQUIREMENTS 1. Scope of Preliminary Requirements The expansion joint stem opening must be formed to a uniform width for the entire length of the joint. To select the proper seal size, the following should be considered: A. The size of the joint opening measured at a 70 F temperature should be verified and recorded by the Engineer of record (see Figure 1). Correlate the measured joint width with the deck temperature. Verify that the opening width is synchronized with the values in the Temperature- Adjustment Table supplied by the Engineer of Record. Please note that the joint width provided in Figure 1 is representative. Actual joint width may vary from that indicated in Figure 1. B. The Engineer of Record shall determine the movement required at the joint location. Regional temperature history and construction material properties will determine the increment of movement per degree of temperature. Other movement requirements, such as longitudinal rack, deflection, etc. should also be considered and accounted for. Review all directional change locations; advise Balco, Inc. of the details. C. Verify that the deck is formed level and at the same elevation across the joint. Report any areas exceeding +/- ¼ inch to Balco for instructions prior to commencing with installation of seal. D. Verify that the joint opening to receive the new expansion joint system is constructed to the exact dimensions shown on Balco, Inc. shop drawings, straight, parallel and plumb. Concrete saws and diamond grinding disks should be used to correct any deviations. Verify that the joint interfaces are parallel to, and continuously equidistant from, each other and that they are straight and plumb. 2. Concrete Joint Opening Preparation A. The stem opening of the expansion joint must be constructed straight, parallel and plumb. Concrete saws and diamond grinding disks should be used to correct any deviations. A tooled edge on the corners of the concrete is desired. The radiused edge reduces the effects of impact loading from vehicles and lessens the chance of edge erosion, cracking or spalling. Access to the bonding surface of the interface walls must be free and clear. Any obstructions must be accounted for in the installation process. B. Concrete adjacent to the expansion joint system must be sound. This should be confirmed by tapping these areas with a hammer (see Figure 2). If a hollow sound is heard or the concrete cracks, crumbles or loosens, the unsound concrete must be removed and repaired with a structural repair mortar. Repair mortars acceptable to Balco, Inc. include; Thoroc 1060, Emaco T-415 and Sika 123. C. Edge spalling, sharp projections and concrete voids (bug holes) shall also be repaired prior to proceeding with the joint installation. All repair materials used should have reached full cure conditions as specified by the repair material manufacturer. All obstructions such as form work and refuse shall be removed from the joint opening. Spalls in the concrete must be repaired by using a pre-approved patching material. Consult the Engineer of Record for a list of acceptable patching products. D. Areas that are repaired must also be sound and their soundness must be confirmed by tapping these areas with a hammer. If a hollow sound is heard or the repaired area cracks, crumbles or loosens, the unsound repair must be completely removed and repaired again with a structural repair mortar. E. Sandblast the interface walls to expose the aggregate (see Figure 3). This will enhance the bond and remove any surface contaminants. If sandblasting is not possible, the joint faces must be 4

5 Figure 4 Figure 5 Figure 6 5

6 ground with a coarse disc grinder to produce an abraded surface. Be careful not to polish the concrete surface as this could cause failure of the adhesive. After sandblasting, or abrading, blow out the area with an air compressor fitted with an oil trap; this will eliminate the possibility of recontamination from oil and moisture in the lines. F. Prior to progressing with the installation of the seal, clean the interface walls of the concrete using Profile Conditioner - PC33. This will remove fine dust particles and prepare the surface to receive the adhesive. 3. Seal Preparation A. The seal will be delivered to the site protected in shrink-wrap and banded to a pallet. When ready to begin installation, remove the wrap and uncoil the seal. Allow the seal length to relax until all of the kinks have been relieved. Balco, Inc. recommends placing the seal on a piece of clean plastic sheet to prevent soiling of the seal. B. Cut the seal to the lengths required for the application. Lengths should be accurate in order that the seal is not stretched during the installation process. C. Using a stiff nylon brush, scrub the ribbed areas of the sidewalls of the seal with the Profile Conditioner - PC33 (see Figure 4). Do this for the entire length of the seal. D. Scrub the sidewalls of the seal again using clean white rags soaked in the Profile Conditioner - PC33. Do this for the entire length of the seal. INSTALLATION These installation instructions are for use in the installation of the DuraFlex TM FS Series - Flex Seal Systems Types FS-100, FS-150, FS-200, FS-250, FS-300 and FS-400. The system shall be installed as follows: STEP 1. Review Balco, Inc. approved shop drawings for types and locations. STEP 2. STEP 3. Ensure that the joint and concrete, or steel, have been properly prepared for the seal installation in accordance with the section of these instructions entitled "Concrete Joint Opening Preparation". Select the Traffic Plate, if provided, and place it into its installed position. Ensure that the traffic plate is straight, level and properly positioned over the joint. Using the traffic plate as a template, mark the locations for the anchor holes on the substrate (see Figure 5). Remove the traffic plate from its installed position, and drill the anchor holes into the concrete at the marked locations. Clean away any dust, dirt or debris from the joint area. NOTE: OBSERVE NORMAL SAFETY PRECAUTIONS WHEN DRILLING TO AVOID ALL UTILITIES AND RE-BAR. STEP 4. Apply tape to the interface walls of the joint, to a depth located above where the first rib on the sidewall of the seal will be when the seal is installed (see Figure 6). Apply tape to the deck surfaces adjacent to the stem opening (see Figure 7). NOTE: TAPE IS USED AS A BOND BREAKER AND WILL KEEP THE CONCRETE FREE OF SMEARED ADHESIVE. STEP 5. Select the Epoxy Bonding Adhesive - EBA32 components, Part A and Part B. Pour the EBA32 Part A onto a clean piece of plywood, an 18" square piece of plywood is 6

7 Figure 7 Figure 8 Figure 9 7

8 recommended. Pour an equal amount of the EBA32Part B onto the piece of plywood. With both components now on the plywood surface, use a trowel or a putty knife to fold the materials together until they are fully mixed and there is no sign of streaking in the batch. Approximately two minutes should allow for full blending. NOTE: COVERAGE RATES FOR THE EBA32 DEPEND ON THE SEAL SIZE BEING BONDED IN PLACE AND ON CONTRACTOR CARE AND APPLICATION. EBA32 HAS A POT LIFE OF 60 MINUTES AT 68 F (20 C); ITS POT LIFE DECREASES AS THE TEMPERATURE INCREASES. STEP 6. STEP 7. STEP 8. STEP 9. Apply the adhesive to the joint interface walls using putty knives (see Figure 8). The adhesive thickness should be 1/16 to 1/8. Wipe the putty knives clean with a solvent soaked rag frequently. Do not allow the adhesive to set up on the surface of the putty knives. Do not allow the adhesive to drip through the joint onto surfaces below. Allow the adhesive to set while the profile is selected and laid out next to the opening. Ensure that the seal has been prepared for installation in accordance with the section of these installation instructions entitled "Seal Preparation". Apply tape to the top of the seal to protect it from excess adhesive and the collection of dust and grime during the installation (see Figure 9). Apply a layer of adhesive to both sides of the seal (see Figure 10). Ensure that the deck surface is protected so that adhesive does not drip or is not tracked onto it. STEP 10. Position the seal over the joint opening. Compress the seal, and using a blunt tool or the flat of a wooden 2x4, press the seal into the joint to the proper depth, ensuring it is level (see Figure 11). STEP 11. After the seal length is installed, carefully remove the tape from the deck surfaces and the interface walls of the joint before the adhesive sets up (see Figure 12). Carefully remove the tape from the top of the seal before the adhesive sets up (see Figure 13). STEP 12. Place the traffic plate into its installed position, ensuring that the anchor holes in the traffic plate are properly aligned with the anchor holes in the concrete (see Figure 14). Ensure that the traffic plate remains straight, level, and properly aligned. STEP 13. Using the fasteners provided by the factory, attach the traffic plate to the concrete (see Figure 15). STEP 14. Clean the installation area. Ensure that any remaining Conditioner and Adhesives are properly stored away or are disposed of properly. Ensure that all trash, used duct tape and refuse are disposed of properly. 8

9 Figure 10 Figure 11 Figure 12 9

10 Figure 13 Figure 14 Figure 15 10

11 WARRANTY POLICY Balco, Inc. warrants to its purchasers that all products sold by it will be free from manufacturing and material defects. Any defective product will be replaced or repaired free of any charge, provided a claim is brought to our attention, in writing, within the established warranty period following the date of shipment by us and provided our examination shows the product has failed under the terms of this warranty. The established warranty period for exterior joint cover systems (Duraflex TM) is five (5) years provided the systems are installed by a Balco Certified Installer. The established warranty period for grids and mats is two (2) years. The established warranty period for all other Balco, Inc. products is one (1) year. Balco, Inc. will not be responsible for installation costs involved in such repair or replacement. Balco, Inc. shall have no obligation under this warranty if owner subjects materials to improper conditions (refer to Balco's installation instructions) This is in lieu of all other warranties, expressed or implied, and is the sole warranty extended by Balco, Inc. Our liability under this warranty is limited to repair or replacement and does not include any responsibility for consequential or other damage of any nature. It is further agreed and understood that the price stated for the seller's products is consideration for the limitation of seller's liability hereunder. REGISTERED TRADEMARKS: BALCO, INC. PATENT NUMBERS: "VINYLINES" "SAF-T-GLO" 5,782,044; 5,829,216; 5,832,678; "METAFLEX" "SAF-TEN BEVEL" 6,014,848; 6,115,980; 6,581,347; "SENTRY" "DURAFLEX" 6,942,419; 6,955,017; 6,962,026; "ILLUMI-TREAD" "METABLOCK" 7,104,717; 7,856,781; 7,946,784; "MICHAEL RIZZA COMPANY" 8,079,190; 8,245,471; 8,464,485; 8,607,519; 8,601,760; 8,646,235; Fire Resistant Joint Covers Patents Pending