Abstract:
A joint seal comprises two elastomeric elements, configured to fit as a nested assembly within the gap between adjacent slabs. The outer element (the &#34;outer seal&#34;) is a generally U-shaped channel (with sides and a bottom), and performs the actual sealing function. The outer surfaces of the channel sides are formed with a series of longitudinally-extending fins, which frictionally engage the slab edges. The inner element (&#34;the core&#34;) is formed as a generally rectangular tube that provides a structural strength for the seal assembly. It includes a tubular outer wall and an internal truss-type framework consisting of a number of interconnected webs. The seal assembly is installed under compression.

Description:
This is a Continuation of application Ser. No. 846,371, filed Mar. 31, 1986, now abandoned. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the sealing of joints, and more particularly to a seal for preventing leakage between adjacent concrete slabs in the bottom of a liquid-retaining structure. 
     BACKGROUND OF THE INVENTION 
     It is well known to form a large expanse of concrete as a series of discrete slabs separated by appropriate expansion joints. When such a structure forms the lining of a canal, reservoir, or the like, the ability of such expansion joints to remain water-tight becomes a significant issue, and provision must be made to provide some sort of joint seal. 
     By way of example, consider a seawater canal, perhaps on the order of 10 km long with three channels, each 30 m wide and 6 m deep. Naturally, the seal must prevent water leakage under the normal hydrostatic pressure of approximately 10 psi. Furthermore, if the channel is drained of water, the seal must remain in place despite upwardly directed ground water forces. Additionally, since the need for a resilient seal arises from the possibility of relative movement between adjacent slabs due to settlement and the like, the seal must accommodate such movement. For example, the seal may be required to accommodate horizontal displacements (expansion and contraction) of approximately 6 mm and vertical differential displacements on the order of 10-20 mm. Moreover, for longevity, the seal should be able to withstand bacterial and chemical action, ultraviolet irradiation, and extremes of temperature. 
     One type of prior art joint seal utilizes a resilient sealant such as a polysulfide resin to fill the gaps between slabs. The sealant adheres to the concrete slab edges to provide a water-tight joint. Unfortunately, while such seals are typically effective when initially installed, differential vertical and horizontal movement and environmental effects can cause the adhesion to break down to the point where significant leakage occurs. 
     The problem of retrofitting the seals on a canal or similar structure is rather different from, and typically more difficult than, the problem of designing and installing the original seals. While there are other types of seal that might be more suitable than those discussed above, they can only be installed as part of the original construction, not as a retrofit. 
     Thus there is presented the problem of providing a retrofit seal capable of maintaining water-tight joints over a significant range of slab movement and hydrostatic forces. 
     SUMMARY OF THE INVENTION 
     The present invention provides a joint seal, suitable for initial or retrofit installation, that meets the performance criteria outlined above. Additionally, the seal is relatively simple to install and inspect and fits flush with the top surface of the slabs so as to be immune to damage during cleaning or maintenance of the canal. 
     A joint seal according to the present invention comprises two elastomeric elements, configured to fit as a nested assembly within the gap between adjacent slabs. It is generally contemplated that the gap has a stepped configuration, wider at the exposed slab surface so as to define a seal-receiving recess, rectangular in cross-section. 
     The outer element (referred to as &#34;the outer seal&#34;) is a generally U-shaped channel (with sides and a bottom), and performs the actual sealing function. The outer surfaces of the channel sides are formed with a series of longitudinally-extending fins, which frictionally engage the slab edges. The inner element (referred to as &#34;the core&#34;) is formed as a generally rectangular tube that provides structural strength for the seal assembly. It includes a tubular outer wall and an internal truss-type framework consisting of a number of interconnected webs. 
     The sides of the outer seal are formed with inwardly extending flanges at their upper ends to retain the core when it is installed inside the outer seal prior to installation. While the outer seal is installed as a continuous strip, the core is installed as separate sections, each a few meters long, with longitudinal gaps of a few millimeters. This allows the water to fill the inside of the outer seal as well as the core interior, thereby maintaining even pressure at all times. 
     The seal assembly is installed under compression (approximately 15%) whereupon the fins frictionally engage the concrete and restrict movement of the seal. The internal structure of the core controls the deformation transverse to the length of the seal assembly in a manner that maintains a positive sealing under various conditions. Given that the seal is installed under compression, it automatically provides a certain reserve compression in the event of joint expansion (slab separation). In the event of joint contraction, the core undergoes controlled compression to maintain the outer seal sidewalls in proper alignment and contact with the slab edges. When installed under compression, the core deforms relatively easily in response to shear motion caused by differential vertical movement of the two slabs and maintains the sides of the outer seal vertical and in contact with the slab edges. 
     Prior to installing the seal assembly, one may coat the facing vertical concrete surfaces (or alternatively the vertical outer surfaces of the seal) with a liquid such as polyurethane resin, which acts as a lubricant and ultimately sets up as an adhesive. In such a case, the fins on the outer surface act as reservoirs for this material so that it can remain in position to increase the sealing action. It is noted, however, that the adhesive is not an essential part of the invention; the geometry and material of the seal itself provide a positive water-tight joint under the various loading conditions. 
     The present invention is versatile in that the core may be configured in a wide variety of ways so as to accommodate considerations such as manufacturability and cost of materials. A preferred embodiment of the invention contemplates a core configuration including four major internal webs, each joined to the tubular outer wall near a respective corner, and converging to a central region. In some embodiments, additional minor webs extend between the major webs and the outer wall. In other embodiments, the major webs are curved in cross-section. 
     A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the attached drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     .FIG. 1 is a cross-sectional isometric view of an installed joint seal according to the present invention; 
     FIGS. 2A-B are cross-sectional views of the components of a preferred embodiment of the joint seal; 
     FIGS. 3A-E are cross-sectional views illustrating a procedure for installing the joint seal in existing concrete; 
     FIGS. 4A-B are cross-sectional views showing the deformation of the joint seal under design loads; 
     FIGS. 5A-B are computer-generated deformed geometry plots showing the deformation of the preferred embodiment under anticipated loadings; 
     FIGS. 6 and 7 are cross-sectional views of alternative embodiments; and 
     FIGS. 8A-B and 9A-B are deformed geometry plots for the alternative embodiments. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Structure and Installation of Preferred Embodiment 
     FIG. 1 is a cross-sectioned isometric view of a joint seal assembly 10 (sometimes referred to simply as &#34;seal 10&#34;) installed between adjacent concrete slabs 12a and 12b. Although seal 10 is effective regardless of orientation, it will be assumed that the exposed surfaces of slabs 12a-b are horizontal, and references to orientation and relative height will reflect that assumption. In actual fact, the seal of the present invention was developed in connection with retrofitting the concrete lining on the bottom and sloping sides of a seawater canal. 
     The gap has a stepped configuration, widened at the top so as to define a pair of seal-engaging shoulders 15a and 15b and a seal-receiving recess 17. The latter has facing edges 18a and 18b. Although specific dimensions are not a part of the present invention, it will be noted that slabs 12a-b are generally on the order of 20-30 cm thick. Seal-receiving recess 17 is approximately 4.5 cm wide and 6 cm deep; the lower portion of the gap is on he order of 1-2 cm. In the case where the seal is used to retrofit a previously sealed joint, the lower portion of the gap may contain resilient material from the previous installation. 
     Seal 10 is basically a two-part elastomeric structure, comprising an outer seal 20 and a nesting core 22. These elements are preferably extruded from neoprene rubber. A typical installation also utilizes a backing strip 25 spanning the gap and supported on shoulders 15a-b. The backing strip may be made of a hard plastic. In broad functional terms, seal 10 is a resilient structure, installed under compression, to maintain water-tight contact between the outer surfaces of the seal and facing edges 18a-b of the concrete slabs. The water-tight contact is maintained over a range of differential horizontal and vertical movement of slabs 12a-b. 
     FIG. 2A is a cross-sectional view of outer seal 20, with core 22 and backing strip 25 shown in phantom. Outer seal 20 is generally in the form of a U-shaped channel defined by a pair of channel sides 27a and 27b, and a channel bottom 28. Channel sides 27a and 27b carry respective core-retaining flanges 30a and 30b at their upper edges. Each of the channel sides is formed with a plurality of longitudinally-extending, upwardly-angled fins 32 that impart a serrated form to the cross-section. Channel bottom 28 is formed with longitudinally-extending, upwardly-thrust (or downwardly-opening) medial fold 35. In the particular embodiment, the outer dimensions of outer seal 20, exclusive of fins 32, are 2 inches wide and 2 inches high (about 5.1 cm by 5.1 cm) The channel sides are about 4 mm thick; the channel bottom about 3 mm. 
     FIG. 2B is a cross-sectional view of core 22 with outer seal 20 and backing strip 25 shown in phantom. Core 22 is generally in the form of a rectangular tube (square in the preferred embodiment) comprising a tubular outer wall and a plurality of internal webs that divide the core interior into a number of longitudinally-extending passageways. More particularly, the tubular outer wall includes a top 40, a bottom 42, and opposed sides 43a and 43b. The internal webs include four generally diagonally extending major webs, each joining the outer wall near a respective corner, and converging toward a central region. The major webs include a pair of upper webs 45a-b and a pair of lower webs 47a -b. In the preferred embodiment, each upper web meets a corresponding lower web, and the two convergence points are spanned by a central horizontal web 48. A pair of minor webs 50a-b extend between lower webs 47a-b and sides 43a-b. The core bottom is formed with a longitudinally-extending fold 55 configured correspondingly with respect to fold 35 of outer seal 20 so that the core and outer seal nest. The tubular outer wall has lower corner regions 56a-b which engage portions of channel bottom 28 and upper corner regions formed with indentations 57a-b to accommodate core-retaining flanges 30a-b. 
     FIGS. 3A-E are cross-sectional views illustrating the sequence of steps for preparing the joint and installing seal 10. FIG. 3A shows the original joint, designated 60, between slabs 12a and 12b. As noted above, the joint has previously been filled with a compressible resilient material, such as polysulfide resin. The first step entails forming a number of parallel, vertical sawcuts with a diamond-tipped saw. This is preferably done in two passes. FIG. 3B shows the result of the first pass wherein four vertical sawcuts 62 have been made in the concrete slabs. The outermost extent of the sawcuts provides a dimension very slightly less than the ultimate width of seal-receiving recess 17, and the depth is very slightly less than the ultimate depth of the seal-receiving recess. In the present case, the ultimate width and depth are 1.875 inches (about 4.8 cm) and 2.5 inches (about 6.4 cm), respectively. The sawcuts, once made, leave relatively thin slices of concrete. FIG. 3C shows these strips having been broken away and the debris removed. A second pass with the saws set to establish the final dimensions provides the finished seal-receiving recess 17. FIG. 3D shows the finished seal-receiving recess with backing strip 25 in place. 
     FIG. 3E shows the finished joint with seal 10 having been compressed and seated in recess 17. Once the seal is installed, it is flush with or slightly below the upper surface of the concrete slabs, and therefore is not subject to damage when vehicles drive over the joints, as for example when the bottom of the canal is cleaned. 
     Outer seal 20 is formed in sufficient lengths to extend the entire length of the joint without gaps. Core 22, on the other hand, is cut into sections of a few meters each. Prior to installation, the sections of core are placed into the outer seal, with adjacent core sections being separated by gaps of a few millimeters. Thus, once the canal is flooded, water occupies the core interior and any space between the core and the outer seal. 
     Seal 10 is installed under lateral compression, generally on the order of 15% compression. A lubricant is normally used to facilitate installation. The lubricant may be applied to the concrete or the rubber, or both. Application to the concrete is typically easier, and is therefore generally preferred. A polyurethane resin is preferred since it acts as an adhesive when it sets, thereby enhancing the engagement between fins 32 and slab edges 18a-b. Additionally, the resin tends to seal small fissures or voids in the concrete, further enhancing the integrity of the rubber-to-concrete contact. 
     The effectiveness of the seal derives jointly from the resilience of the compressed seal and the pressure of the water that fills the seal interior. As noted above, the core interior and the interstice between the core and outer seal are in fluid contact with the water above the slabs, so that the water pressure acts outwardly on the bottom and sides of the seal. 
     Performance and Testing of Preferred Embodiment 
     The purpose of the internal webs in core 20 is to control the transverse deformation in a manner that keeps the core sides as vertical as possible. With the core sides vertical, the reaction forces from the deformed core top and bottom and the deformed webs are transmitted to the channel sides to maintain an effective seal. 
     FIGS. 4A-B are cross-sectional views illustrating the deformation that the seal undergoes when subjected to the compressive and differential vertical loading. FIG. 4A shows the deformation resulting from the compressive loading at installation. It will be noted that the seal undergoes a symmetric deformation where channel sides 27a-b, and more particularly fins 32, maintain their frictional engagement with facing edges 15a-b of seal-receiving recess 17. Medial fold 35 in outer seal 20 and medial fold 55 in core 22 operate to control the deformation so that it occurs predictably. 
     FIG. 4B shows the deformation when one of the lower corners of the seal is displaced vertically relative to the other. In this case, it is noted that the internal web structure operates to maintain core sides 43a-b and channel sides 27a-b in substantial parallelism despite significant vertical displacement. The initial lateral compression provides reserve both for joint expansion and for such differential vertical displacement. 
     The preferred embodiment was subjected to bench testing wherein a structural steel test frame supported two parallel concrete sidewalls to simulate the cut joint. One sidewall was displaceable vertically and laterally relative to the other by means of turnscrews. The ends of the joint were sealed with a rubber cement (Isoflex 907 from H. S. Peterson Co.) and the region over the joint was sealed with a rubber cover plate in order to allow the seal to be subjected to a range of hydrostatic pressures. The seal used in initial testing was poorly fabricated, with jagged fins, and could not sustain 9 psi pressure (leaking occurred at pressures between 3.5 and 8 psi). A seal having thicker fins with smooth continuous edges was fabricated for the subsequent test. The sawcut concrete sidewalls had any pinholes and aggregate voids filled with epoxy. 
     Table 1 shows a summary of the test results. As can be seen, the seal was able to maintain 9 psi pressure at vertical displacements of up to 1/2 inch for gap widths of up to 2 inches. At the nominal gap width of 1.875 inches, and no vertical displacement, the seal was able to withstand up to 35 psi pressure before leaking. 
     Computer Modeling 
     FIGS. 5A-B are deformed geometry plots, which were generated in connection with a beam model analysis of the preferred embodiment. Dashed lines denote the original (undeformed) configuration while solid lines show the deformed configuration. 
     The analysis utilized the computer program ANSYS, a general-purpose, finite element computer program for static or dynamic structural analysis, supplied by Swanson Analysis Systems, Inc., of Houston, Pa. The program is capable of including non-linear effects of material, geometry, and &#34;gap elements.&#34; The assumptions regarding materials and loading were relatively conservative, as will now be described. 
     As noted above, the seal is made of neoprene rubber, which, depending on the exact composition, exhibits considerable variation in its properties. The modulus of elasticity is one property subject to a large degree of variation. Therefore, while a value of 3500 psi was initially used, a value of 1000 psi was also used to confirm the validity of the results. Conservative values were used for the coefficients of friction (0.8 for rubber-to-concrete and 0.6 for rubber-to-rubber). The actual value of the rubber-to-concrete coefficient is higher since the value used does not take into account the serrated edges provided by fins 32 or the lubricant/adhesive applied to the seal prior to installation. A conservatively high value for the coefficient of thermal expansion was used to analyze the effect of temperature change on the seal performance, but temperature effects proved to be negligible. 
     The analysis recognized the four primary loadings to which the seal is subject, namely those resulting from installation (lateral compression), water pressure, temperature, and differential vertical displacement due to settlement of the concrete slabs. These four loadings occur in sequence in the field and were addressed in that manner in the analysis. 
     The installation load, in which the seal is compressed into place in the seal-receiving recess between the slabs, was represented as equal opposed displacements on both sides of the seal. The water pressure load is a uniform pressure load pushing out on the exterior surfaces of the seal. The temperature load, represented by a uniform cooling from 60° C. in direct sunlight during the warmest part of the year to 10° C. during the coolest part of the year, was found to have a negligible effect. The differential vertical load was represented by a 1-inch (2.5-cm) displacement of one side of the seal relative to the other. The analyses were static, non-linear structural analyses where the applied displacement, temperature, and pressure loadings were considered with no time-dependent effects. No unloading effects were considered, but rather all loadings that were applied remained in effect. 
     The material was modeled with a linear stress-strain curve, and so no plastic effects were considered. However, geometric non-linearities were considered due to the magnitudes of the applied vertical displacements. These displacements are large enough compared to the dimensions of the structure that the stiffness of the distorted structure is no longer described by its original geometry, and must be successively redefined based on the distorted geometry. 
     The contact between core 22 and outer seal 20 and between the outer seal and the concrete recess were modeled with gap elements, which are structural, compression-only axial elements. Gap elements provide resistance to compression, but no tensile stiffness, and have a sliding capability in that while in contact, they slide if the tangential force exceeds the product of the coefficient of friction and the normal force. 
     The consideration of large displacements and the inclusion of gap elements in the model make the analysis non-linear. The non-zero coefficients of friction make the analysis non-conservative (path-dependent); that is, the results make be affected by the sequence and incremental magnitudes of the loadings. The ANSYS program solves non-linear problems as a series of linear problems where the loads are applied in incremental load steps. Each load step is solved in a series of iterations until a convergent solution is obtained. Convergence is defined as occurring when the displacements and gap statuses (in contact, sliding contact, or open) change by less than specified amounts between successive iterations. The non-conservative nature of the process was handled by applying the load steps in the order they occur in the field. 
     FIG. 5A shows the deformed geometry plot of the preferred embodiment under the action of the installation and water pressure loads. FIG. 5B shows the deformed geometry plot of the preferred embodiment after the differential vertical displacement loading has been applied. Despite the large degree of deformation (the vertical displacement is 50% of the seal dimension), the vertical sides of the core and outer seal are deformed surprisingly little and remain vertical to maintain effective sealing. The maximum stress is about 900 psi, which is well within the elastic range and much less than the ultimate tensile strength of about 3500 psi. A comparison of the computer-generated plots of FIGS. 5A-B with the actual deformations shown in FIGS. 4A-B shows good correspondence, thereby justifying confidence in the computer model. 
     Alternative Embodiments 
     FIGS. 6 and 7 are cross-sectional views illustrating alternative embodiments. Primed and double-primed reference numerals denote elements corresponding to those in FIGS. 2A-B. The embodiment of FIG. 6 is somewhat larger, 2.5 inches (6.35 cm) on a side, and differs further from the preferred embodiment in that the core bottom is straight rather than formed with a medial fold and that the major webs in the core come together at a single point rather than at a pair of points spaced apart by a central web. The embodiment of FIG. 7 differs in that the internal webs within the core are curved rather than flat as in the other embodiments. 
     FIGS. 8A-B and 9A-B are the deformed geometry plots for the alternative embodiments. The fundamental difference in response between these embodiments and the preferred embodiment occurs in the differential displacement loading, where the alternative embodiments exhibit a greater degree of deformation. In particular, it is noted that the lower corner of the core pulls significantly away from the wall, thereby allowing the outer seal to pull away so that leakage could possibly occur. 
     Approximately 1200 meters of the seal embodiment shown in FIG. 6 was installed in a section of canal, and performed correctly. The smaller embodiment of FIGS. 2A-B was developed for areas of lesser slab thickness. Since the smaller seal appears superior on the basis of the computer modeling, and uses less material, it is considered the preferred embodiment regardless of slab thickness. 
     Conclusion 
     In conclusion, it can be seen that the present invention provides a concrete joint seal that is simple to install and maintain and highly effective in preventing leakage under a wide variety of conditions. 
     While the above is a complete description of the preferred embodiments of the invention, alternate constructions, modifications, and equivalents can be employed. For example, the core, rather than being installed as completely separate sections, could be formed in one section, but having a number of gaps in the top to allow water in. Additionally, while the core and outer seal are normally formed of the same material, thereby avoiding any possible incompatibility, there may be some benefits to having one of the elements harder than or otherwise different from the other. Therefore, the above description and illustrations should not be taken as limiting the scope of the invention which is defined by the appended claims. 
     
                       TABLE 1______________________________________SUMMARY OF TEST RESULTS   VerticalHorizontal   Displacement              Test   TestSpacing of   of Side    Pres-  Pres-Concrete   Concrete   sure,  sure,Joint, in.   Wall, in.  psi    min.  Remarks______________________________________17/8    0          9      15    No leaks17/8    1/8        9      15    No leaks17/8    1/4        9      15    No leaks17/8    3/8        9      15    No leaks17/8    1/2        9      15    No leaks13/4    0          9      15    No leaks13/4    1/8        9      15    No leaks13/4    1/4        9      15    No leaks13/4    3/8        9      15    No leaks13/4    1/2        9      15    No leaks15/8    0          9      15    No leaks15/8    1/8        9      15    No leaks15/8    1/4        9      15    No leaks15/8    3/8        9      15    No leaks15/8    1/2        9      15    No leaks17/8    0          9      15    After 3 mins. a                           single teardrop ex-                           uded past the rubber                           joint seal. There                           were no other leaks.2       0          9      15    There was slight                           dripping/weeping at                           three locations along                           the rubber joint                           seal.2       1/8        9      15    Dripping stopped at                           one location; contin-                           ued at other two lo-                           cations.2       3/8        9      15    After 10 mins. the                           dripping stopped                           completely.2       1/2        9      15    No leaks21/8    0          --     --    Water leaked past the                           rubber joint seal on                           the right sidewall.                           A constant test pres-                           sure could not be                           sustained.17/8    0          35     --    The rubber joint seal                           was loaded to fail-                           ure. Water leaked                           past the seal at                           35 psi.______________________________________