IMPROVED WATERSTOP BARRIER DEVICE

Abstract: A waterstop barrier device (10) providing a continuous liquid tight diaphragm between an existing concrete section (12) and a newly poured concrete section (14). The waterstop barrier device (10) includes a base (16) having a first sidewall (18) and a second sidewall (19). The sidewalls (18, 19) extend downwardly from an upper end of the base (16). The first side wall (18) is secured to the existing concrete section (12) so that the upper end of the base (16) is positioned in generally co-planar relationship with an upper surface of at least one of the concrete sections. The upper end of the base (10) restricts entry of liquid into the joint area (17) between adjacent concrete sections. The waterstop barrier device (10) further includes at least one arm (50) projecting laterally outwardly from the second sidewall (19). The arm (50) is spaced below the upper end of the base (16), and includes at least one waterstop element (56) projecting outwardly from the arm (50) for channeling liquid away from the joint area (17).

Description: IMPROVED WATERSTOP BARRIER DEVICE Technical Field This invention relates to concrete joint sealing devices, and in particular to a waterstop for a containment structure that is retroactively fitted to an existing concrete structure prior to pouring adjacent new concrete to provide a liquid tight barrier that does not allow for passage of fluid through the joint formed between the new and existing concrete structures. While the present invention is directed generally to waterstops used in containment systems, other applications for this invention will be apparent in view of the accompanying disclosure. Use of waterstops to prevent migration of fluids in spaces or joints formed between adjacent concrete slabs in a fluid containment structure is well known in the art. One application in which waterstops are frequently employed is containment systems for hazardous materials. Such containment systems generally include a primary containment structure for holding the material, and a secondary containment structure that is designed to contain the material in the event of a chronic or catastrophic spillage of the material from the primary structure. The secondary containment structure must allow for containment, detection and collection of hazardous material after a spill. Typically, concrete containment structures (often referred to as vaulting or concrete vault systems) are employed as the secondary system since such structures offer desired stability, construction and durability for hazardous waste containment, and allow for easy detection and clean-up of spills. When secondary containment areas are expanded to accommodate larger quantities of materials, it is necessary to provide a liquid tight diaphragm at joints that are formed between the existing concrete structures and the new concrete that is poured adjacent to the existing structure. To prevent liquid from seeping into these new joints, several methods of retrofitting waterstops to the existing structure have been developed. One such method is referred to as the sawcut method, wherein the existing concrete structure is sawcut to form an opening having a width and depth sufficient enough to allow a portion of the waterstop to be secured in the opening by a chemical resistant epoxy gel or non- shrink epoxy grout material. However, the sawcut method is expensive, time consuming, and sometimes impractical because of existing construction obstacles, rebar depth, working conditions or clearances. Therefore, it is desirable to develop a waterstop device that is less labor intensive and structurally intrusive to install to existing concrete when additional concrete structures are added to the containment facility. Another disadvantage of prior art retrofit systems such as the sawcut method is that the waterstops are secured at a location below the upper surface ofthe concrete structures so that spilled liquid actually flows into the joint area to a limited extent before encountering the waterstop. Such a configuration adversely impacts the life of the concrete, causing deterioration and buckling over time. To prevent these adverse conditions and protect the joint areas, a chemically resistant sealant or caulking material generally is applied to the joint areas to restrict fluid flow into the joint. However, most of the sealants have minimal durability and elasticity. The sealants often cannot endure expansion, contraction and other movements of the concrete that result from outside pressures. Improper preparation and handling also may contribute to sealant failure. Thus, it further is desirable to provide a waterstop that acts as a barrier to prevent fluid flow into the joints so as to eliminate the need for sealants or caulking material in the joint areas. The waterstop preferably has an upper or inner surface that is disposed in a coplanar arrangement with respect to the upper or inner surface of either the new or existing concrete structure, or both. Background Art Accordingly, one object of the present invention is to provide an improved waterstop barrier device for mounting on an existing concrete structure that overcomes all ofthe aforementioned limitations ofthe prior art. Another object of this invention is to provide an improved waterstop barrier device that provides a continuous fluid tight diaphragm preventing passage of fluid or the like into concrete joints without using sealant or caulking material. Still another object of this invention is to provide an improved waterstop barrier device that accommodates joint expansion, contraction and other lateral and transverse movements in the concrete. Yet another object of this invention is to provide an improved waterstop device that is easily mounted on an existing concrete structure, and does not detrimentally affect the structural integrity ofthe concrete. These and other objects will become apparent to those skilled in the art in light ofthe following disclosure and accompanying drawings. In accordance with the invention, generally stated, a waterstop barrier device is disclosed for providing a continuous liquid tight diaphragm to protect a joint area formed between an existing concrete section and a newly poured concrete section that is adjacent to the existing concrete section. The waterstop barrier device includes a base having a pair of oppositely facing sidewalls including a first sidewall and a second sidewall. The sidewalls extend between an upper end and a lower end of the base. The first sidewall is secured to the existing concrete section at a desired location so that the upper end ofthe base is positioned in generally co-planar relationship with an upper surface of at least one ofthe concrete sections. The upper end of the base restricts entry of liquid into the joint area between the adjacent concrete sections. The waterstop barrier device further includes at least one arm projecting laterally outwardly from the second sidewall. The arm is spaced below the upper end of the base, and includes at least one waterstop element projecting outwardly from the arm for channeling liquid away from the joint area. Thus, the waterstop forms a continuous seal protecting the joint area from outside foreign matter originating above the adjacent concrete sections. The waterstop also preferably includes a plurality of teeth extending outwardly from the first sidewall. Prior to mounting the waterstop to the existing concrete section, an epoxy gel is applied to the concrete at the desired location for the waterstop. The teeth of the waterstop are embedded in the uncured epoxy gel so that the teeth oppose movement of the waterstop in the joint area. The waterstop also includes at least one inwardly extending recess having at least one opening formed therein and extending through the base. When the waterstop is positioned on the uncured epoxy gel, the epoxy gel is forced through the openings in the recess as the waterstop is pressed into the epoxy gel to assist in securing the waterstop to the existing concrete section. The waterstop barrier device is further secured to the existing concrete section by a fastener that is inserted through openings drilled through the recess of the base and into the existing concrete section. A batten bar preferably is disposed in each recess to further strengthen the waterstop assembly. The batten bar has at least one opening extending therethrough. When the batten bar is positioned in the recess of the base, the openings in the recess and the existing concrete section preferably are drilled at locations corresponding to the openings in the batten bar. In this configuration, the fastener is inserted through the aligned openings in the batten bar and the base prior to being secured to the concrete. Other objects and features will be apparent and in part pointed out hereinafter. Brief Description of Drawings The objects of the invention are achieved as set forth in the illustrative embodiments shown in the drawings which form a part ofthe specification. In the drawings, FIG. 1 is a cross-sectional view of the waterstop barrier device of the present invention, showing the waterstop disposed in a joint area between existing and newly poured concrete sections so that the upper end of the waterstop is co-planar with the upper surface of the newly poured concrete section: FIG. 2 is a cross-sectional view of the waterstop secured to the existing concrete section in the joint area so that the upper end of the waterstop is co- planar with the upper surfaces ofthe adjacent concrete sections; FIG. 3A is a perspective view of one embodiment of a 90 degree change-of-direction waterstop; FIG. 3B is a perspective view of a second embodiment of a 90 degree change-of-direction waterstop; FIG. 3C is a perspective view of a tee-shaped waterstop; FIG. 3D is a perspective view of a cross-shaped waterstop; FIG. 4 is a side elevational view ofthe waterstop base and arm; FIG. 5 is a partially exploded perspective view of a 90 degree change-of- direction waterstop mounted on an existing concrete section; and FIG. 6 is a partially exploded sectional view of a waterstop mounted on an existing concrete section. Corresponding reference characters indicate corresponding parts throughout the several views ofthe drawings. Best Mode for Carrying Out the Invention The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what we presently believe is the best mode of carrying out the invention. Referring now to the drawings, one illustrative embodiment of a waterstop barrier device, as designated by reference numeral 10, is shown in FIGS. 1 and 2 mounted to an existing concrete section 12. The waterstop 10 forms a continuous diaphragm between the existing concrete section and a new concrete section 14 that is disposed adjacent to the existing section 12, thereby protecting a joint area 15 between the existing and newly poured concrete sections 12, 14 from foreign matter originating above the adjacent concrete sections 12, 14. As shown in FIGS. 3A-3D, there are four basic standard shapes for the waterstops 10, namely, 90 degree change-of-direction waterstops (FIGS. 3A and 3B), a tee-shaped waterstop (FIG. 3C), and a cross-shaped waterstop (FIG. 3D). While these four configurations satisfy the requirements for many applications, it will be appreciated by those skilled in the art that additional configurations having unique shapes are available for various applications based the particular design specifications and environment in which the waterstop is installed. As shown in FIG. 4, the waterstop 10 includes a base 16 having a pair of oppositely facing sidewalls, namely, a first sidewall 18 and a second sidewall 19. The first sidewall 18 includes a plurality of teeth 20 protruding outwardly therefrom. As discussed below, the first surface 18 of the base 16 preferably is secured to the existing concrete section 12 at a desired location by a chemically resistant epoxy gel 22 (see FIGS. 1 and 2). The teeth 20 of the first sidewall 18 are imbedded in the epoxy gel 22, and assist in preventing movement of the waterstop 10 in the joint area 17. The base 16 further includes at least one pair of recesses 26 formed in the oppositely facing second sidewall 19. Each recess preferably has at least one opening 27 formed that extends through the base. When the waterstop 10 is pressed against the epoxy gel 22, the epoxy gel 22 is forced through the openings 27 to further assist in securing the waterstop 10 to the existing concrete section 12. The waterstop 10 of the preferred embodiment also includes at least one pair of batten bars 28 that are sized to be disposed inside the recesses 26 as shown in FIGS. 1, 2, 5 and 6. Each batten bar 28 preferably has at least one opening 30 extending therethrough (FIGS. 5 and 6). In the preferred embodiment, the openings 30 in the batten bars 28 are spaced at six inch intervals. When the batten bars 28 are positioned inside the recesses 26, openings 29 are drilled through the base 16 ofthe waterstop 10 into the existing concrete section 12 at locations corresponding to the openings 30 I the batten bars 28 (FIG. 6). The openings 30 in the batten bar 28 are not aligned with the openings 27 formed in the recess 16 that allow for flow of the epoxy gel 22 through the base 16. The batten bars 28 preferably are constructed from an 11 gauge stainless steel material with Vi inch holes 30. After the batten bars 28 are placed in the recesses 26 and the openings 29 are drilled through the base 16 and into the existing concrete section 12, the waterstop 10 is secured to the existing concrete structure 12 by concrete fasteners 34 such as anchor bolts. Each fastener 34 includes a head 36 and a cylindrical rod 38 extending outwardly from the head 36. Each rod 38 is inserted through the aligned openings 30 in the batten bar 28 and drilled opening 29 in the base 16, and then into the drilled opening formed in the existing concrete section 12 so that the head 36 of the fastener 34 is disposed in the recess 26 ofthe base 16 when the waterstop 10 is attached to the concrete 12 (see FIGS. 1 and 2). The sidewalls 18, 19 extend between oppositely facing outer ends 40, 42 of the base 16. The outer ends 40, 42 of the base 16 are of sufficient length / to extend the width of the joint area 15 that is formed when the new concrete structure 14 is poured. One ofthe outer ends 40, 42 ofthe base 16 is adapted to lie in a substantially co-planar relationship with respect to an interior or upper surface 44 of either the existing concrete structure 12, an upper surface 46 ofthe new concrete structure 14 (FIG. 1), or the upper surfaces 44, 46 of both concrete structures 12, 14, respectively (FIG. 2). These configurations allow the outer end 40 or 42 of the waterstop 10 to act as a barrier that obstructs fluid flow into the joint area 15 between the concrete structures 12, 14. Such configurations also eliminate the need for sealants or caulking material to be applied to the joint areas, as required in prior art waterstop assemblies. In one preferred embodiment, the length / of the outer end of the base is approximately 0.5 inches, and the distance w between the outer ends (i.e., the length of the base sidewall) is approximately 5 inches (see FIG. 4). The waterstop 10 also includes an arm 50 that extends a predetermined distance outwardly from the second sidewall 19 of base 16 in an opposite direction to that of the teeth 20. The arm 50 preferably is spaced at an approximately equidistant location between the outer ends 40,42 of the base 16, but can be disposed at a different location to suit the arrangements desired for a particular application. The arm 50 includes a bulb 52 formed at its innermost end so that the bulb 52 is connected to the sidewall 19 of the base 16. The bulb 52 has a substantially cylindrical opening 54 extending therethrough. The arm 50 further includes a plurality of waterstop elements 56 projecting upwardly and downwardly from the arm 50 for channeling liquids away from the base 16 and from the joint area 15 of adjacent concrete structures 12, 14. More specifically, the outer end 40 or 42 obstructs fluid and foreign matter from entering the joint area 15, and the waterstop elements 56 direct any fluid that manages to bypass the outer end away from the joint area 15, so that the waterstop 10 forms a fluid-tight closure between the concrete structures 12, 14. If liquid bypasses the outer end 40 or 42, it travels downwardly along the sidewall 19 of the base 16 until it is halted by the projecting arm 50. The waterstop elements 56 on the projecting arm 50 further disrupt fluid flow by forming a tortuous path that hinders entrance of foreign matter into the joint area 15. Thus, the waterstop 10 forms a continuous diaphragm that obstructs entry of matter into the joint area 15. In the preferred embodiment, the waterstop 10 is made by an extrusion molding process from a thermoplastic elastomeric rubber (TPER) material. TPER is preferred because of its durability, elasticity and non-reactivity, although it will be appreciated that various other types of materials can be used, if desired. Waterstops constructed from TPER material further accommodate expansion, contraction and other lateral and transverse movements that otherwise may cause the concrete joints to open, close or misalign. To attach the waterstop 10 to the existing concrete section 12, the existing concrete section 12 is prepared by grinding away any surface irregularities to ensure a strong bond between the concrete 12 and epoxy 22. The chemical resistant epoxy 22 is applied to the existing concrete section 12 in the area where the waterstop 10 is to be attached. The waterstop 10 then is positioned on the uncured epoxy 22 so that the teeth 20 of the base 16 are embedded in the epoxy 22, and the epoxy is forced through the openings 27 in the base 16. One of the outer ends 40 or 42 of the base 16 is positioned in a substantially co-planar relationship with at least one of either the upper surface 44 ofthe existing concrete structure 12 or the anticipated upper surface 46 ofthe new concrete structure 14 that is not yet poured. The batten bars 28 are positioned in the recesses 26, and openings 29 are drilled in the base 16 and existing concrete section 12 at locations corresponding to the openings 30 in the batten bars 28. The fasteners 34 are inserted through the openings 30 in the batten bars 28, through the aligned drilled openings in the base and into the drilled openings in the existing concrete section. The fasteners 34 are tightened to secure the waterstop 10 to the concrete 12. Preferably, a layer of epoxy (not shown) is applied over the batten bars 28 and fasteners 34 to protect the bars 28 and fasteners 34 from corrosion. Expansion joint filler (not shown) preferably is applied at joint areas where significant differential movement is anticipated to minimize shear stresses. After the waterstop 10 is secured to the existing concrete structure 12 and the epoxy 22 has cured for approximately 24 hours, the new concrete section 14 is poured carefully to avoid displacing the waterstop 10 from its proper position. The concrete 14 around the waterstop 10 is thoroughly and systematically vibrated to obtain impervious, void-free concrete in the vicinity of the joint area 15 and to maximize intimate contact between the concrete sections and the waterstop 10. In view of the above, it will be seen that the several objects and advantages ofthe present invention have been achieved and other advantageous results have been obtained. The foregoing description is set forth only for illustrative purposes only and is not meant to be limiting. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Numerous variations, within the scope of the appended claims will be apparent to those skilled in the art in light ofthe foregoing description and accompanying drawings.

Claims: Claims: 1. A waterstop barrier device providing a continuous liquid tight diaphragm to protect a joint area formed between an existing concrete section and a newly poured concrete section that is adjacent to the existing concrete section, comprising a base having a pair of oppositely facing sidewalls including a first sidewall adapted to be secured to said existing concrete section and a second sidewall, said sidewalls extending between an upper end and a lower end of said base, the upper end of said base being positioned in a generally co-planar relationship with respect to an upper surface of at least one of said concrete sections, and the upper end of said base restricting entry of liquid into the joint area. 2. The waterstop barrier device as set forth in claim 1 and including at least one arm projecting laterally outwardly from the second sidewall, said arm being spaced below the upper end of said base, said arm including at least one waterstop element projecting outwardly from said arm for channeling liquid away from said joint area. 3. The waterstop barrier device as set forth in claim 1 wherein said first sidewall includes a plurality of teeth extending outwardly therefrom to prevent movement of said waterstop when secured to said existing concrete section. 4. The waterstop barrier device as set forth in claim 2 wherein said second sidewall of said base includes at least one recess formed therein. 5. The waterstop barrier device as set forth in claim 4 and including at least one batten bar sized to be received in said recess, said batten bar having at least one opening extending therethrough, said recess having an opening drilled therethrough and said existing concrete section having an opening drilled therein at locations corresponding to each batten bar opening, said waterstop barrier device being secured to said existing concrete section by a fastener that is inserted through each opening in the batten bar and through the corresponding opening in the recess of the base and then into the corresponding opening in the existing concrete section. 6. The waterstop barrier device as set forth in claim 4 wherein said first sidewall of said base is secured to said existing concrete section by an epoxy gel. 7. The waterstop barrier device as set forth in claim 6 wherein said recess includes at least one opening that extends through said base, said epoxy gel being forced through said opening in said recess when said waterstop barrier device is pressed against the uncured epoxy gel to secure said waterstop barrier device to said existing concrete section. 8. A waterstop barrier device for providing a continuous liquid tight diaphragm to protect a joint area formed between an existing concrete section and a newly poured concrete section that is adjacent to the existing concrete section, comprising: a base having a pair of oppositely facing sidewalls including a first sidewall and a second sidewall, said sidewalls extending downwardly from an upper end of said base, the upper end of said base being positioned in generally co-planar relationship with an upper surface of at least one of said concrete sections, the upper end of said base restricting entry of liquid into the joint area between adjacent concrete sections; and at least one arm projecting laterally outwardly from said second sidewall, said arm being spaced below said upper end and including at least one waterstop element projecting outwardly from said arm for channeling liquid away from said joint area; whereby said waterstop forms a continuous seal protecting the joint area from outside foreign matter originating above the adjacent concrete sections. 9. The waterstop barrier device as set forth in claim 8 in which said first sidewall includes a plurality of outwardly extending teeth that oppose movement of said waterstop when secured to said existing concrete section. 10. The waterstop barrier device as set forth in claim 9 in which said second sidewall includes at least one inwardly extending recess, said waterstop barrier device being secured to said existing concrete section by at least one fastener that is inserted through an opening formed in said base and into said existing concrete section. 11. The waterstop barrier device as set forth in claim 10 further including at least one batten bar sized to be received in said recess, said batten bar having at least one opening extending therethrough, said opening in said base being formed at a location corresponding to the opening in the batten bar, said fastener being inserted through the aligned openings in said batten bar and said base prior to being secured to said concrete. 12. The waterstop barrier device as set forth in claim 9 wherein said first sidewall of said waterstop is secured to said existing concrete section by an epoxy gel. 13. The waterstop barrier device as set forth in claim 12 wherein said recess includes at least one opening that extends through said base, said epoxy gel being forced through said opening in said recess when said waterstop barrier device is pressed against the uncured epoxy gel. 14. The waterstop barrier device as set forth in claim 8 in which said waterstop barrier device is integrally molded as a one-piece flexible element. 15. The waterstop barrier device as set forth in claim 14 in which said waterstop barrier device is formed from a movable flexible material that accommodates lateral and transverse movements. 16. The waterstop barrier device as set forth in claim 8 in which said arm includes a plurality of adjacent spaced waterstop elements restricting entry of fluid between the adjacent concrete sections. 17. A waterstop barrier device providing a continuous liquid tight diaphragm to protect a joint area formed between an existing concrete section and a newly poured concrete section that is adjacent to the existing concrete section, comprising: at least one batten bar having at least one opening extending therethrough; a base having a pair of oppositely facing sidewalls including a first sidewall and a second sidewall, said first sidewall being secured to said existing concrete section and having a plurality of teeth extending outwardly therefrom to oppose movement of said waterstop barrier device with respect to said concrete sections, said second sidewall including at least one inwardly extending recess that is sized to accommodate said batten bar, said recess having at least one opening extending through said base at a location corresponding to the opening in said batten bar, said sidewalls extending downwardly from an upper end of said base, said first sidewall being secured to said existing concrete section at a predetermined location so that the upper end of said base is positioned in generally co-planar relationship with an upper surface of at least one of said concrete sections, the upper end of said base restricting entry of liquid into the joint area between adjacent concrete sections; at least one fastening mechanism for securing said base to said existing concrete section, said fastening mechanism being inserted through the opening in said batten bar, through the opening formed in said base, and then secured in said existing concrete section; and at least one arm projecting laterally outwardly from said second sidewall, said arm being spaced below said upper end and including at least one waterstop element projecting outwardly from said arm for channeling liquid away from said joint area; whereby said waterstop forms a continuous seal protecting the joint area from outside foreign matter originating above the adjacent concrete sections.

Inventors: ESTES MICHAEL J, NEW DEAN W, ESTES, MICHAEL, J., NEW, DEAN, W.
Applicants: ESTES MICHAEL J, NEW DEAN W, WESTEC BARRIER TECHNOLOGIES IN, ESTES, MICHAEL, J., NEW, DEAN, W., WESTEC BARRIER TECHNOLOGIES, INC.
Application year: 1999
Main classification: E04B1
IPC codes: E04B1