Expansion joint construction system

Abstract

The present invention relates generally to an improved expansion joint construction and a method for creating an expansion joint between adjacent roadway slabs. The invention relates specifically to the use of an epoxy blend having improved set times that can be applied in cold weather.

1 . A method for creating an expansion joint between adjacent structures having an expansion gap there between comprising the steps of:
 a) preparing at least one recess along an edge of at least one of said adjacent structures;   b) installing at least one form to define at least one nosing area; and   c) installing a mortar into said at least one nosing area, wherein said mortar is an epoxy-urethane blend that cures in less than two hours.   
     
     
         2 . The method of  claim 1  further comprising the step of installing a seal spanning said expansion gap. 
     
     
         3 . The method of  claim 2  wherein said seal is selected from a group consisting of compression seals, pre-compressed foams, closed cell foam seals, pre-formed silicone profile seals, liquid applied joint sealants, liquid applied seals, and pressurized compression seals. 
     
     
         4 . The method of  claim 2  wherein the step of installing a seal further comprises the step of removing said at least one form. 
     
     
         5 . The method of  claim 2  wherein the step of installing a seal further comprises the steps of inserting a backing; and applying a seal on top of said backing. 
     
     
         6 . The method of  claim 1  further comprising the step of cutting said at least one recess into at least one of said adjacent structures. 
     
     
         7 . The method of  claim 1  wherein the step of installing a mortar further comprises the steps of:
 a) combining said mortar with at least one aggregate to create a mortar mixture; and   b) pouring said mortar mixture into said at least one nosing area.   
     
     
         8 . The method of  claim 7  wherein said aggregate is stone. 
     
     
         9 . The method of  claim 7  wherein said aggregate is sand. 
     
     
         10 . The method of  claim 7  wherein said aggregate is a combination of sand and stone. 
     
     
         11 . The method of  claim 1  wherein said mortar has a tensile strength of approximately 1500 pounds per square inch when cured. 
     
     
         12 . The method of  claim 1  wherein said mortar has a compressive strength of approximately 3500 pounds per square inch when cured. 
     
     
         13 . The method of  claim 1  wherein said mortar has elongation properties in the range of approximately 30 to 40 percent when cured. 
     
     
         14 . The method of  claim 1  wherein said mortar has a Shore D hardness in the range of approximately 60 to 70 when cured. 
     
     
         15 . The method of  claim 1  wherein said mortar is Silspec 1000. 
     
     
         16 . The method of  claim 1  wherein said mortar may be applied in temperatures below 70 degrees Fahrenheit. 
     
     
         17 . The method of  claim 1  wherein said mortar may be applied in temperatures below 40 degrees Fahrenheit. 
     
     
         18 . The method of  claim 1  wherein said mortar may be applied in temperatures below 20 degrees Fahrenheit. 
     
     
         19 . The method of  claim 1  wherein said mortar may be applied in temperatures between 70 degrees Fahrenheit and 0 degrees Fahrenheit. 
     
     
         20 . A method for creating an expansion joint between adjacent structures having an expansion gap there between comprising the steps of:
 a) preparing a first recess along an edge of a first structure of said adjacent structures;   b) preparing a second recess along an edge of a second structure of said adjacent structures, wherein said first recess is adjacent to said second recess and said expansion gap is there between;   c) installing at least one form to define at least two adjacent nosing areas at said first recess and said second recess; and   d) installing a mortar into each of said at least two adjacent nosing areas, wherein said mortar is an epoxy-urethane blend that cures in less than two hours.   
     
     
         21 . The method of  claim 20  further comprising the step of installing a seal spanning said expansion gap. 
     
     
         22 . The method of  claim 21  wherein said seal is selected from a group consisting of compression seals, pre-compressed foams, closed cell foam seals, pre-formed silicone profile seals, liquid applied joint sealants, liquid applied seals, and pressurized compression seals. 
     
     
         23 . The method of  claim 21  wherein the step of installing a seal further comprises the step of removing said at least one form. 
     
     
         24 . The method of  claim 21  wherein the step of installing a seal further comprises the steps of inserting a backing; and applying a seal on top of said backing. 
     
     
         25 . The method of  claim 20  further comprising the step of cutting said first recess into said first structure. 
     
     
         26 . The method of  claim 25  further comprising the step of cutting said second recess into said second structure. 
     
     
         27 . The method of  claim 20  wherein the step of installing a mortar further comprises the steps of:
 a) combining said mortar with at least one aggregate to create a mortar mixture; and   b) pouring said mortar mixture into said nosing areas.   
     
     
         28 . The method of  claim 27  wherein said aggregate is stone. 
     
     
         29 . The method of  claim 27  wherein said aggregate is sand. 
     
     
         30 . The method of  claim 27  wherein said aggregate is a combination of sand and stone. 
     
     
         31 . The method of  claim 20  wherein said mortar has a tensile strength of approximately 1500 pounds per square inch when cured. 
     
     
         32 . The method of  claim 20  wherein said mortar has a compressive strength of approximately 3500 pounds per square inch when cured. 
     
     
         33 . The method of  claim 20  wherein said mortar has elongation properties in the range of approximately 30 to 40 percent when cured. 
     
     
         34 . The method of  claim 20  wherein said mortar has a Shore D hardness in the range of approximately 60 to 70 when cured. 
     
     
         35 . The method of  claim 20  wherein said mortar is Silspec 1000. 
     
     
         36 . The method of  claim 20  wherein said mortar may be applied in temperatures below 70 degrees Fahrenheit. 
     
     
         37 . The method of  claim 20  wherein said mortar may be applied in temperatures below 40 degrees Fahrenheit. 
     
     
         38 . The method of  claim 20  wherein said mortar may be applied in temperatures below 20 degrees Fahrenheit. 
     
     
         39 . The method of  claim 20  wherein said mortar may be applied in temperatures between 70 degrees Fahrenheit and 0 degrees Fahrenheit.