# US 2014/0154008 A1 · Expansion joint and methods of preparing same

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- Number: US 2014/0154008 A1
- Document ID: US20140154008A1
- Status: Published application
- Kind: A1
- Application number: 13/691,079
- Filed: 2012-11-30
- Published: 2014-06-05
- Earliest claimed: 2012-11-30
- Assignees: Dynamic Surface Applications, Ltd.
- Applicants: Dynamic Surface Applications, Ltd.
- Inventors: Michael F. Stachowicz; Richard P. Lee
- Web page: https://patentgrep.com/patent/US20140154008A1

## CPC

- E01C 11/02: Arrangement or construction of joints {(for pavings consisting of prefabricated units E01C5/00)}; Methods of making joints {(machines therefor E01C23/02, E01C23/09; removable joint shutterings E01C23/021)}; Packing for joints (sealing joints not restricted to road or airfield paving E04B1/68)
- E01D 19/06: Arrangement, construction or bridging of expansion joints ({E01D19/005 takes precedence; in movable bridges E01D15/005 - E01D15/10}; sealing joints not restricted to expansion joints for bridges E04B1/68)
- E01C: CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR (forming roads or like surfaces by compacting or grading snow or ice E01H)
- E01D: CONSTRUCTION OF BRIDGES, {ELEVATED ROADWAYS} OR VIADUCTS; ASSEMBLY OF BRIDGES (bridges extending between terminal buildings and aircraft for embarking or disembarking passengers B64F1/305; {tracks for special kinds of railways E01B25/00; culverts E01F5/005})

## Abstract

An expansion joint formed within a channel between two adjacent road surfaces and a method of preparing an expansion joint. The joint is formed within a channel having sides each extending from an adjacent road surface to a bottom side of the channel. The joint construction may include at least one layer of a binder covering at least a portion of the sides of the channel, and one or more layers of aggregate chips and the binder covering the at least one binder layer so as to fill the channel to at least the top of the road surface. The cumulative surface area of the two channel sides may be greater than the cumulative surface area of two channel sides each planar and perpendicular to the bottom. The joint construction may include a plate on the bottom side of the channel. The joint construction may include a flexible sheeting between the plate and the at least one binder layer.

## Claims

### Claim 1

A method for preparing an expansion joint within a channel between two adjacent road surfaces, with a gap at the channel bottom, the method comprising: preparing the channel with two non-parallel sides, each side extending from an adjacent road surface to a bottom side of the channel at an angle of 100 to 170 degrees from the channel bottom;
placing a backer rod within the gap;
filling at least a portion of the gap with a binder;
placing a plate over the gap;
positioning flexible material over the plate and extending beyond the plate in each direction, wherein opposing ends of the flexible material contact the channel bottom;
covering the flexible material, the channel bottom and at least a portion of the sides of the channel with at least one layer of aggregate chips and a binder so as to fill the channel to at least the top of the road surface;
wherein the flexible material is comprised of a heat resistant and pliable plastic.

### Claim 2 (depends on 1)

The method of claim 1 further comprising compacting the one or more layers of aggregate chips and binder.

### Claim 3 (depends on 1)

The method of claim 1 wherein the two non-parallel sides join to the bottom of the channel at an angle of 120 to 150 degrees.

### Claim 4

(canceled)

### Claim 5 (depends on 1)

The method of claim 1 wherein the flexible material is neoprene.

### Claim 6 (depends on 1)

The method of claim 1 further comprising placing a top coating over the uppermost layer of aggregate chips and binder.

### Claim 7 (depends on 6)

A method of claim 6 wherein the top coating extends laterally beyond the uppermost layer of aggregate chips and binder and onto each of the two adjacent road surfaces.

### Claim 8 (depends on 1)

The method of claim 1 wherein the aggregate chips have a size such that at least 90% by weight of the chips pass through a ⅞″ sieve.

### Claim 9 (depends on 1)

The method of claim 1 wherein the binder is an asphalt based elastomeric material that contains thermal plastic polymers.

### Claim 10 (depends on 1)

The method of claim 1 further comprising adding additional binder to one or more of the at least one layers of aggregate chips and binder after placing of the layer into the channel, but prior to adding any additional layer of aggregate chips and binder.

### Claim 11 (depends on 1)

The method of claim 1 further comprising adding an anti-skid material over the top of a filled expansion joint.

### Claim 12

A bridge joint comprising:
a channel having two non-parallel sides formed by bridge material and joined to the bottom of the channel at an obtuse angle;
a gap at the bottom of the channel;
a backer rod within the gap;
a plate extending over the backer rod;
a flexible sheeting extending over the plate and beyond the plate in each direction, wherein opposing ends of the flexible sheeting contacts the channel bottom;
at least one binder layer covering the plate, the bottom and at least a portion of the sides of the channel; and
one or more layers containing aggregate chips and binder covering the at least one binder layer.

### Claim 13

(canceled)

### Claim 14 (depends on 12)

The bridge joint of claim 12 wherein the two sides join to the bottom at an angle of 110-150 degrees.

### Claim 15 (depends on 12)

The bridge joint of claim 12 wherein the flexible sheeting is comprised of a heat resistant and pliable plastic.

### Claim 16 (depends on 12)

The bridge joint of claim 12 further comprising a top coating covering the uppermost layer of aggregate chips and binder.

### Claim 17 (depends on 12)

The bridge joint of claim 12 wherein the channel is at least 20 inches wide and at least 2 inches deep.

### Claim 18 (depends on 12)

The bridge joint of claim 12 wherein the plate is comprised of aluminum, galvanized steel, stainless steel, or zinc oxide coated steel.

### Claim 19 (depends on 12)

The bridge joint of claim 12 wherein the plate contains at least one locating pin positioned through the plate and into the backer rod.

### Claim at position 20

20-34. (canceled)

### Claim 35 (depends on 1)

The method of claim 1 wherein the binder below the plate and the binder above the plate is the same material.

### Claim 36 (depends on 12)

The bridge joint of claim 12 wherein the flexible sheeting is positioned to allow lateral movement of the plate relative to the at least one layer of aggregate chips and binder.

### Claim 37

A bridge joint comprising:
a channel having two non-parallel sides formed by bridge material and joined to the bottom of the channel at an obtuse angle;
a gap at the bottom of the channel;
a backer rod within the gap;
a plate extending over the backer rod;
a locating pin positioned through the plate and into the backer rod;
at least one binder layer covering the plate, the channel bottom and at least a portion of the sides of the channel; and
one or more layers containing a binder and aggregate chips covering the at least one binder layer.

### Claim 38

A bridge joint comprising:
a channel having two non-parallel sides formed by bridge material and joined to the bottom of the channel at an obtuse angle;
a gap at the bottom of the channel;
a backer rod within the gap;
a binder filling at least a portion of the gap above the backer rod;
a plate extending over the backer rod;
a flexible sheeting extending over the plate and beyond the plate in each direction, wherein opposing ends of the flexible sheeting contacts the channel bottom; and
one or more layers containing a binder and aggregate chips covering the flexible sheeting, the channel bottom and at least a portion of the two non-parallel sides of the channel;
wherein the binder below the plate and the binder above the plate is the same material.