E L I F O R P Y N A P M O C
OCEAN
RUBBER ® is
the leading and the biggest manufacturer and supplier of Elastomeric Engineering products and services in the Middle East & Africa region, with products being exported worldwide. The factory is ISO 9001:2008 accredited, with a dedicated quality assurance and quality control department monitoring all processes starting from raw material approval, manufacturing and testing of the finished products. With almost a quarter century of experience, our products and services are well known for their quality and durability. Being an exclusive en gineering products designer and manufacturer, we have products for many industrial sectors like the Construction, Marine as well as Oil & Gas. One of our most accepted products for the construction industry is the PIONEER bearing pads and Expansion joints series. Backed up by an equipped testing laboratory and equipment, our products can be rd inspected and certified by 3 party inspection agencies like Germanischer Lloyds, ABS, Velosi, SGS etc .
PIONEER BRIDGE SOLUTIONS
PIONEER BEARING PADS INTRODUCTION Bridge decks supported by piers are susceptible to damage due to vehicle movement and expansion due to heat. The function of Elastomeric Bearing Pads is to provide a connection to control the interactions of loading and movements between parts of a structure, usually between superstructure & substructure. Bearing pads provide a uniform transfer of load from beam to substructure. Bearing pads are used extensively in bridge structure; Prestressed & Pre-cast concrete buildings. Pioneer Bearing pads are manufactured from premium quality Natural Rubber or Neoprene. All the bearing pads are manufactured in compliance to standards like AASHTO, BS 5400, EN-1337, DIN 4141 etc hardness ranging from 50 Shore ‘A’ to 70 Shore ‘A’. Specially designed bearing pads for non-standard application can also be provided including testing and certification. BEARING FUNCTION Support vertical loads • Accommodate girder rotation • Permit lateral movements due to temperature change, traffic movements, wind, • shrinkage & creep, foundation movement, seismic actions, dynamic forces & resulting vibrations. Transmitting load to substructure foundations. •
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PIONEER BRIDGE SOLUTIONS
DESIGN Bearing pads are designed as per AASHTO LRFD Bridge Design Specifications-2007. The design rule is based on the assumption that Rubber is a viscoelastic material, the deflection of which under compressive load is influenced by its shape. Reinforcing plates in the bearing are chemically bonded to the elastomer to prevent any relative movement. Designing of the bearing pads results in achieving the sizes which would be stable under the specified loads, translation, and rotations about the given axis
TYPICAL MATERIAL SPECIFICATIONS Elastomer Used: I. PHYSICAL PROPERTIES
S.N
DESCRIPTION
TEST METHOD
UNIT
SPECIFICATION
1
Hardness
ISO 7619
Shore A
60±5
2
Specific Gravity
ISO 2781
-
1.33±0.05
3
Tensile Strength, Min.
ISO 37
MPa
15.5
4
Elongation at break, Min.
ISO 37
%
350
5
Compression Set, Max. (22hrs @ 100 0C
ISO 815
%
35
6
Accelerated Ageing Resistance (70 hrs @ 100 0C)
6.1
Change in Hardness
ISO 7619
Shore A
+15
6.2
Change in tensile strength, Max.
ISO 37
%
-15
6.3
Change in Elongation at break, Max.
ISO 37
%
-40
II. GENERAL PROPERTIES
1
Resistance to Water
Good
2
Resistance to Acids
Good
3
Resistance to Alkalis
Good
4
Resistance to Weathering
Excellent
Inner Reinforcing Plates The inner reinforcing steel plates shall be of steel grade ASTM A36 or steel of minimum equivalent elongation at break. The minimum thickness of the plates used shall be 2mm
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PIONEER BRIDGE SOLUTIONS
LAMINATED ELASTOMERIC BEARING PADS (STEEL REINFORCED)
Laminated elastomeric bearing pads can accommodate movement in any direction and rotational movement about any axis by elastic deformation. Usually used where bridges are susceptible to high loading, high translation & rotations. Alternate layers of Steel & Rubber are vulcanised together to attain the desired load bearing capacity. Laminated bearing can be either rectangular or circular as per the requirement at the abutments
Bearing pads can also be reinforced with Cotton duck fabric which is commonly known as cotton duck pads (CDP). CDP are known to be quite stiff and to have large compressive load capacity. Because of this great stiffness, the rotational capacity and translational movements of CDP has been severely limited. The below sizes are nominated as per the AASHTO Standards and calculations:
SN
Length (mm)
Breadth (mm)
Thickness (mm)
Maximum Load (kN)
Maximum Movement (mm)
Maximum Rotation (rad)
1
150
150
15
240
6
0.001
2
200
150
20
320
8
0.001
3
250
250
25
650
9
0.001
4
400
250
30
1050
10
0.001
5
400
300
42
1250
13
0.001
6
400
250
52
1050
18
0.0015
7
400
300
63
1250
21
0.002
8
450
400
129
1850
45
0.004
10
400
500
164
2100
60
0.005
11
400
500
182
2100
70
0.007
12
400
500
200
2100
75
0.008
13
600
400
236
2450
90
0.001
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PIONEER BRIDGE SOLUTIONS
PLAIN ELASTOMERIC BEARING PADS
Plain elastomeric bearing pads are solid blocks of rubber without any steel reinforcement plates. They are not generally used in bridges. They are predominantly used where there is low pressure or loads and static conditions. Plain elastomeric bearing pads are simple, low-cost rubber separation strip capable of carrying compressive loads, and providing limited translational movement and rotational capacity. They have a varied application in prefabricated structures.
The below sizes are nominated as per the AASHTO Standards and calculations:
SN
Length (mm)
Breadth (mm)
Thickness (mm)
Maximum Load (kN)
Horizontal Movement (mm)
Maximum Rotation (rad)
1
150
150
10
120
4
0.0006
2
200
150
10
160
4
0.0006
3
200
200
10
210
4
0.0006
4
150
150
15
120
7
0.0007
5
200
150
15
160
7
0.0007
6
200
200
15
210
7
0.0007
7
150
150
20
120
9
0.0009
8
200
150
20
160
9
0.0009
9
200
200
20
210
9
0.0009
10
1000
150
15
800
4
0.0001
11
1000
200
20
1000
7
0.0001
12
1000
200
25
1300
9
0.0001
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PIONEER BRIDGE SOLUTIONS
SPECIAL TYPES OF BEARING PADS POT BEARINGS Pot bearings are special type of bearing
pads for taking larger loads, translation & rotation in smaller confined area. Pot bearings are often regarded as suitable for use when bridge bearing rotations are large. Rotation may occur about any axis and is accommodated by deformation of the elastomeric pad. Pot bearings are fixed against all translations unless they are used with a PTFE sliding surface. . The pad
is
deformable
but
almost
incompressible and the pot bearing has large reserve capacity against vertical loads. Pot bearings are divided in to three types: 1. Fixed pot bearing Constrains longitudinal and transversal movements • Bears longitudinal and transversal horizontal loads • 2. Free sliding pot bearing Allows longitudinal and transversal movements • Bears longitudinal and transversal horizontal loads • 3. Guided pot bearings Allows longitudinal movements • Constrains transversal movements • Bears horizontal transversal loads • The basic elements of a pot bearing are 1. 2. 3. 4. 5. 6. 7. 8.
Shallow cylinder or pot Elastomeric pad 4 Set of sealing rings Piston PTFE Sliding surface Stainless steel mating surface Sliding plate 1 Anchors
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3 2
PIONEER BRIDGE SOLUTIONS
When compared to normal Elastomeric Bearing pads, it has following advantages: Takes larger loads where space is a constraint as compared to that of Elastomeric • bearing pads It can sustain larger cycles of rotation and movements. • Maintenance is economical as the replacement is effected only for the rubber disc • Long term serviceability • Effect of atmospheric correction is minimal • GUIDED TYPE ELASTOMERIC BEARING PADS
These types of special purpose bearing pad consists of a top and bottom load plates with a guide to restrict the movement to the required direction. The top and bottom load plates are hot vulcanised to the rubber. Anchor rods are also provided in the load plates for anchoring to the bridges as per the BS Standards. The rubber pads could be either plane or reinforced as per the load conditions prevailing. SLIDING TYPE BEARING PADS (FRICTIONLESS BEARING PADS)
Sliding type bearing pads are provided where there is a requirement of higher translation with respect to available area in the abutment, especially in large malls or airports where spans are very wide and the relative translations are more. PTFE sheets with Mirror finished stainless steel plates are used for obtaining the desired result of higher translations. PTFE is either chemically bonded or fixed using adhesives to the top portion of the bearing pads. Bearing pads are either plain or reinforced with respect to the loads defined. STANDARDS & SPECIFICATION AASHTO LRFD Bridge Design Specifications • AASHTO M251 (Standard Specification for Bridge Bearing Materials) • BS5400 • EN1337 •
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PIONEER BRIDGE SOLUTIONS
INSTALLATION PROCEDURE
ELASTOMERIC BEARING PADS (PLAIN & LAMINATED)
STEP 1: CLEAN THE SURFACE
STEP 2: CAST THE MORTAR TO LEVEL THE SURFACE & APPLY THE EPOXY RESIN
STEP 3: LOCATE THE BEARING PAD APPLY ANOTHER LAYER OF EPOXY RESIN
STEP 4: PLACE THE UPPER BEAM
ELASTOMERIC BEARING PADS WITH ANCHOR BARS (PLAIN & LAMINATED)
STEP 1: PREPARE THE CONCRETE SURFACES WITH HOLE & CLEAN WITH COMPRESSED AIR
STEP 3: LOCATE THE UPPER BEAM SUPPORTED BY HYDRAULLIC JACKS AT REQUIREED HEIGHT
STEP 2: LOCATE THE BEARING PAD IN THE SPACE PROVIDED & FILL IT WITH RESIN
STEP 4: FILL THE CAVITY WITH RESIN REMOVE THE JACK AFTER CURING OF RESIN
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PIONEER BRIDGE SOLUTIONS
PIONEER EXPANSION JOINTS Pioneer bridge solution offers a variety of expansion joints to suit wide range of movements and gap between the bridge decks. The complex rubber- metal composite structure of the Pioneer expansion joints facilitates to accommodate the displacement and rotation of the concrete structures relative to each other in all directions.
ADVANTAGES
Long service life Corrosion resistance Water proof Low noise Easy installation MATERIAL
The materials used for the Pioneer Bridge Expansion Joints are completely in compliance with the relevant bridge standards like AASHTO/BS/DIN/EN. Pio neer bridge expansion joints are manufactured from virgin polychloroprene based elastomer. The specially formulated rubber compound helps to meet stringent requirements such as abrasion resistance, extreme weather conditions, and longer service life.
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PIONEER BRIDGE SOLUTIONS
DESCRIPTION
UNIT
TEST METHOD
Hardness, max
Shore ‘A’
Specify gravity
----
Tensile strength
Kg/cm
BS 903 Part A2 ASTM D 412 / DIN 53504
1.55
Elongation at break, Min
%
BS 903 Part A2 ASTM D 412 / DIN 53504
450
Tear strength Min
KN/m
BS 903 A3 / ASTM D624
50
Resistance to Ozone 25 pphm, 48hrs, 40°C, 5% strain
—
ASTMD 1149 B
No cracks
Compression set, max (24hrs. at 70°C, 25% strain)
%
ASTMD 395 BS 903 Part A6
30
ASTM D429 B
>12 N per mm
BS 903 Part A26 ASTMD 2240 / DIN 5350 BS 903 Part A1
2
Bonding of rubber to steel
SPECIFICATION 60 = 5 1.15-1.35
AFTER AGEING PROPERTIES (22 HRS.AT 70°C Change in hardness, max
Shore ‘A’
BS 903 Part A 26 ASTM D 2240 / DIN 53505
+5
Change in tensile strength, max
%
BS 903 Part A2 ASTM D 412/ DIN 53504
-15
Change in elongation at break, max
%
BS 903 Part A2 ASTM D412/ Din 53504
-15
Structural steel elements are fabricated from steel grade ASTM A 36 or equivalent. The fabricated steel plates are blasted to a surface cleanliness of SA2.5 with the surface amplitude of 50-75 microns. KERB UNITS AND EXPANSION JOINTS WITH ARMOUR PLATE
Kerb units can be manufactured with different angles and lengths based on customer requirements to suit the structural alignment of decks. Metal inserts are fabricated in accordance to the required alignments and are vulcanized along with the elastomer.
Expansion joints with armour plates are generally used where heavy traffic flow is found. Armour plates decreases the wear and tear due to vehicle flow. Specially designed aluminum profiles are used as armour plates in bridge expansion joints.
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PIONEER BRIDGE SOLUTIONS
Below table shows the different sizes of expansion joints offered by OCEAN PIONEER BRIDGE SOLUTIONS. PIONEER EXPANSION JOINT (XJ-47 to XJ-85)
PIONEER EXPANSION JOINT (XJ-105 to XJ-235)
Model
Width mm
Total movement mm
Gap btw deck mm
Length per module mm
X mm
Y mm
Z mm
l mm
no. of holes Per side
Fastener size
Torque N-m
PIONEER-XJ-47
240 270 355 430 580 620 650 720 800 850 900
47(±24) 57(±29) 75(±38) 85(±43) 105(±53) 125(±63) 145(±73) 165(±83) 185(±93) 205(±103) 235(±118)
35 46 62 74 94 98 105 110 125 134 145
2000 1830 1830 1830 1830 1830 1830 1830 1830 1830 1830
188 210 280 340 494 524 576 612 698 744 794
334 305 305 305 305 305 305 305 305 305 305
165 152.5 152.5 152.5 152.5 152.5 152.5 152.5 152.5 152.5 152.5
9 9 9 9 9 9 12 12 12 12 12
6 6 6 6 6 6 6 6 6 6 6
M12 M14 M14 M16 M16 M18 M18 M20 M22 M24 M24
45 100 100 175 175 180 180 190 230 275 275
PIONEER-XJ-57 PIONEER-XJ-75 PIONEER-XJ-85 PIONEER-XJ-105 PIONEER-XJ-125 PIONEER-XJ-145 PIONEER-XJ-165 PIONEER-XJ-185 PIONEER-XJ-205 PIONEER-XJ-235
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PIONEER BRIDGE SOLUTIONS
INSTALLATION PROCEDURE
Before installing an expansion joint it is very important to make sure of the bridge movements and to check the asphalt thickness in order to conform that it can be installed correctly. Layout a ground plan for the joint and mark the cut width at both side of the axis . Remove the concrete to obtain the required recess of width and depth for the respective expansion joints In case of aged concrete, prior to installation, the weak, loose, deteriorated or contaminated concrete must be removed and replaced with new one. The joint interface must be dry and clean. It must be completely free from dirt, rust, grease, oil and other contaminants. Prepare block outs to proper dimensions, grade and make sure levels are verified. The gap will be protected with a polystyrene piece. The points are marked and drilled for anchoring and holes are flushed with compressed air. The bolt sizes are as per the table above. Then it is filled with a fast curing pour able epoxy grout before inserting the anchor bolts. Care to be taken to ensure all anchors are set at right angles. Install the pioneer expansion joint units starting at the curb over the sealant. Proceed until reaching the field cut piece. Apply the sealant to the ends of the field cut pieces prior to the final placements. Nuts will be adjusted with appropriate tightening. Bolt hole cavity may be fi lled with the sealant.
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PIONEER BRIDGE SOLUTIONS
QUALITY CONTROL Quality control department in ocean rubber has highly qualified personnel equipped with the most modern testing equipments to ensure the quality at every stages of the production. The function of the quality control starts from the inspection of incoming raw material continues through the various stages of production and sustains till the final finished product moving out of the company. The department is highly dedicated to ensure the product quality to satisfy the customer requirements .
Rubber is compounded in internal mixers; quality is monitored round-the-clock by continuously testing samples for their physical properties and chemical characteristics. Every ingredient is checked and monitored regularly; in-process inspection conducted at various stages of production, performance test and final inspection carried out. The products of Ocean Rubber are certified to meet the most demanding requirements of civil construction, oil & gas, infrastructure, marine and military applications.
Laboratory Testing The exclusive in-house laboratory is equipped with computerized facilities to test the properties of rubber according to ASTM, BS and other international standards. The laboratory plays a crucial role in implementing quality a s well as developing new products. Test Certificates are issued on request.
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