GB2416797A

GB2416797A - Expansion joint

Info

Publication number: GB2416797A
Application number: GB0417660A
Authority: GB
Inventors: David John Helliwell; Michael David Harper
Original assignee: Stirling Lloyd Polychem Ltd
Current assignee: Stirling Lloyd Polychem Ltd
Priority date: 2004-08-07
Filing date: 2004-08-07
Publication date: 2006-02-08
Also published as: WO2006016131A2; GB0417660D0; US20080034692A1; WO2006016131A3; EP1778920A2

Abstract

The expansion joint, for use in roads, bridges, car parks, buildings etc., is designed to be located between two structural elements and comprises a sealing element 12 and at least one anchor element 13, with the anchor element having a first portion 17 for connecting to the sealing element and a second portion 18 for connecting to one of the structural elements, with the first and second portions of the anchor element being integrally formed. The anchor element is preferably formed from an organic polymer resin which may contain groups derived from an unsaturated organic monomer compound and a reinforcement material. One of the first element of the anchor and the sealing element preferably defines a projection 14 which is received in a slot 15 defined in the other of the elements. The second portion of the anchor is preferably connected to one of the structural elements via mortar cast into the gap defined between the two structural elements, with the mortar preferably being formed from the same material as the anchor element. A skid resistant material, preferably an organic polymer resin, may be provided on the upper exposed surface of the first portion of the anchor element and the mortar. The second portion of the anchor is preferably elongate and tapered with apertures 20 extending through it to enable it to lock with the mortar. Also claimed is a method for forming an expansion joint.

Description

241 6797 AN EXPANSION JC)1NT ASSEMBLY The present invention relates to an

expansion Joint assembly for location in a gap defined betwocn first and second structural members, such as sections of a road, bridge structure, car park or a combination thereof or parts of a building or buildings, and methods for forming such a joint.

Expansion joints are typically disposed between sections of a road or at the end of a bridge structure where it jOiTlS the road and must satisfy a number of requirements. For example, they must be suitably robust to withstand the loads generated by passing vehicles whilst being sufficiently flexible to accommodate changes in the gap width between sections resulting from environmental changes such as variations m temperature.

A particular type of joint defined by the Highways Agency Standard BD33/94 is the Highways Type 6 bridge expansion Joint, which is commonly referred to as an Elastomer in Rail - Resin Encapsulated, (EMR-RE) expansion loins. Current EMR-RE joints arc based on essentially the same design, which is more than 30 years old. An example of an EMR-RE joint is shown in figure 1.

Referring to figure 1, there are four basic components to a conventional EMR-RE joint 1: a pair of extruded steel rails 2; steel reinforcing bars 3 bolted or welded to the rails 2; pitch or bitumen extended hot apphed epoxy resin based mortar 4, which is used to hold the reinforcing bars 3 and thereby the rails in place; and an elastomeric seal 5 disposed between the raids 2. l ypical]y the rails 2 are laid down; one to each side of an expansion gap 6, With the reinforcing bars 3 extending away from the centre of the gap 6. Uncured mortar 4 is then poured into cavities defined between the outer surface 7 of each rail 2 and a surface 8 of the road or bridge sections 9 between which the jowt I is to he fonned. Once the mortar 4 has fully cured tle elastomeric seal 5 is interposed between the inner surfaces 10 of the rails 2 to complete the joint I. An example of such an EMR-REJont is described In GB-A-20(()734.

Although EMR-RE Joints of the kind described above are widely used in the road/hridge construction industry, they suffer from a number of problems. For example, undesirable levels of stress can be induced between components within the joint as a result of employing components made from materials having different physical and chemical properties, such as differing thermal expansion coefficients. Moreover' a joint may lose its structural integrity due to failure of the welds or bolts connecting the reinforcing bars to the rails. Furthermore, corrosion of the rails and/or reinforcing bars due to aging or exposure to water and de-icing salts is known to be a significant factor in Joint failure. Additionally, the exposed upper surface of the mortar 4 can be slippery and produce a risk of vehicles skidding as they pass over the joint 1. The culvert solution to this problem is to cast a skid resistant aggregate into the upper surface of the mortar whilst the mortar 4 IS curing. However, the bond between the skid resistant aggregate and the mortar is typically unsatisfactory and often leads to the loss of skid resistance at an early stage m tile lifetime of the joint 1.

An object of the present invention is to obviate or mitigate the aforementioned problems.

According to a first aspect of the present invention there Is provided an expansion joint assembly for location in a gap defined between first and second structural members, the assembly comprising a sealing member and at least one anchor member, said anchor member having a first portion for connection to the sealing member and a second portion for connechon to one of said structural members, wherein said first and second portions of the anchor member are integrally formed.

By integrally fowling the first and second portions of the anchor member, problems related to the failure of the welds or bolts connecting the reinforcing bars to the rails of a conventional joint are ovei-come.

Preferably the anchor member is fowled From a material comprising an orgamc polymer resin. It is preferred that the resin IS selected from a group consisting of a polyester resin, a vmyl ester resin, a polyurethane resin, an acrylic resin and an epoxy resin.

The resin preferably contains chemical groups derived from an unsaturated organic monomer compound. The resin may contain moieties selected from a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester (e.g. methyln1etllacrylate ester).

The material from which the anchor member is fowled preferably incorporates a suitable reinforcing material, e.g. a reinforcing material selected from a group consisting of glass fibre, glass mat, steel, carbon fibre and polyparapllenylenetereplltllalamide.

In a preferred embodiment of this aspect of the present invention one of the first portion of the anchor member and the sealing member defines a projection configured for receipt in a complementary slot defined in the other member.

A layer of skid resistant material may be provided on an exposed upper surface of the first portion of the anchor member. The skid resistant material may comprise an organic polymer resin, which is preferably selected from a group consisting of a polyester resin, a vinyl ester resin and an acrylic resin. The resin comprised In the skid resistant material preferably contains chemical groups derived from an unsaturated organic monomer compound and more preferably contains moieties selected from a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester (e.g. methylmethacrylate ester). It is preferred that both the skid resistant material and tile material from which the anchor member is formed are organic polymer resins. More preferably both the skid resistant material and tile material from which the anchor member is fonned are tile same organic polymer resin.

Preferably the second portion of the anchor member is adapted to be connected to one of said structural members via mortar cast into the gap defined between the structural Lechers. The mortar is preferably an organic polymer resin and is preferably selected front a group consisting of a polyester r esin, a vinyl ester resin, a polyurethane resin, an acrylic resin and an epoxy r esin.

The resin preferably contains chemical groups derived from an unsaturated organic monomer compound. The resin may contain moieties selected from a group consisting of styrene, vinyl to]uene, acrylic ester and metllacry] ate ester (e.g. metlly]nletllacry]ate ester).

In a preferred embodiment of the first aspect of tile present invention both the material frown which the anchor member is fonned and the mortar are organic polymer resins.

More preferably both the maters] from which the anchor member is formed and the mortar are the same organic polymer resin. Yet more preferably, when a layer of skid resistant inaterial is provided on an exposed upper surface of the first portion of the anchor member, the resins comprised in the anchor member, skid resistant layer and the mortar are organic polymer resins, preferably the same organic polymer resins. Forming the anchor member from a similar material to the mortar (and the skid resistant layer if present) overcomes problems resulting from employing components made fi own rnaterals having different physical and chemical properties, which might otherwise result In joint failure due to Undesirable levels of stress being induced between components within the joint.

A layer of skid resistant material may be provided on an exposed upper surface of the mortar cast into the gap defined between the structural members. The skid resistant natcrial nay comprise an organic polymer resin, which is preferably selected from a group consisting of a polyester resm, a vinyl ester resin and an acrylic resin. The resin comprised in the skid resstailt material preferably contains chemical groups derived from an unsaturated organic monomer compound and more preferably contains moieties selected frown a group consisting of styrene, vinyl toluene, acrylic ester and metllacrylate ester (e.g. mcthylmethacrNylate ester).

It is preferred that both the resin comprised in the skid resistant material and the mortar are organic polymer resins. More preferably both the resin comprised in the skid resistant material and the mortar are the same organic polymer resin.

It is preferred that a]aycr of skid resistant is material provided on both the exposed upper surface of the mortar and the first pal lion of the anchor member. Preferably the layers of skid resistant material prodded on the exposed upper surfaces of the mortar and the first portion of the anchor member comprise the same organic polymer material.

It is preferred that else second portion of the anchor men1ber defines a locking member configured to contact said mortar when said mortar is cast into said gap to loci: said anchor member against said mortar. The locking member is ideally elongate and at least a section of it may be tapered such that its thickness at a position proximal to the first portion is less than that distal from the first portion. Moreover, a surface of the locking member that is adapted to be in contact with the mortar when the mortar is cast into said gap may be provided with surface texturing. Additionally, said locking member may define at least one aperture for receipt of mortar when said mortar is cast into said gap.

The aperture may be in the foam of an elongate slot.

The anchor members may be in the form of elongate rails for location iTI an elongate gap between the structural members.

In a preferred embodiment of the invention the assembly comprises two anchor members, one anchor member having a second portion for collection to the first structural member and the other anchor member having a second portion for connection to the second structural member.

According to a second aspect of the present invention there is provided a method for fondling, an expansion joint between first and second structural members comprising locating an assembly according to the first aspect of the present invcnton in a gap defiecd between said stnctura] members; said locating of the assembly comprising comectiilg the first portion of the anchor member to the sealing member and connecting the second portion of the anchor member to one of the structural members.

PrcLerably the method comprises the step of casting a layer of a skid resistant material on an exposed upper surface of the first portion of the anchor member.

It is preiened that said connects of the second portion of the anchor member to said one of the first and second members comprises casting mortar into said gap such that said mortar contacts the second portion of the anchor member and said one of the first and second members. Preferably a layer of a skid resistant material is cast on an exposed upper surface of the mortar cast into the gap defined between the structural members.

According to a third aspect of the present invention there is provided a method for Donning an expansion joint between first and second structural members comprising ocating an assembly comprised of a sealing member and at least one anchor member having first and second portions in a gap defined between said structural members; said locating of the assembly composing connecting the first portion of the anchor member to the sealing member, placing the anchor member into said gap, and casting mortar into said gap to connect the second portion of the anchor member to one of the structural members, wherein at least a part of at least the second portion of the anchor r?lember chemically bonds to the mortar.

In this way, the connection between the anchor member and the structural member via the Collar IS sig?llficantly stronger and more uniform than that i?1 prior art Joints employing steel rails and reinforcing bars.

The anchor member is preferably fonned from a material comprising an organic polymer resin co?lta?ni?lg crosslinkable moieties. Preferably the crosslinkable moieties are double bonds between adjacent carbon atoms of the polymer resin. The resin may be selected from a group consisting of a polyester resin, a vinyl ester resin and an acrylic resin. The r esin preferably contains chemical groups derived from an unsaturated organic monomer compound. The resin play contain moieties selected from a group consisting of styrcne, vinyl toluene, acrylic ester and methacrylate ester (e.g. methylmethac?ylate ester).

In a prefen ed embodiment of this aspect of the present invention said material incorporates a suitable reinforcing material, e.g. a reinforcing material selected fi-o?ll a group co?lsistng of glass fibre, glass mat, steel, carbon fibre and po Iyparaphenyleneterepl?lllalamidc.

Preferably the mortar composes an organic polymer rcsm containing terminal crosslinkablc moieties and a crosshnking agent. The resin Is preferably selected from a group consisting of a polyester resin, a vmyl ester resin and an acrylic resin. The resin preferably contains chancel groups derived from an unsaturated organic monomer compound. The resin may contain moieties selected front a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester (e.g. methylmethaciylate ester). In a preferred embodiment of the third aspect of the present invention both the material from which the anchor member Is formed and the mortar comprise organic polymer resins containing crosslinkable moieties. More preferably both the material from which the anchor member is formed and the mortar comprise the same organic polymer resh containing crosslinkab]c moieties.

It is preferred that the crosslinthlg agent is an unsaturated organic monomer compound.

The crosslnking agent may be selected frown a group consisting of styrene, vinyl tolucnc, acrylic ester and methacrylate ester (e.g. nethylmethacrylate ester).

Furthermore, the terminal crosslmkable moieties are preferably inethacrylate ester moieties.

In a further preferred embodiment of this aspect of the invention, during casting said mortar into said gap said crosslnking agent in tle mortar reacts with said crosslnkable moieties in the resin of the anchor member and said terminal crosslinkable moieties in the mortar to provide chemical crosslnking between said pan' of the second portion: of the anchor member and the mortar.

In a yet further preferred embodiment of the third aspect of the present invention, the method comprises the additional step of casting a layer of a skid resistant material on an exposed upper surface of at least one of the mortar cast into the gap defined betwocn the structural members and the first portion of the anchor member. It is preferred that the layer of skid resistant material is cast on an exposed surface of both the cast mortar and the first portion of the anchor member. The layer of skid resistant material is preferably chemically bonded to said exposed upper surface of at least one of the mortar cast into the gap defined between the structural members and the first portion of the anchor member.

Preferably the skid resistant material comprises an organic polymer resin contamng terminal crosslinkable moieties and a crosslinking agent. The resin is preferably selected from a group consisting of a polyester resm, a vinyl ester- resin and an acrylic resin. The resin preferably contains chemical groups derived fi-orn an unsaturated organic monomer compound. The resin may contain moieties selected fiom a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester (e.g. methylrllethacrylatc ester). The terminal crosslinkahle moieties are preferably methacrylate ester moieties.

When the layer of skid resistant material is applied to the exposed upper surface of the mortar it is preferred that during casting said layer of skid resistant material the crosslinking agent in the skid resistant material and/or the crosslinking agent in the mortar reacts with the terminal crosslinkable rnoleties in the resin of the skid resistant material and the mortar to provide chemical crosslrnking between the layer of skid resistant material and the mortar. Moreover, when the layer of skid resistant material is applied to the exposed upper surface of the first portion of the anchor member it is preferred float during casting said layer of skid resistant material the crosslmking agent in the shed resistant material reacts with the crosslirable moieties in the resin of the anchor member and the terminal crosslinkable moieties in the resin of the skid resistant material to provide chemical crosslinking between the layer of skid resistant material and tile anchor member.

Preferably said first and second portions of the anchor nembcr are integra]]y formed.

A fourtl1 aspect of the present invention provides an expansion joint assembly for- location in a gap defined between first and second str-uctura] members, the assembly comprising a sealing member and at least one anchor member, said anchor member ]avng a first portion for connecho?1 to the sealing member and a second portion for connection to one of said structura] members, wherein a layer of skid resistant nater-ial is provided on an exposed upper- surface of the first portion of the anchor member.

This aspect of the present invention is based on the reahsation that the exposed upper surface of the anchor member represents a skidding risk in addition to the risk presented by the exposed upper surface of the mortar. In addition to the benefit in overcoming tile risk of skidding, providing a layer of skid resistant material on the surface of the anchor member helps to protect the anchor member from wear and tear over the lifetime of the joint.

The second portion of the anchor member is preferably adapted to be connected to one of said structural members via mortar cast into the gap defined between the structural nembeis. Additionally, a layer of a skid resistant material may be provided on an exposed upper surface of the mortar cast into the gap defined between the structural members. This layer of skid resistant material should help protect the mortar front general wear and tear.

A fifth aspect of the present invention provides a method for fondling an expansion joint between first and second structural members comprising locating an assembly according to the fourth aspect of the present invention in a gap defined between said structural members; said locating of the assembly comprising connecting the first portion of the anchor n1ember to the sealing member, connecting the second portion of the anchor member to one of the structural members and providing a layer of skid resistant material on an exposed upper surface of the first portion of the anchor member.

Preferably the layer of skid resistant material is provided on said exposed upper surface of the first portion of the anchor member by casting.

it is proffered that said connecting of the second portion of the anchor member to said one of the first and second members comprises casting mortar into said gap such that said mortar contacts the second portion of the anchor member and said one of the first and second members. Preferably a layer of a skid resistant material is cast on an exposed upper- surface of the No tar cast into the gap defined between the structural members.

A sixth aspect of the present invention provides a method for forming an expansion Jomt between first and second structural members compnsmg locating an assembly comprised of a sealing member and at least one anchor member having first and second portions in a gap defined between said structural Novembers; said locating of the assembly comprising connecting the first portion of the anchor member to the sealing member, placing the anchor member into said gap, casting mortar into said gap to comlect at least the second portion of the anchor member to one of the structural members and providing a layer of skid resistant material on an exposed upper surface of the mortar cast into said gap, wherein during provision of said layer of skid resistant material, said layer of skid resistant inaterial chemically bonds to the mortar.

The layer of skid resistant material is preferably provided on said exposed upper surface of the inoltar by casting.

Having regard to the fourth, fifth and sixth aspects of the present invention, preferably the skid resistant material comprises an organic polymer resin containing tenumal crosslinkable moieties and a crosslmking agent as hereinbefore described in relation to the third aspect of the present invention. 'lithe mortar preferably comprises an organic polymer resh1 containing terminal crosslinlable moieties and a crosslinking agent as hereinbefore described in relation to the third aspect of tile present invention. It is preferred that the anchor member is Donned from a material comprising an organic polymer resin containing crosslinkable moieties as hereinbefore described in relation to the third aspect of the present invention.

In preferred embodiments of the fourtll, fifth and sixth aspects of the present invention the skid resistant matenal'is chemically bonded to the anchor member and, where applicable, the molter (when a skid resistant layer is provided on the surface of the mortar). 'lithe chemical bonding is preferably provided by the crosslinkng agent in the skid resistant material and/or the crosslinking agent in the No tar chemically reacting with the various crosslinkable moieties In the skid resistant matenal, anchor member and, Where applicable, the mortar in a snnlar way to that described in relation to the third aspect of the present inveJlton. By chemically bonding the layers of'skd resistant material to the anchor member and the mortar the skid resistant material is more resistant to being stripped from the surface of the joint, which Is a common problem with conventional joints, and the skid resistant layer, anchor and mortar foam an effectively homogeneous mass.

In the fourth, fifth and sixth aspect of the present invention said first and second portions of the anchor member are preferably integrally formed.

An embodiment of the present invention wild now be described, by way of example only, with reference to the accompanying drawings m which: Figure 1 is a schematic sectioned side view of a prior art EMR-RE joint; Figure 2 Is a schematic side view of an EMR-RE joint in accordance with an embodiment of the present invention; Figure 3 is a schematic plan view of an anchor member forming part of the EMR-RE joint of figure 2; Figure 4 is a schematic side view of the Thor member of figure 3 connected to a structural member such as a road; and Figure 5 Is a schematic side view of the ancllor- member of.figure 4 with a layer of a skid resistant material.

Figure SilOWS an expansion Jowt assembly 11 in accordance with an embodiment of the present invention which may be located in a gap defined between a pair of neighbounng road sections (not shown) to forth an EMRRE expansionJoint.

The assembly 11 comprises an elongate elastomeric seal 12 interposed between a pair of opposed rails 13 that serve to anchor tle seal in place. The seal 12 is of conventional design and possess a pair of outwardly extending lugs 14 for receipt in complementary grooves 15 defined in an inner surface 16 of each rail 13, thereby fomnrlg a dovetail connection. Eacll rail 13 is of a unitary structure and consists of an inner portion 17 corresponding to the steel rail 2 of tle prior art loins I shone In figuec 1 and an integral outer portion 18 WiliC]1 defines an elongate vedge-s]1apcd locking men1ber l9. The taper of the wedge Is such that the thickness of the locking member 19 u1creascs in the outwards direction. The inner and outer portions]7, 18 of the raid 13 are integrally fonned as a single cast frown a pultruded viny] ester resin composite Incorporating glass fibre to provide r enforcement.

It will be understood by the skilled reader that whilst the rails are shown in the figures to have sharp edges, in practice they arc likely to be rounded to avoid the tendency of cracks to form in the rcsn at those edges and to avoid the entrapment of air in sharp internal angles.

Rectangular slotted apertures 20 are defined in each locking n1ember 19 to accommodate an amount of mortar (not shown) when mortar is cast between the rail 13 and the adjacent road section to increase the strength of the connection between the rail 13 and the road section via the mortar. The apertures are elongate and extend in parallel to the longitudinal axis of the rails.

Figure 3 illustrates a single rail 13 and S]lOWS the inner and outer portions 17, 18, and the apertures 20 descriDcd above in relation to figure 2. Figure 3 also S]lOWS surface texturing 21 which has been applied to the locking n1ember 19 to increase the surface area of the locking member 19 available to contact mortar when mortar is cast between the rail 13 and tile adjacent road section. The tcsturng is an optional feature.

Referring now to figure 4, a single rail 13 is connected to an adjacent asphalt road section 21 laid on a concrete bridge deck 22. The rail 13 Is connected to the road section 2 I via an appropriate amount of v Vinyl ester resin based mortar 23 which Is provided in a space defined between the rear and]oNver surfaces 24, 25 of the rail 13, the road section 21 and the deck 22.

figure 5 shoNvs the same aTangencut as figure 4 but with a layer of skid resistant material 26 cast on to exposed upper surfaces 27, 28 of the mortar 23 and the raid l 3 In order to form a joint between a pair of road sections 21 supported on a concrete bridge deck 22, two rails 13 are located In a gap between the road sections 21. The rails 13 are arranged in a face-to-face relationship as ShONVn in figure 2 but without the sea} 12 m place. Mortar 23 Is then cast into spaces defined between the rear and lower surfaces 24, 25 of each rail 13 and the road section 2 l and deck 22 to whacks that rail 23 Is to be connected. Whilst the mortar 23 Is curing the layer of skid resistant material 26 Is cast on exposed upper surfaces 27, 28 of the mortar 23 and the rail 13. Finally, when the mortar 23 has cured, the seal 12 is interposed between the rails 13 and held In place by insertion of the lugs 14 of the seal 12 into the complementary grooves 15 defined in each rail 13. The wedge shape of the locking member 19, its textured surface and the slotted apertures 20 ensure that it forms an effective key with the rioter 23.

Each rail 13 is fonned fiom a vinyl ester resin dissolved in styrene and processed into a composite which incorporates glass fibre reinforcement. The resin is not fully saturated (i.e. it contains one or more carbon-carbon double bond) and thus contains crosslinkable notes. The mortar 23 and the skid resistant material 26 comprise a vmyl ester resin dissolved in an excess of methylmethacrylate monomer to provide a vinyl ester resin containing terminal methylmetllacrylate groups and unreacted n1ethylmethacrylate monomer as a crosslinking agent.

When the mortar 23 and the skid resistant material 26 are cast, the methyhnethacrylate monomer reacts with the carbon-carbon double bonds in the vinyl ester resin forming the rails 13 and the terminal methacrylate groups in the vinyl ester resin in the mortar 23 and skid resistant nateial 26 to provide chemical crosslmking between the resin forming the rails 13, the resin in the mortar 23 and the resm in the skid resistant material 26. In this way, the rails]3, molter 23 and skid resistant material 26 in the finished joint fond a composite mass of essentially nifolll chemical composition. 'The connection between the rails 13, mortar 23 and skid resistant layer 26 is thereby significantly stronger and more unifon1l than that in prior art joints. It also provides for greater longevity Moreover, the present invention provides a joint possessing greatly improved physical and chemical compatibility between the rails] 3, mortar 23 and skid resistant layer 26. Furthermore, since the rails] 3 are fonned from an organic polymer resin they offer much greaterresistance to moisture and deicing salt than the steel components used in conventional joints The design and construction of the expansion joint assembly also provides for reduced mstallaLion tonnes, reduced component weight and reduced environmental risk by the elimination of toxic materials.

While a specific en1bodinlent of the present invention has been described above it will be evident to tile skilled person that the assembly of the present invention may take any convenient size and/or shape to suit a particular application. The inventive assembly may be used to fonn an expansion joint assembly between any two structural members and is not limited to use in road or bridge construction. For example, it is envisaged that the assembly of the present invention may be used to form a joint between structural components using no the construction of buildings or other civil engineering structures.

The first portion of the rail may take any suitable forth to provide a connection with the seal and the second poition of the rail may have any desirable configuration, including any suitable fond of surface texturing, as long as it facilitates a satisfactory connection between the rail, the mortar and the adjacent structural member.

Moreover, the anchor member whilst being described as a u edge shaped member may take any suitable fond that serves to interlock mechanically with the mortar.

Furthennore, the organic polymer resins Conning the rail, moitar and skid resistant layer should be chosen such that their physical and chemical compatibility fallwithin acceptable limits. It is particularly preferred that the rail, mortar and skid resistant layer are made from materials which incorporate chemical groups which can react to provide chemical bonding between these components to strengthen the connection betwce the rail, mortar and skid resistant layer, and In tun1 the neighbourii1g structural member.

Claims

C:LAIMS I An expansion joint assembly for location In a gap defined

between first and second structural members, tile assembly comprising a sealing member and at least one anchor member, said anchor member having a first portion for connection to the sealing member and a second portion for connection to one of said first and second structural members, wherein said first and second portions of the anchor member are integrally fonlled.

2. An expansioTI joint assembly aecordng to c]a.nn 1' wherem the anchor member is fonned from a material comprising an organic polymer resin.

3. An expansion joint assembly according to claim 2, wherein the resin is selected from a group consisting of a. polyester resin, a vinyl ester resin, a polyurethane resin, an acrylic resin and an epoxy resin.

it. An expansion Joint assembly according to Elaine 2 or 3, wherein the resin contains chemical groups derived from an unsaturated organic monomer compound.

is. An expansion joint assembly according to claim 2, 3 or 4 wherein the resin contains moieties selected from a group consisting of styrene, vinyl toluene, acrylic ester and metllaerylate ester.

G. An expansion joint assembly according to any one of claims 2 to a, wilei-ein said bacterial ineoporates a reinforcing material selected from a group consisting of glass fbre, glass mat, steel, carbon Abbe and polyparaplenyleneterepllthalanlide.

7. l\n expansion joint a.ssernbly according to any preceding claim, wherein one of tile first portion of the anchor member and the sealing member defines a prcjecton configured for receipt in a complementary slot defined in tile other member.

8. An expansion Joint assembly according to any preceding claim, wherem a layer of skid resistant material is provided on an exposed upped surface of the first portion o f the anchor member.

9. An expansion Jomt assembly according to claim 8, wherein the skid resistant material comprises an organic polymer resin.

10. An expansion joint assembly according to any preceding claim, wherein at least the second portion of the anchor member is connected to one of said structural members via mortar cast Into the gap defined between the structural members.

11. An expansion joint assembly according to claim 10, wherein the mortar is an organic polymer resin.

12. An expansion joint assembly according to claim 11, wherein the mortar resin is selected from a group consisting of a polyester resin, a vinyl ester resin, a polyurethane resin, an acrylic resin and an epoxy resin.

13 An expansion Joint assembly according to claim 11 or 12, wherein the mortar resin contains chemical groups derived from an unsaturated organic monomer compound.

14. An expansion joint assembly according to claim 11, 12 or 13, wherein the mortar resin contains moieties sc]ected from a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester.

15. An expansion joint assembly according to any one of claims 10 to 14, wherein both the material from whirls the anchor member is foi1ned and the mortar are organic polymer resins.

16. An expansion Joint assembly according to claim 15, wherein both the material from whet the anchor member- Is Conned and the mortar are the same organic polymer resin.

1 7. An expansion joint assembly according to any one of claims 10 to 16, wherein a layer of a skid resistant material Is provided on an exposed upper surface of the mortar cast into the gap defined between the structural members.

18. An expansion Joint assembly according to claim 17 wherein the skid resistant material is an organic polymer resin.

19. An expansion joint assembly according to any one of claims 10 to 1 S. wherein the second portion of the anchor member defines a locking men?ber configured to contact said mortar when said mortar is cast mto said gap to lock said anchor member against said mortar.

20. An expansion joint assembly according to claim 19, wherein the locking member Is elongate.

21. An expansion joint assembly according to clatill 19 or 20, wherein at least a section of said locking nen1ber is tapered.

22. An expansion joint assembly according to clain1 21, wherein the locking member Is tapered such that its thickness at a position proximal to tile first portion is less than that distal frown the first portion.

23. An expansion joint assembly according to any one of claims 21 to 22, wherein a surface of the locking November adapted to be In contact with the mortar when tile mortar Is cast into said gap is provided with surface texturing.

24. An expansion joint assembly according to any one of claims] 9 to 23, wherein said locking member defines at least one aperture for receipt of mortar when said mortar Is cast into said gap.

25. An expansion Joint assembly according to any preceding clam, wherein the sealing meillber is elastomeric.

26. An expansion joint assembly according to aunt preceding claim, wherein the anchor member is a unitary structure.

27 An expansion joint assembly according to any preceding claim, wherein the anchor member is an elongate rail.

28. An expansion joint assembly according to any preceding claim, wherein the assembly comprises two anchor menbers, one anchor member for connection to the first structural member and the other anchor member for connection to the second structural member and the sealing member disposed between the anchor members.

29. An expansion joint assembly for location in a gap defined between first and second structural members to fonts a joint between said structural Novembers substantially as hereinbefore described and with r eference to figures 2 to 4 of the accompanying drawings.

30. A method for forming an expansion joint betNNeen first and second structural members comprising locating an assembly according to any preceding claim in a gap defined between said structural members; said locating of the assembly comprising connecting the first pOitiOil of the anchor member to the sealing nenber and connecting the second portion of the anchor member to one of the structural members.

31. A method according to claim 30, wherein the method comprises the step of casting a layer of a skid resistant material on an exposed upper surface of the first portion of the anchor member.

32. A method according to claim 31 or 32, whercn said comectinY' of the second portion of the anchor- November to said one of tile first and second members comprises casting mortar into said gap such that said mortar contacts the second portion of the anchor member and said one of the first and second members.

33. A method according to claim 30, 31 or 32, wherein the method comprises the step of casting a layer of a skid resistant material on an exposed upper surface of the mortar cast Into the gap defined between the structural members.

34. A method for fondling an expansion joint between first and second structural members comprising locating an assembly comprised of a sealing nen1ber and at least one anchor memler having first and second portions in a gap defined between said structural members; said locating of the assembly comprising connecting the first portion of the anchor member to the sealing member, placing the anchor member into said gap, and casting mortar into said gap to connect at Icast the second portion of the anchor member to one of the structural members, wherein during said casting of the mortar into said gap at least a part of at least the second portion of the anchor member chemically bonds to the mortar.

35. A method according to claim 34, wherein the anchor member is formed from a material comprising an organic polymer resin containing crosslin:lable moieties.

36. A method according to claim 35, wherein the crosslinliable moieties are double bonds between adjacent carbon atoms of the polymer resin.

37. A method according to claim 35 or 36, wherein the resin is selected front a group consisting of a polyester resin, a vinyl ester resin and an acrylic resin.

38. A method according to claim 35, 36 or 37, wheren1 the resin contains chemical groups derived from an unsaturated organic monomer compound.

39. A method according to any one of claims 35 to 38 wherein the resin contains moieties selected from a group consisting of styrene, vinyl toluene, acrylic ester and metl1acr,vlate ester.

40. A method according to any one of claims 35 to 39, wherein said material incorporates a reinforcing material selected from a group consisting Of glass fibre, glass mat, steed, carbon fibre and polyparapheny]enetereplltllalamide.

41. A method according to any one of claims 35 to 4O, wherein the mortar comprises an organic polymer resin containing tennrlal crosshnkable moieties and a crosslinking agent.

42. A method according to claim 41, wherem the resin is selected frown a group consisting of a polyester resin, a vinyl ester resin and an acrylic resin.

43. A method according to claim 41 or 42, wherein the resin contains chemical groups derived from an unsaturated organic monomer compound.

44. A method according to claim 41, 42 or 43, wherein the resin contains moieties selected from a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester.

45. A method according to any one of claims 41 to 44, wherein both the mateiial frown which the anchor member is fowled and the mortar comprise organic polymer resins containing crosslinkable moieties.

46. A method according to any one of claims 41 to 45, wherein the material from Nvhcb the anchor member is Donned and the mortar comprise the same organic polymer resin containing crosslinkabl: moieties.

47. A method according to any one of claims 41 to 46, wherein the crosslinkig agent is selected from a group consisting of styrene, vinyl tolucne, acrylic ester and metllacrylate ester.

I. A method according to any one of claims 41 to 47, wherein the terminal crosslinlable notes are metllacrylate ester- moieties.

49. A method according to any one of claims 41 to 48, wherein during casting said mortar mto said gap said crosslinking agent in the mortar reacts with said crossln1kable moieties in the resin of the anchor member and said terminal crosslinkable moieties in the mortar to provide chemical crosslinking between said part of the second poition of tl1e anchor member and the mortar.

50. A method according to any one of claims 34 to 49, wherein the method comprises the additional step of casting a layer of a skid resistant nateral on an exposed upper surface of at least one of the mortar east into the gap defined between the structural Novembers and the first portion of the anchor member.

51. A method according to claim 50, wherein the layer of skid resistant material is chemically bonded to said exposed upper surface of at least one of the mortar east into tile gap defined between tile structural members and the first portion of the anchor member.

59.A method according to claim 50 or 51, wherein the skid resistant material comprises an organic polymer resin eo1taining terminal crosslinkable moieties and a erosslinking agent.

53. A method according to any one of claims 34 to 52, Nvl1eren said first and second portions of the anchor men1ber are integrally Conned.

54. An expansion Joint assembly for location in a gap defined betNvcen first and second structural members, the assembly comprising a sealing member and at least one anchor member, said anchor member having a fir st portion for connection to the sealing member and a second portion for connection to one of said structural members, wherein a layer of skid r esstant material is provided on an exposed upper surface of the first portion of the anchor member.

55. An expansion joint assembly according to claim 54, wherein the anchor member is formed from a material comprising an organic polymer resin containing crosslinkable moieties.

56. An expansion Joint assembly according to claim 54 or 55, wherein the skid resistant material comprises an organic polymer resin containing terminal crosslinkable moieties and a crosslinkmg agent.

57. An expansion joint assembly according to cluing 54, 55 or 56, wllcreiT1 the skid resistant material is chemically bonded to the anchor member.

58. An expansion joint assembly according to any one of claims 54 to 57, wherein the second portion of the anchor member Is adapted to be connected to one of said structural members via mortar cast into the gap defined between the structural members.

59. An expansion joint assembly according to claim 58, wherein ibe mortar comprises an organic polymer resin containing terminal crosslinka.ble moieties and a crosslinking agent.

60. Phi expansion joint assembly according to claim 58 or 59, herein a layer of a skid resistant material is provided on an exposed upper surface of the mortar cast into the gap defined between the structural members.

6]. An expansion joint assembly according to claim 60, wherein the skid resistant material comprises an organic polymer resin containing terminal crosslinkable moieties and a crosslinking agent.

69. An expansion Joint assembly according to any one of clanks 54 to 61, wherein said first and second portions of the anchor member- are integrally formed.

63. An expansion joint assembly for location in a gap defined between first and second structural members to form a Joint between said stnichrral members substantially as hcreinbefore described and wattle rcIerelcc to figure of the accompanying drawings.

64. A method for forming an expansion joint between first and second structural nen1bers comprising locating an assembly according to any one of clanks 54 to 63 in a gap defined between said structural members; said locating of the assembly comprising connecting tlae f rst portion of the anchor member to the sealing member, connecting the second portion of the anchor member to one of the structural members and providing a layer of skid resistant material Oil art exposed upper surface of the first portion of the anchor member.

65. A method according to claim 64, wherein during provision of said layer of skid resistant Lateral said layer of skid resistant material chemically bonds to at least a past of the exposed upper surface of the first portion of the anchor member.

66. A method according to claim 64 or 65, wherein the layer of skid resistant material is provided on said exposed upper surface of the first portion of the anchor member by casting.

67. A method according to claim 64, 6: or 66, wherein said connecting of the second portion of the anchor member to said one of the first and second members comprises casting mortar into said gap such that said mortar contacts the second portion of the anchor member and said one of the first and second members.

68. A method according to claim 67, wherein a layer of a skid resistant material is provided Oil an exposed upper surface of the mortar cast into the gap defined between the structural menbe2-s.

69. A method according to claim 68, wherein during provision of said layer of skid resistant material said layer of skid resistant material chemically bonds to said mortar.

70. A method according to claim 68 or 69, wherein the layer of skid resistant material Is provided on said exposed upper surface of the mortar by casting.

71. A method for forming an expansion joint between first and second structural nernbers comprising locating an assembly comprised of a sealing member and at least one anchor member having first and second portions in a gap defined between said structural members; said locating of the assembly comprising connecting the first portion of the anchor member to the sealing member, placing the anchor member into said gap, casting mortar into said gap to collect at least the second portion of the anchor member to one of the structural members and providing a layer of skid resistant material on an exposed upper surface of the mortar cast mto said gap, wherein during provision of said layer of skid resistant material, said layer of skid resistant material chemically bonds to the mortar.

72. A method according to claim 71, wherein the layer of skid resistant material is provided on said exposed upper surface of the mortar by casting.

73. A method according to claim 71 or 72, wherein the skid resistant material comprises ah organic polymer resin containing terminal crosslinkable moieties and a crosslinking agent.

74. An expansion joint assembly according to claim 71, 72 or 73, wherein the mortar comprises an organic polymer resin containing terminal crosslinkable moieties and a cross]inking agent.

75. A method according to claim 73 or 74, wherein said organic polymer resin is selected from a group consistulg of a polyester resin, a vinyl ester resin and an acrylic resin.

76. A method according to claim 75, wherein the resin contains chemical groups derived from an uilsat'.'rated organic monomer compound.

77. A method according to claim 75 or 76, wherein the resin contains moieties selected from a group consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester.

78. A method according to any one of claims 73 to 77, wlleren the terminal crosslinkable moieties are methacrylate ester moieties.

79. A method according to any one of claims 73 to 78, wherein the crosslinkng agent is selected from a grony consisting of styrene, vinyl toluene, acrylic ester and methacrylate ester.