12th Pilot Project: Sealing of expansion joints against ... · Sealing of expansion joints against...
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Newsletter
12th Pilot Project:
Sealing of expansion joints against stone chippings
and water flow
Wolf Kabeltechnik GmbH of Stuttgart was commissioned by DB Netz AG Hannover with
the task of finding a quick but lasting solution for sealing a 46-metre long expansion joint
against stone chippings and water flow. The railway bridge crosses the B522 highway to
Hanover airport. Due to defective joint sealing tapes, the passage of trains causes small
stones to fall through the 46-metre expansion joint onto the road below. Fortunately, this
has so far not caused any accidents or serious damage.
03/14
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The problem:
It was soon clear that our standard expansion-joint sealing cushions against water flow would not
provide a long-term solution for this particular case. Additional measures would be required to
ensure protection against small stones.
The solution: A further development of the expansion-joint sealing cushion:
Art. No. 21.3 SVS-QADK/V L, for protection against small stones
The aim of this further development was to optimise the tried and tested
Art. No. 21.1 QADK/V in such a way that it could be set into the joint cavity from the road, in the
course of renovation work, and would provide lasting protection against friction from small stones
and grit.
The task of was fulfilled with the development of a protective material, Art. No. 21.4 SVS-VF-QV
140x2x60, which is added to the upper side of the air-inflated
expansion-joint sealing cushion No. 21.1 QADK/V L. Laboratory tests have shown that for longer
expansion-joint sealing cushions (here 2 x 23 m) it is too complicated to assemble the protective
material on-site, so they should be delivered pre-assembled, but the assembly of shorter lengths
on-site is no problem.
Pic. 1:
Art. No. 21.3 SVS-QADK/V L Protective device against stone chippings and grit
Pic. 2:
Protective device installed in a functional model with joint width 6 cm
Pic. 3:
View from below into the expansion joint (model pic. 2) with installed protective device
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RIGHT! Protective film in overlap area of 21.4 F-SVS-QADK/V
WRONG! No protective film in overlap area.
Danger of water leakage!
The project:
Mr Mike Dinter of DB Netz AG,
responsible for maintenance and
special repair work in facilities in the
northern region, was present at the talk
on “The economical sealing of expansion
joints with swelling-material expansion-
joint sealing cushions” given by our
affiliated company, Fibre Optics CT
GmbH, at the ARGE meeting in Cologne
in September 2013. He was able to
examine the functional model for
expansion joints that was on display.
In the course of his research for a solution to his problem, and after discussion with the
colleagues in charge of the western and central regions regarding their practical experience with
Wolf expansion-joint sealing cushions, Mr Dinter contacted Wolf Kabeltechnik GmbH on
26.06.2015, to discuss the technical feasibility of sealing against falling stones and water flow
and to request a quotation. On receipt of the order on 09.07.2015, Fibre Optics CT GmbH
started on the modification of the standard sealing cushion for pilot project No. 12, and the new
product was supplied on 22.07.2015.
In the meantime, Mr Dinter was busy with preparations for the installation of the new protection
material. He organised assembly teams and the road closure that would be necessary during
the installation of the protection material in the 46-metre expansion joint on 23.07.2015. He also
found a locality for the training session that Fibre Optics CT GmbH would give as part of the
assembly process.
Mr Roland Wolf of Fibre Optics CT GmbH in Stuttgart had set to work on the development
immediately after hearing of the problem situation. He tested the protective material in the lab
on 3 functional models. The lab tests made it clear that additional protection against water entry
would be required in the overlap area between two lengths of stone-protection material. This
meant that when the pilot project was actually carried out, all necessary materials were
available to ensure a reliable, lasting seal. As a consequence of water entry, icicles can form
and ice can build up on the road, which can cause accidents or damage. (See picture.)
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22.07.2015 Training session in theory and praxis given by Fibre Optics CT GmbH
On the day before the installation of the 46-metre expansion-joint seal and the practical briefing for
it, the DB Netz AG employees were introduced to the theory and praxis of the sealing system and
the materials used in a training session given by Mr Roland Wolf.
Functional tests on products samples of
swelling material, sealing cushions and
laminated film
Art. No. 13.1 VF-QV-DF surface protection,
Art. No. 13.2 VF-QV-DES liquid and diffusion
barrier
Test No. 1: Pressure test
with small stones, 85 kg/ 10x10 cm
Test No. 4
Resistance and positional stability of the sealing system
with repeated vertical movement.
Test No. 2: Tightness of the swelling-material sealing system i.e. no water entry, despite - holes in the laminated foil - the foil being attached by screws
Test No. 3: (carried out by the bridge inspector) Tightness of the swelling material even after damage (a cut 1.5 cm in length)
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23.07.2015 Expansion joint renovation on the railway bridge
with installation instructions from given by
Mr Roland Wolf of Fibre Optics CT GmbH
Project (diagrammatic representation)
Start 08.40
Lane closure on the B522, the quick route to
Hanover airport
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09.00 – 09.15 Team 1 from DB Netz Hanover Team 2 from DB Netz Braunschweig scaffolding in lane 1 erects scaffolding in lane 2
Lanes 1 + 2 are closed while the scaffolding The sealing cushion 21.3 SVS-QADK/V L, is erected length 23 m, is rolled up with the valve end at the beginning
Closure of road
lanes 1 and 2,
carried out by B.A.S
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09.15 Start of installation
On the scaffolding "emergency exit" lane 1, The end of the sealing cushion is folded over
sealing cushion 21.3 SVS-QADK/V L 23 m, 180° for ~1.5 m and laid in the joint cavity of the
weight 9.3 kg, is raised to a height of 5.2 m bridge support, with the blue SVS protective
layer facing in the direction of the stones
The sealing cushion is laid in the joint cavity Lane1, 09.30 at a height of 7.5 m, with the blue SVS protective layer towards the stones. A gradient is produced, with the aid of PE round cord and fixed in place transversely at 3-metre intervals.
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09.30 – The sealing cushion installation is completed in the bridge support and emergency exit areas, lane 1. The scaffolding is moved over to lane 2.
10.00 The sealing cushion is fixed in place trans-versely between lanes 2 and 3. 10.15 The scaffolding is taken down for removal to lane 4
10.15 – 10.30 The road closure is transferred to lanes 4 and 5 and the vehicles repositioned
10.15 – 10.30 The scaffolding from lane 1 is moved to lane 4 and from lane 2 to lane 3
Scaffolding is erected in lanes 3 and 4
10.15 The joint sealant over lane 3 is removed
The other end of the sealing cushion SVS-QADK/V L 23m is transported from lane 4 to lane 3
10.30 – 11.00 The protective aluminium strips are dismantled over lane 4
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Installation of the protective foil F-SVS-QADK/V for the prevention of water flow in the overlap area of two sealing cushions
11.00 Both ends of the cushion overlap in the joint over lane 3 by about 0.5 m, and are fixed in place with PE round cord
11.00 – 11.25 Inflation of the first 23 m SVS-QADK/V
The inflated sealing cushion with PE round cord
11.28 – 11.45 The scaffolding is taken from lane 3 to lane 6. The sealing cushion in lane 4 is fixed in position.
Demonstration of the functional model with the sealing cushion SVS-QADK/V L used here.
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Functional test carried out on-site 13.1 VF-QV-DF surface protection 13.2 VF-QV-DES liquid & diffusion barrier Demonstration of thewatertightness of a test strip with a hole made by a screw (as used for attachment)
12.00 – 12.50 All the aluminium strips have been removed over lane 4
12.50 – 13.10 To fit the sealing cushion ends (valve side), approx. 2m are folded over 180°and fixed in position in the joint.
13.10 – 13.20 Inflation of the second sealing cushion to 0.5 bar. Removal of scaffolding, lane 5.
13.30 Completion of inspection of the SVS-QADK/V joint seal
Team DB Netz AG Hanover
Team DB Netz AG Braunschweig
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Summary:
Time required
− From beginning of lane closure to the end (total duration) 360 min
− Erection and removal of scaffolding (total) 70 min
− Removal of aluminium strips and remains of the old joint sealant 85 min
− Lane closure processes/repositioning of vehicles ~ 70 min
− Fitting the sealing cushions, incl. transverse fixture ~ 135 min
Project planning and implementation
Excellent project planning, the exemplary cooperation of both installation teams from the DB
Netz AG and the assistance of the construction-site barrier service made it possible to carry out
a traffic-friendly, accident-fee installation in a relatively short time.
Assessment of the installation procedure
After the scaffolding had been removed, we saw from the photo documentation that the fixture
in position of the sealing cushions with PE round cord had not always been carried out as
prescribed.
This could have been caused by the bad lighting conditions in the 7.5 m
high joint cavity and uneven joint widths of 6.7 cm or narrower. It may
be that in a few places the PE round cord became twisted when the
sealing cushion was inserted and pulled and that it may now lie
between the joint wall and the cushion. It is possible that water could
enter at these points.
Research into this is already being carried out by Fibre Optics CT and Wolf KT. The results will
show if it is necessary to make corrections.
Wolf Kabeltechnik GmbH - over 30 years of innovative products!
Quality management system
The Wolf KT company is not certified according to DIN ISO IEC 17025:2000. The company's
internal Q-system is based on the specifications of DIN ISO 9001:2000 and corresponds to the
QS specifications of German Telekom “T-Com”. As quality certification, Wolf Kabeltechnik
GmbH supplies a tightness test report with each expansion-joint cushion (valve).
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Fibre Optics GmbH
The quality of joint sealing carried out with Wolf expansion-joint sealing technology depends largely
on good planning and how the installation process is carried out.
FibreOptics CT offers training sessions for familiarisation with Wolf products. For example:
Expansion-joint sealing technology & surface protection
on 22nd-23rd of October, 2015 A specialist conference
for construction supervisors and engineers, bridge inspectors and system decision-makers
(see Wolf Newsletter WO03/15)
3-day seminar
for construction supervisors and installation teams
(equivalent to Wolf WO03/15)
On successful completion, each participant is
awarded a certificate.
All information, pictures and graphic representations correspond to our current state of information and are correct to the best of our knowledge and belief. However, they cannot be considered as a binding warranty of the properties described. Such a warranty applies only to our product standards. The user must judge for himself on his own responsibility whether the product described is suitable for his intended application. Our liability for this product is based exclusively on our general terms and conditions of business. We reserve the right to alter our specifications without prior notice. We reserve the right to alter our specifications without prior notice..
Supplier Your local sales partner
National sales
Kabeltechnik GmbH,
Zazenhäuser Str. 52, 70437 Stuttgart, Germany
Tel. ++49 (0) 711 87 39 41 Fax ++49 (0) 711 87 12 30 e-mail: [email protected] www.wolfkabeltechnik.de
International Tel.: +49 (0)7071 9597-94 Email: [email protected]