Fire and water resistant expansion joint system

• US 9,644,368 B1
• Filed: 05/15/2014
• Issued: 05/09/2017
• Est. Priority Date: 11/20/2008
• Status: Expired due to Fees

• Current Assignee: Emseal Joint Systems Limited (Compagnie De Saint-Gobain S.A.)
• Original Assignee: Emseal Joint Systems Limited (Compagnie De Saint-Gobain S.A.)
• Inventors: Witherspoon, Bill
• Primary Examiner(s): GILBERT, WILLIAM V
• Application Number:
  US14/278,210
• Time in Patent Office: 1,090 Days
• Field of Search: 52395, 5239601, 52465, 52466, 52467, 52468, 52232, 52317, 52393, 5239603, 5239604, 5239607, 5239606, 525861, 525862, 404 47, 404 68
• CPC Class Codes: C08J 2201/038 Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass
• CPC Class Codes: C08J 2205/05 Open cells, i.e. more than 50% of the pores are open
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 2400/26 Elastomers
• CPC Class Codes: C08J 9/365 Coating
• CPC Class Codes: C08J 9/40 Impregnation
• CPC Class Codes: C08K 3/016 Flame-proofing or flame-retarding additives
• CPC Class Codes: E04B 1/66 Sealings damp-proof courses E04B1/644; fire-proof sealings E04B1/948; additions of anti-leak properties to plaster C04B; bituminous sealing masses C08L95/00; sealings for hydraulic engineering work in general E02B3/16; against ground humidity or ground water E02D31/02; coverings against rain or other precipitations of the atmosphere E04D; composition of material or manufacture of sealing foils, see the relevant classes for these foils
• CPC Class Codes: E04B 1/68 of joints, e.g. expansion joints packing for joints in roads or airfields E01C11/02; expansion joints for bridges E01D19/06; sealing joints between foundation piles E02D5/14; joints in foundation structures E02D29/16; devices for sealing the spaces or joints between roof-covering elements E04D1/36; sealing joints between roof-covering elements E04D3/38; construction of joints for flooring or floor layers composed of a number of similar elements E04F15/02005; construction of joints for flooring or floor layers made of masses in situ E04F15/14
• CPC Class Codes: E04B 1/6806 Waterstops E04B1/6807 takes precedence
• CPC Class Codes: E04B 1/6812 Compressable seals of solid form
• CPC Class Codes: E04B 1/944 covered with fire-proofing material
• CPC Class Codes: E04B 1/948 Fire-proof sealings or joints for doors or windows E06B5/164
• CPC Class Codes: E04B 1/98 against vibrations or shocks on foundations E02D31/08; against mechanical destruction, e.g. by air-raids against incendiary damage only E04B1/94; finishing work therefor E04F; buildings withstanding earthquake or the like, shelters, arrangements of splintercatching walls E04H9/00
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced

Abstract

A fire resistant and water resistant expansion joint system comprises a compressed lamination of fire retardant infused open celled foam, one coat of an elastomeric waterproofing or water resistant material on the lamination, and another coat of an intumescent material on an opposing surface of the lamination, thereby providing fire resistance in one direction and water resistance in the opposite direction. The intumescent material may be further coated with a similar elastomeric material, thereby providing fire resistance in one direction and water resistance in both directions. In the alternative, the compressed lamination may comprise first and second opposing layers of intumescent material thereon each having a respective layer of elastomeric material to provide both water resistance and fire resistance in both directions.

Claims

1. An expansion joint system, comprising:

foam;

a fire retardant material infused into the foam; and

wherein the expansion joint system is configured to facilitate compression of the system when installed between substrates, wherein the foam has a density when installed in a range of about 200 kg/m³ to about 700 kg/m³, and the system is capable of withstanding exposure to a temperature of about 540°

C. at about five minutes, and the fire retardant infused foam is configured to pass testing mandated by UL 2079.

2. The expansion joint system of claim 1, wherein the foam uncompressed has a density of about 130 kg/m³ to about 150 kg/m³.

3. The expansion joint system of claim 1, wherein the foam has an infused foam density when compressed in a range of about 400 kg/m³ to about 450 kg/m³.

4. The expansion joint system of claim 1, wherein the system is configured to withstand exposure to a temperature of about 930°

C. at about one hour to pass the UL 2079 testing.

5. The expansion joint system of claim 1, wherein the system is configured to withstand exposure to a temperature of about 1010°

C. at about two hours to pass the UL 2079 testing.

6. A method of installing an expansion joint system utilizing the expansion joint system of claim 1, comprising:

locating a first substrate of the substrates;

locating a second substrate of the substrates arranged to be at least substantially coplanar with the first substrate and being spaced therefrom by a gap;

inserting the expansion joint system into the gap between the first substrate and the second substrate; and

allowing the expansion joint system to decompress to fill the gap between the first substrate and the second substrate.

7. The method according to claim 6, wherein the foam has an infused foam density when compressed in a range of about 400 kg/m³ to about 450 kg/m³.

8. A fire resistant expansion joint system, comprising:

foam;

a fire retardant material put into the foam; and

wherein the fire resistant expansion joint system is configured to be installed in a gap between substrates and configured to facilitate compression during use to accommodate movement of the substrates as the fire resistant expansion joint system repeatedly cycles by expanding and contracting in the gap, wherein the foam has a density when installed in a range of about 200 kg/m³ to about 700 kg/m³, and the fire resistant expansion joint system is configured to maintain fire resistance upon exposure to a temperature of about 540°

C. at about five minutes, and the foam with the fire retardant material is configured to pass testing mandated by UL 2079.

9. The fire resistant expansion joint system of claim 8, wherein the foam with the fire retardant material uncompressed has a density of about 130 kg/m³ to about 150 kg/m³.

10. The fire resistant expansion joint system of claim 8, wherein the foam with the fire retardant material compressed has a density in a range of about 400 kg/m³ to about 450 kg/m³.

11. The fire resistant expansion joint system of claim 8, wherein the system is configured to maintain fire resistance upon exposure to a temperature of about 930°

C. at about one hour to pass the UL 2079 testing.

12. The fire resistant expansion joint system of claim 8, wherein the system is configured to maintain fire resistance upon exposure to a temperature of about 1010°

C. at about two hours to pass the UL 2079 testing.

13. A method of installing a fire resistant expansion joint system utilizing the fire resistant expansion joint system of claim 8, comprising:

locating a first substrate of the substrates;

locating a second substrate of the substrates, the second substrate being spaced from the first substrate by a gap;

inserting the fire resistant expansion joint system into the gap between the first substrate and the second substrate; and

allowing the fire resistant expansion joint system to decompress to fill the gap between the first substrate and the second substrate, and the fire resistant expansion joint system facilitates compression during use after installation and accommodates movement of the substrates as the fire resistant expansion joint system repeatedly cycles by compressing and decompressing in the gap.

14. The method according to claim 13, wherein the foam with the fire retardant material compressed has a density in a range of about 400 kg/m³ to about 450 kg/m³.

15. A fire resistant expansion joint system, consisting essentially of:

foam;

a fire retardant material put into the foam; and

wherein the fire resistant expansion joint system is configured to be installed in a gap between substrates, wherein the foam has a density when installed in a range of about 200 kg/m³ to about 700 kg/m³, and the fire resistant expansion joint system is configured to facilitate compression during use to accommodate movement of the substrates as the fire resistant expansion joint system repeatedly expands and contracts in the gap, and is configured to maintain fire resistance upon exposure to a temperature of about 540°

C. at about five minutes, and the foam with the fire retardant material is configured to pass testing mandated by UL 2079.

16. The fire resistant expansion joint system of claim 15, wherein the system is configured to maintain fire resistance upon exposure to a temperature of about 930°

C. at about one hour to pass the UL 2079 testing.

17. The fire resistant expansion joint system of claim 15, wherein the system is configured to maintain fire resistance upon exposure to a temperature of about 1010°

C. at about two hours to pass the UL 2079 testing.