W-SEAL EXPANSION JOINTS

TechStar
I N C O R P O R A T E D
 W-SEAL
Background Collectively, D.S. TechStar, Inc. has been involved in expansion joint design for bridges
and highways for over 60 years. D.D. Brown, a company co-founder, invented the syn-
thetic rubber process which led the way to continuous curing of neoprene extrusions
and was responsible for the first neoprene compression seal. Mr. Brown designed,
manufactured, and installed the first neoprene bridge seal in the I-10 bridge near Jarrel,
Texas in 1963.
Compression seal has been used to seal movements of less than 75 mm for nearly 40
years. The compression seal relies on the force created by the internal web configura-
tion to apply enough pressure against the sidewall of the expansion joint to remain
watertight. In many cases, after a few years, the seal hardens and the “compression
set” of the polymer reduces the force being applied against the sidewall and, therefore,
does not permit the seal to remain watertight. The hardening of the seal also prohibits
the adhesive from being able to pull the seal open when the expansion joint contracts.

Innovation To improve the compression seal, D.S. TechStar, with the assistance of a bridge
engineer, developed a new type of seal which eliminated many disadvantages of the
compression seal. The W-Seal utilizes a classical “arch” shape. The design of the
W-Seal is less complex; therefore, the seal can be extruded and cured properly. Unlike
the compression seal, the W-Seal will not tend to harden over time. TechStar’s single
component adhesive remains bonded and can pull the seal open. The bond does not
degenerate with age as compression seal adhesives tend to do. After more than
five years service on Florida’s Interstate 95, the first installation of the
W-Seal is still bonded and remains watertight. The arch configuration also assists
in expelling debris from the joint, and the joint looks extremely clean for this length of
service.
W-Seal is ideal for expansion joints in:
• Parking garages
• Small bridges
• Concrete pavements
• Expansion joints where strip seal
might be considered
The W-Seal is on the approved product list for expansion joints by Walker Parking
Consultants. Parking garages have often been sites for poor expansion joint practice.
Walker Parking Consultants view the W-Seal as a breakthrough between compression
seals and cast-in-place “wing seals.” The arch effect enables the W-Seal to comply with
the American Disabilities Act (ADAAG), thereby enabling it to compete against far more
expensive expansion joint systems. The W-Seal can be considered a link between
compression seals and strip seals in that the W-Seal can obtain significantly more
movement than compression seals, although not as much as larger strip seals.

Field The W-Seal has been field tested by several key State Departments of Transportation,
Observation including Florida, Nevada, Arkansas, Illinois, Missouri, Idaho, Oregon, Connecticut,
Maryland, and New Jersey. As part of the FDOT’s Product Evaluation of Qualified
Expansion Joints for Bridges, the W300 was installed on Interstate 95 near Port St.
Lucie, Florida. The W-Seal outperformed all other comparable products. The following
are some excerpts from the FDOT’s report:
“The installation of the TechStar seal was quick and simple.” (2/96)
“The TechStar W300 is performing very well.” (2/96)
“Based on more than two years of testing and field observation, the SRC recommends
that the FDOT Product Evaluation Section place the TechStar W300 Seal on the FDOT’s
Qualified Products list (QPL) for bridge expansion joints and seals.” (2/97)

Thermoplastic The W-Seal can also be extruded into a dual polymer thermoplastic material. The dual
Concept polymer enables TechStar to coat the center arch with a thin hard plastic membrane,
making the arch impervious to tear or puncture. This has often been characterized as
the single most difficult problem with strip seals. The hard shell of the thermoplastic
W-Seal eliminates this problem.

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 W-SEAL INSTALLATION
W-Seal Detail
D

A
B
C E

W-Seal Sizes W050 W100 W125 W150 W175 W200 W300 W400 W500 W600
Jeene Seal Comparison – – 25 – 40 – 50 65 75 100
Bridge Seal Comparison 0.687 1.50 1.75 2.00 2.50 3.00 4.00 5.00 6.00 –
Strip Seal Comparison – – – – – 200 300 300 400 500
Joint Data
Min Opening, in. (A) 0.25 0.65 0.88 1.00 1.20 1.375 1.750 2.250 2.625 3.00
Mid Opening, in. (B) 0.375 1.00 1.25 1.50 1.75 2.00 2.50 3.00 3.50 4.00
Mid Opening, mm (B) 9.5 25.4 32.0 38.0 45.0 50.8 63.5 76.0 89.0 102.0
Max Opening, in. (C) 0.50 1.25 1.51 1.88 2.10 2.50 3.00 3.625 4.50 5.00
Ht in Joint, in. (D) 1.57 1.73 1.83 1.94 2.10 2.25 2.625 3.875 4.25 4.75
Ht in Joint, mm (D) 40 44 47 49 53 57 67 98 108 121
Flat Width, in. (E) 1.97 3.50 3.875 4.125 4.375 4.625 5.50 8.50 9.50 10.50
Flat Width, mm (E) 50 89 98 105 111 118 140 216 241 267

Installation Sequence

W-Seal installation is quick and simple. The seal and expansion joint face are
coated with the recommended adhesive. The seal is compressed into a W shape and
forced from the surface into the joint opening. While the adhesive is still wet, the seal is
adjusted to the appropriate height. W-Seal is available in sizes fitting .250" to .375"
sawed joints for concrete pavement use and in bridge joint sizes up to 4 inches
nominal opening. W-Seal can be installed in any dry joint opening above 45°F.

Physical Characteristics
Virgin Material Neoprene – ASTM D2628 Virgin Material Neoprene – ASTM D2628
Test Description (Modified) Requirement Test Description (Modified) Requirement
Hardness, Shore A Ozone Resistance
Durometer 55 ± 5 20% Strain, 300 pphm in
Tensile Strength, PSI Min 2,000 Min Air 70 Hrs @ 104°F No Cracks
Elongation at Break, % Min 250% Min Low Temperature Stiffening
For 7 Days @ 14°F Changes
Oven Aging 70 Hrs @ 212°F in Hardness 0 to +15
Changes in Hardness, Points 0 to +10
Changes in Tensile, % Max -20 Compression Set
Changes in Elongation, % Max -20 @ 75% Compression for
24 Hrs @ 212°F Measured
Aged 70 Hrs @ 212°F in Against Original Thickness, % 40
ASTM #3 Oil
Changes in Weight, % Max 45

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 W-GRID
W-Grid System W-Grid is a joint system that combines positive anchorage to the blockout header
compound such as elastomeric concrete with the benefits of W-Seal. W-Grid consists of
W-Seal extruded with a tab along its exterior that provides a mechanical and adhesive
connection to a carbon- or glass-fiber anchorage grid. This grid is cast into the header,
and the seal is installed after the header compound has hardened. W-Grid is compat-
ible with several standard, readily available elastomeric concrete products. Unlike wing
seals, which cast rubber/plastic wings into the blockouts, W-Grid does not cause high
stress concentrations in the header material. The W-Grid anchorage cannot compress
under load. The W-Seal gland can be replaced while utilizing the existing grid and
header.

1.25"

1.5"

3.5"

Grid Layout

Section View

W-Seal Field Bridge Applications

Approvals In Use Experimental Parking Structures
Applications Florida DOT Idaho DOT Illinois DOT Tampa, FL (2)
Kentucky Missouri Maryland Bloomington, IL
Nevada Ohio Arkansas Boise, ID
Oregon Connecticut New Jersey Wilmington, DE
Michigan Utah Fresno, CA
Panama Louisiana Peoria, IL
Chicago, IL (2)

TechStar
I N C O R P O R A T E D

D.S. TechStar, Inc.

1219 West Main Cross Street
Findlay, Ohio, USA 45840
Tel: 419-424-0888 • Fax: 419-424-5959
www.techstar-inc.com