COMPANY PROFILE

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 inspected and certified by 3rd party inspection agencies like Germanischer Lloyds, ABS, Velosi, SGS etc .

OCEAN RUBBER

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 1 2 3 4 5 6 6.1 6.2 6.3 1 2 3 Hardness Specific Gravity Tensile Strength, Min. Elongation at break, Min. Compression Set, Max. (22hrs @ 100 C
0

TEST METHOD ISO 7619 ISO 2781 ISO 37 ISO 37 ISO 815
0

UNIT Shore A MPa % % Shore A % % Good Good Good

SPECIFICATION 605 1.330.05 15.5 350 35 +15 -15 -40

Accelerated Ageing Resistance (70 hrs @ 100 C) Change in Hardness Change in tensile strength, Max. Change in Elongation at break, Max. Resistance to Water Resistance to Acids Resistance to Alkalis ISO 7619 ISO 37 ISO 37

II. GENERAL PROPERTIES

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 1 2 3 4 5 6 7 8 10 11 12 13

Length (mm) 150 200 250 400 400 400 400 450 400 400 400 600

Breadth (mm) 150 150 250 250 300 250 300 400 500 500 500 400

Thickness (mm) 15 20 25 30 42 52 63 129 164 182 200 236

Maximum Load (kN) 240 320 650 1050 1250 1050 1250 1850 2100 2100 2100 2450

Maximum Movement (mm) 6 8 9 10 13 18 21 45 60 70 75 90

Maximum Rotation (rad) 0.001 0.001 0.001 0.001 0.001 0.0015 0.002 0.004 0.005 0.007 0.008 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: Horizontal Movement (mm) 4 4 4 7 7 7 9 9 9 4 7 9

SN 1 2 3 4 5 6 7 8 9 10 11 12

Length (mm) 150 200 200 150 200 200 150 200 200 1000 1000 1000

Breadth (mm) 150 150 200 150 150 200 150 150 200 150 200 200

Thickness (mm) 10 10 10 15 15 15 20 20 20 15 20 25

Maximum Load (kN) 120 160 210 120 160 210 120 160 210 800 1000 1300

Maximum Rotation (rad) 0.0006 0.0006 0.0006 0.0007 0.0007 0.0007 0.0009 0.0009 0.0009 0.0001 0.0001 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

3 2

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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 2: LOCATE THE BEARING PAD IN THE SPACE PROVIDED & FILL IT WITH RESIN

STEP 3: LOCATE THE UPPER BEAM S UPPORTED BY HYDRAULLIC JACKS AT REQUIREED HEIGHT

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 service life Long Corrosion resistance proof Water noise Low installation Easy MATERIAL The materials used for the Pioneer Bridge Expansion Joints are completely in compliance with the relevant bridge standards like AASHTO/BS/DIN/EN. Pioneer 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 Hardness, max Specify gravity Tensile strength Elongation at break, Min Tear strength Min Resistance to Ozone 25 pphm, 48hrs, 40C, 5% strain Compression set, max (24hrs. at 70C, 25% strain) Bonding of rubber to steel

UNIT Shore A ---Kg/cm % KN/m %

2

TEST METHOD BS 903 Part A26 ASTMD 2240 / DIN 5350 BS 903 Part A1 BS 903 Part A2 ASTM D 412 / DIN 53504 BS 903 Part A2 ASTM D 412 / DIN 53504 BS 903 A3 / ASTM D624 ASTMD 1149 B ASTMD 395 BS 903 Part A6 ASTM D429 B

SPECIFICATION 60 = 5 1.15-1.35 1.55 450 50 No cracks 30 >12 N per mm

AFTER AGEING PROPERTIES (22 HRS.AT 70C

Change in hardness, max Change in tensile strength, max Change in elongation at break, max Shore A % % BS 903 Part A 26 ASTM D 2240 / DIN 53505 BS 903 Part A2 ASTM D 412/ DIN 53504 BS 903 Part A2 ASTM D412/ Din 53504 +5 -15 -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 exp ansion 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 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

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

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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 case of aged concrete, prior to installation, the weak, loose, deteriorated or In contaminated concrete must be removed and replaced with new one. joint interface must be dry and clean. It must be completely free from dirt, rust, The 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. points are marked and drilled for anchoring and holes are flushed with The 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. the pioneer expansion joint units starting at the curb over the sealant. Install Proceed until reaching the field cut piece. Apply the sealant to the ends of the field cut pieces prior to the final placements. will be adjusted with appropriate tightening. Bolt hole cavity may be fi lled with Nuts 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 s well as developing new a products. Test Certificates are issued on request.

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