tunnel expansion joint fire rating and sealing calgary emseal

(YYC) Calgary Airport Trail Tunnel

Alberta

Date: 2013

Calgary Airport Trail Tunnel Gets RWS-Rated Expansion Joints and Tunnel Roof Lining

Calgary Airport Trail Tunnel Gets RWS-Rated Expansion Joints and Tunnel Roof Lining

Calgary, Alberta, Canada — The $294.8 million Airport Trail Tunnel provides access across the city under the Calgary International Airport.

It does so by running partially under the runways and adjacent taxiways. People, and goods and services providers will use the tunnel. Fuel tankers will use the tunnel. What if one exploded?

The RWS time-temperature curve was developed in The Netherlands to simulate this scenario. It remains the standard against which tunnels today seek structural protection under these extreme conditions.

The fireproofing on the the tunnel roof surface is a spray-applied fireproofing material.

Expansion joints through the tunnel roof are a gap in the fireproofing. Restoring the fire-protection across the gaps fell to EMSEAL’s Emshield TFR-RWS rated tunnel joints.

More on the Calgary Trail Tunnel at YouTube

The final run of EMSHIELD DFR3 material provides a continuous RWS-compliant joint filler, capable of handling expected structural movement at the expansion joints.

The finished installation of RWS-compliant Emshield DFR3-RWS in the sprayed-on-fireproofing coated concrete tunnel roof.

The tunnel is 620 Meters long (2,033 FT). The roof was poured in 50 sections.

The tunnel is 620 Meters long (2,033 FT). The roof was poured in 50 sections.

To facilitate winter work, the tunnel entrance was sealed and the tunnel heated with mobile heating units.

To facilitate winter work, the tunnel entrance was sealed and the tunnel heated with mobile heating units.

The work of fireproofing the roof and expansion joints fell to Zerodraft Calgary — a full service firestopping and waterproofing contractor.

The work of fireproofing the roof and expansion joints fell to Zerodraft Calgary — a full service firestopping and waterproofing contractor.

Polystyrene board was installed into the concrete expansion joint openings to act as a form for the fireproofing. Wire mesh reinforcing for the fireproofing was installed over the concrete.

Polystyrene board was installed into the concrete expansion joint openings to act as a form for the fireproofing. Wire mesh reinforcing for the fireproofing was installed over the concrete.

The fireproofing was sprayed over the mesh to cover the tunnel roof up to the forms.

The fireproofing was sprayed over the mesh to cover the tunnel roof up to the forms.

The fireproofing in progress on both sides of the formed joint opening.

The fireproofing in progress on both sides of the formed joint opening.

The fireproofing was troweled to achieve the desired finish and compaction.

The fireproofing was troweled to achieve the desired finish and compaction.

Once the fireproofing was properly cured, the polystyrene forms were removed leaving a joint gap in the fireproofing equal in width to the joint in concrete tunnel roof.

Once the fireproofing was properly cured, the polystyrene forms were removed leaving a joint gap in the fireproofing equal in width to the joint in concrete tunnel roof.

The joint faces were wiped with clean, lint-free rags and acetone solvent to remove any dust or fines.

The joint faces were wiped with clean, lint-free rags and acetone solvent to remove any dust or fines.

The EMSHIELD DFR3 was supplied in standard, straight, 2M, lengths as well as in custom curved lengths.

The Emshield DFR3 was supplied in standard, straight, 2M, lengths as well as in custom curved lengths. The material is pre-compressed to less than the joint size for ease of installation. After removal from the shrink-wrap and hardboard packaging, the material slowly expands into a wet epoxy adhesive to seal the joint opening.

The curved corner pieces were factory-fabricated to match the radii on the inner and outer sides of the tunnel roof to wall transition.

The curved corner pieces were factory-fabricated to match the radii on the inner and outer sides of the tunnel roof to wall transition. Continuity of seal is a hallmark of EMSEAL’s approach to joint sealing and fire protection. Universal and custom transition and termination pieces are available from EMSEAL to address all change in plane and direction conditions.

Material, accessories and tools needed for each section were loaded onto utility lifts.

Material, accessories and tools needed for each section were loaded onto utility lifts.

The EMSEAL-supplied, two-part, epoxy is opened and mixed.

The EMSEAL-supplied, two-part, epoxy is opened and mixed.

The EMSEAL-supplied epoxy is hand-troweled onto the concrete and fireproofing joint faces.

The EMSEAL-supplied epoxy is hand-troweled onto the concrete and fireproofing joint faces.

The starting piece, a custom-fabricated curve, is verified against field conditions and checked for length and fit.

The starting piece, a custom-fabricated curve, is verified against field conditions and checked for length and fit.

The starting piece is cut to length while still in the restraining shrink-wrap and hardboard packaging.

The starting piece is cut to length while still in the restraining shrink-wrap and hardboard packaging.

The starting curve installed into the joint. Note the intumescent joining caulk on the face of the DFR foam in anticipation of the next length of material.

The starting curve installed into the joint. Note the intumescent joining caulk on the face of the DFR foam in anticipation of the next length of material.

Straight lengths of DFR material are installed and joined to previous lengths. Each join is made using EMSEAL-supplied intumescent caulk to join the foam, and EMSEAL-supplied silicone to join the silicone bellows.

Straight lengths of DFR material are installed and joined to previous lengths. Each join is made using EMSEAL-supplied intumescent caulk to join the foam, and EMSEAL-supplied silicone to join the silicone bellows.

The final run of EMSHIELD DFR3 material provides a continuous RWS-compliant joint filler, capable of handling expected structural movement at the expansion joints.

The final run of EMSHIELD DFR3 material provides a continuous RWS-compliant joint filler, capable of handling expected structural movement at the expansion joints.

A finishing band of injected liquid silicone seals the silicone bellows to the fireproofing substrate.

A finishing band of injected liquid silicone seals the silicone bellows to the fireproofing substrate.

The silicone sealant is tooled into a corner bead to finish the installation.

The silicone sealant is tooled into a corner bead to finish the installation.

EMSEAL contributes to the preservation, durability and sustainability of the built environment.

We do so by delivering high value, lowest total cost of ownership, structural expansion joints and pre-compressed sealants that work.

Lasting, expansion joint solutions in airport, mixed-use, retail, office, sports, assembly, convention, casino, resort, healthcare and performing arts venues as well as in retrofit of existing structures is a central focus of EMSEAL’s.

The company’s unique approach to expansion joint treatment combines innovative materials technologies with a fresh look at the roles of owners, designers, general contractors, manufacturers and subcontractors, to achieve trouble-free expansion joints.

The approach is grounded in an integrated, collaborative process centered on joint treatment that requires all of these parties to think, design, detail, specify, construct, fabricate, and install three-dimensional solutions.