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Correct procedure for the installation of Bridge Expansion Joints

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  • Types Of Expansion Joints

  • How Expansion Joints Manufacture

  • Installation Procedure Of Strip Seal & Modular Expansion Joints

  • Defects In Expansion Joints

  • Precaution To Be Taken At Site During & After Installation Of Joints

Type of Expansion Joint

Movement (Not Gap)

Popularity

Buried Expansion joint

Upto 10mm

Only for small bridges

Filler Expansion joint

Upto 10mm

Only for small bridges

Asphaltic Plug Expansion Joint

Upto 25mm

Only for small bridge rehabilitation work

Compression seal Expansion joint

Upto 40mm

Shorter life of upto 10years

Slab seal

Upto 80mm

Liable for excessive wear and tear

Strip seal expansion joints

Upto 80mm

Upto 25years , easy to replace seal

Modular Expansion Joints

Each module can take 80mm (above 80 to 2000mm)

Upto 25years , easy to replace seal

Finger Expansion Joint

Above 80mm

Upto 25year, vegetation is openings ,lot of noise,  require regular maintenance

Installation of  Single strip seal Expansion Joint & Modular Expansion Joint

 

Components Of Strip Seal Expansion Joint

STRIP SEAL EXPANSION JOINT T-TYPE LOOP & PLATE, Bridge Expansion Joints DECG

 

Connecting With Splice Plate

 

 

 

 

Components Of Modular Expansion Joint

Modular Expansion Joints

 

Connecting With Splice Plate

 

 

Preparation of the recess/block-out

 

BLOCK-OUT FOR STRIP SEAL EXPANSION JOINT

BLOCK-OUT FOR STRIP SEAL EXPANSION JOINT

BLOCK-OUT FOR MODULAR EXPANSION JOINT

BLOCK-OUT FOR MODULAR EXPANSION JOINT

a) The dimension of block-out  for strip seal must be 650 mm wide & 300 mm

b) The width of block-out for modular joint must be 1100 mm for 2 seal, increase width by 150 mm for every additional seal .Example for 4 seal modular joint the block-out will be 1400 mm.

c) The minimum depth of block-out must be 400 mm better till bottom shuttering .

d) Check the existing structural reinforcement according to the drawings. If it is less add extra reinforcements

1.It is recommended to lay the road surfacing/wearing coat before commencing installation of joint.

2.The Steel Plate / Shuttering / Wood to be used to seal the space between the underside of the joint face of the recess

3.The recess portion shall be filled with sand bag.

Steel Plate for Strip seal expansion joint

Steel Plate for Strip seal expansion joint

 

 

Shuttering for Modular Expansion Joint

Shuttering for Modular Expansion Joint

Filling Sand Bags For Strip Seal Expansion Joint

Filling Sand Bags For Strip Seal Expansion Joint

 

 

Filling Sand Bags For Modular Expansion Joint

Filling Sand Bags For Modular Expansion Joint

 

 

The recess shall be cleaned thoroughly. If necessary, the surface should be roughened. All loose dirt and debris shall be removed by wire brushing, air blowing and dried with hot compressed air or manually if no facility available at site but cleaning must be done thoroughly.

The recess must be thoroughly watered

The recess must be thoroughly watered

Air Blowing

Air Blowing

Clear Block-Out After Cleaning For Strip Seal Expansion Joint

Clear Block-Out After Cleaning For Strip Seal Expansion Joint

Clear Block-Out After Cleaning For Modular Expansion Joint

Clear Block-Out After Cleaning For Modular Expansion Joint

Placing in the recess/block-out

Before placing of expansion joint in the recess, all segments must be joined together at the splicing location provided at the end of the segments by welding / all spice plate but be weld from all sides , no spice plate cut at site.

 

Connecting Segments & Adjusting Gap for Strip Seal Expansion Joint

Connecting Segments & Adjusting Gap for Strip Seal Expansion Joint

Connecting Segments & Adjusting Gap for Modular Expansion Joint

Connecting Segments & Adjusting Gap for Modular Expansion Joint

 

The gap between edge beams / edge and middle beam shall be adjusted at site based on the temperature

Complete Segment Length of Strip Seal Expansion Joint

Complete Segment Length of Strip Seal Expansion Joint

Complete Segment Length of Modular Expansion Joint

 

Lowering the expansion joint into the recess should be done in such a way that the entire length of the joint is evenly lowered into the recess. Thereafter, the

Leveling The Expansion Jointjoint is precisely leveled and adjusted in the longitudinal, transverse and vertical planes.

If required, the joint must also be adjusted to the gradient of the final surface level. As soon as the joint is accurately placed, the engineer in charge shall provide a written confirmation of the correct placement of the same.

Connecting

The preliminary fixing is made by evenly placing then welding of rebars over the entire length between the anchorage and the deck reinforcement.

Connecting Expansion Joint with main Reinforcement

Connecting Expansion Joint With Main Reinforcement

Connected Strip Seal Expansion Joint with main reinforcement

Connected Strip Seal Expansion Joint with Main Reinforcement

Connected Modular Expansion Joint With Main Reinforcement

Concreting

Concreting

 

 

 

 

 

  • Prior to final concreting, the position of the expansion joint must be recorded.
  • Before pouring the concrete the joint construction should be protected by a cover.

Picture1

Form-Work & Covering of Strip Seal Expansion Joint

Form-Work & Covering of Strip Seal Expansion Joint

Form-Work & Covering of Modular Expansion Joint

Form-Work & Covering of Modular Expansion Joint

  • Controlled concrete having strength  ≥  maximum of  ( that in superstructure , M 35) shall be filled into the recess.
  • The water cement ratio ≤ 0.4 & if required admixtures may be used to improve work-ability.

Concreting

conc2

 

 

 

Removing Clamp after 12 to 24 h of Concreting for Strip Seal Expansion Joint

Removing Clamp

Removing Clamp after 12 to 24h of  Concreting for Modular Expansion Joint

Removing Clamp after 12 to 24h of Concreting for Modular Expansion Joint

The filling concrete must

  • Good compaction (properly vibrated)
  • proper curing at-lest 28 days.
  • Don not allow vehicle to move over Expansion joints till curing period of 28 days over , even with any temporary arrangement like putting plates, sandbags etc.

Installation of Neoprene seal

Installing Elastomeric Seal

Installing Elastomeric Seal

 

 

Installing Elastomeric Seal

Installing Elastomeric Seal

 

 

 

 

Don’t join the strip seal

 

Installing Elastomeric Seal

 

 

 

Final Installation of Strip Seal Expansion Joint

Final Installation of Strip Seal Expansion Joint

 

 

Final Installation of Modular Expansion Joint

Final Installation of Modular

 

FAILURE OF EXPANSION JOINTS : REASONS

Reason The joints was installed before laying of wearing coat There is difference in level of edge beam Splice plates not welded at all Lack of curing

Reason

The joints was installed before laying of wearing coat There is difference in level of edge beam Splice plates not welded at all Lack of curing

 

 

Reason Expansion joint failed due to heavy traffic movement

 

Reason

Expansion joint failed due to heavy traffic movement

 

 

Reason Lack of curing The traffic started before complete period of curing

Reason

Expansion joint failed due to vegetation in openings

 

 

Reason Expansion joint failed due to vegetation in openings

Reason

Vegetation there is no traffic movement area

 

 

 

Vegetation there is no traffic movement area

Reason

Vegetation there is no traffic movement area

 

 

 

PRECAUTION TO BE TAKEN AT SITE DURING & AFTER INSTALLATION OF JOINTS

QUALITY CHECKS & Precaution SITE
BASIC QUALITY CHECK before buying Expansion Joints
  • Buy expansion joints from Reputed company only who is having full fledge production and testing facilities, shot blasting is must before primer and painting in factory.
  • The manufacturing must have all type of testing facilities mentioned in IRC specifications SP 69:2011.
  • Check at least 20% Quantity of Edge Beam of expansion Joint without primer & paint at factory so that it can be check whether manufacturer giving Monolithic Edge Beam for strip seal expansion joints
  • Check thickness of paint

Precaution to be taken at site During installation

  • The joints must be kept at least 6inch (150mm) on wooden planks above floor level and under shed till start of installation.
  • The welding rod must of reputed company like Esab , Modi etc , do not use local made welding rod for fabrication at site Expansion joint with deck reinforcement.
  • The expansion joint installation must be under supervision of manufacturer at least 50% Quantity.
  • The concrete must of at least M30 or higher grade, and must be compacted properly.

Precaution to be taken at site After installation

  • The expansion must be cure for at least 28 days
  • No vehicle shall be allowed to run over joints including small trolley for 28Days.
  • The elastomeric strip seal can be install after 48 hours of concreting , and curing must be continue for 28 days.
DECG InternationalCorrect procedure for the installation of Bridge Expansion Joints

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