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MAURER expansion joints

Fitting instructions and check list for engineers

Einb.-Dehnf.englisch.Satz 10/01 20.12.2001 14:22 Uhr Seite 1

2. Recesses and connection of the supporting framework to concrete components

1. Supply

Final assembly of anexpansion joint typeD800 in the workshop

Table of contents:

1. Supply 2. Recesses and connection of

the supporting framework to concrete components

3. Control of gap and installation dimensions

4. Expansion joint assembly 5. Shuttering and concreting 6. Sealing of the construction7. Workmanship at the parapet

cover8. Connections for bridges with

steel carriageways9. Check list

10. Instruction for vulcanization 11. Butt joints 12. Product information: MAURER

modular expansion joints 13. Exchange of damaged parts 14. Further instructions

The expansion joints are supplied to site in one length completelyassembled. For transport, storageand installation transit brackets are provided, to hold together theexpansion joint for installation pur-poses and for shipment to site. Thelifting points for loading and un-loading are marked by colour, thelocation is labelled and the totalweight of each expansion joint is in-dicated on separate appendixes orstickers. The joints have to be storedcarefully on site (e.g. on square tim-bers). Damage and contaminationmust be avoided by means of wellventilated tarpaulins.

The size of the recesses for theexpansion joint construction in the structural concrete on super-structure and abutment side hasto be specified during project planning by using the tables (seebrochures of our girder grid andswivel-joist expansion joints) andaccording to our final structuraldrawings, and must be scheduledbefore construction.

The recess dimensions of the con-struction have to be examined bythe local construction supervisiontogether with our fitter before start-ing the assembly and to be correct-ed if required.

The surfaces of the recesses have to be treated as construction joints.The connection of the supportingframework is to be implementedaccording to specification for re-inforced concrete constructionand/or steel structure. A suitableconnecting reinforcement has to be provided at the recesses.

The anchor loops at the edgebeams of the expansion joint areusually arranged in the longitu--dinal direction of the bridge. Thismeans that the main reinforcementis formed parallel to the anchorloops.

Under the joist boxes a mesh and/or looplike armouring againstsplitting tension must be provided.

For relevant data see our final drawings.

Cross section girder grid expansion joint type D240 joist box

Talbrücke Obere Argen type DS960

bituminous joint

reinforcementto be cut andbent off

lost form looplike reinforcement(closed stirrup)


4. Expansion joint assembly3. Control of gap and installation dimensions

The bridge design engineer deter-mines the temperature-dependentgap and assembly dimensions. Ifthere are no special requirements,the expansion joints are adjusted inthe workshop for a structure tem-perature of +10 °C. The pre-settingalready done in the factory and therelevant expected assembly tem-perature must be registered on theapproved drawings. The dimensionsfor the temperature-dependent pre-settings can be obtained from thetables on the final drawings.

Directly before inserting the expan-sion joint into the recesses the pre-setting must be checked by the con-struction supervision and, if required,readjusted by our fitters . If a cor-rection of the pre-setting becomesnecessary, this has to take place indirection of the angle of movement.A higher structural temperaturerequires a closing, a lower structuraltemperature an opening of the construction. For that purpose the

Insertion of thecomplete expansionjoint into the construction joint

screws of the movable clamps (see:transit clamps) have to be unscrew-ed and then again tightened firmlyafter adjustment.

The gap between ballast wall of theabutment and the outer edge of thesuperstructure has to be controlled.

The construction supervision has tocertify any changes of the assemblydimension to our fitters.

Transit clamp

The expansion joints will be removed from the truck by a crane(lifting apparatus) and insertedinto the construction joint. Accord-ing to indication of the local con-struction supervision the joint islevelled to the required height andassembled parallel to the longitu-dinal and transverse slope of thebridge’s cross section. According to the standard drawing Übe 1 the expansion joint should be lo-cated approx. 5 mm under the re-gular height of the carriageway surfacing. Under no circumstancesmust the top edge of the sealingelement rise above the carriagewaysurfacing.

After the expansion joint has beenaligned in the construction jointand before pouring the concrete,the joist boxes and the anchorloops are welded into the structuralreinforcement as auxiliary support.

After concreting, the connectingscrews of the assembly devices areloosened, so that the expansionjoint can take up the structuralmovement without affecting thesetting procedure of the concrete.

Table to fill-in thegap and assembly dimensions

structuraltemperature

°C

+5

+10

+15

+20

gap dimension e assemblydimension a

these screws must be loosenedand then again tightened foradjusting purposes

Assembly of anexpansion jointconstruction type D80

Expansion joint inthe parapet cover with cable conduit

After our personnel have finishedthe assembly, it must be checkedand accepted by the constructionsupervisor and the completed in-stallation of the expansion jointhas to be certified. (See specialacceptance report).

e a


5. Shuttering and concreting 6. Sealing of the construction

Shuttering and concreting is doneby the construction firm. The re-cesses must be shuttered in such away that the scheduled dimensionsare obtained at the edge beam andthe joist boxes. Attention must bepaid to careful and close shutteringto avoid concrete tearing into thejoist boxes and the joint gap be-tween superstructure and abutment.A sealing drainage (acc. to drawing Was 11) must be assigned for theprevention of banking behind theedge beams.

The recesses must be cleanedcarefully before concreting. Levelsand axial position as well as the correct width of the expansion joint must be checked once again.Concreting the expansion jointrequires the client’s approval. Thelean-mixed concrete must be low-shrink and of even or higher

strength as the structural concrete,at least quality B 35. During con-creting special attention must bepaid to the compression of the con-crete at the anchor plates, underthe base plates of joist boxes andunder the horizontal flange of theedge beams so that a solid bearingof the steel elements to the con-crete is guaranteed and a sufficient composite action is obtained.

The steel and sealing elementsmust be protected during concret-ing or be cleaned with water imme-diately after the concreting proced-ure, so that there is no setting ofconcrete anywhere on the expan-sion joint.

After the setting of concrete thetransit clamps, fastened on theexpansion joint, must be removed.The shuttering in the structural gapbetween superstructure and abut-ment has to be removed and thejoint claw sections located betweenthe steel edge profiles have to becleaned.

Covering of thesealing element

before concreting

Concreting the recesses In order to prevent the penetrationof water between the edge profilesof the expansion joint and the con-crete, the waterproofing has to beattached carefully and according tothe relevant regulations. For perfectconnection a horizontal flange of80 mm in accordance with ZTV-Khas to be provided, which must becleaned carefully before applyingthe isolation. The sealing has to beattached to the expansion joint overthe entire length, i.e. also in themarginal and median strip range.

During the surfacing operation thesteel and sealing elements must be protected against impurities andexcessive heat. A bitumastic filleracc. to the standard drawing Übe 1has to be provided as a connectionto the edge profiles of the expan-sion joint.

The sealing isglued on hot

Gravelling the sealing withquartz sand


7. Workmanship at the parapet cover 9. Check list for the structural planner resp. the inspector

A bitumastic filler has to be provided between the edge profileof the expansion joint and the parapet cover in the marginal andmedian strip range. The joint showsa wedge-shaped design to avoidcavitation. The bitumastic filler onlyallows movements of a few milli-metres between parapet and struc-tural concrete. Constructional design should ensure that largermovements remain impossible.These may occur in particular in acase of loose position without para-pet connection. In such cases thecornice must be connected firmlywith the structural concrete directlybefore the expansion joint in thecarriageway area. If necessary, a secondary joint has to be providedat the parapet cover.

8. Connections at bridges with steel carriageways

Principally three different types exist:

a) Bearing on continuous beams b) Bearing on individual consoles c) Direct connection of supporting

sides of the joist boxes

The design varies with each con-struction and must therefore be de-signed, certified and tested accord-ingly. The technical approval acc. to TL/TP-FÜ 92 is only applicablerestrictively to the superstructuresides.

Assembly is done according to the expansion joint assembly (see par. 4: Expansion joint assembly).First the expansion joint is welded to the steel construction on thesuperstructure side when startingthe assembly.

Direct connection of supporting sides of the joist boxes to steel superstructure

Expansion joints Type of expansion jointDoes a valid technical approval exist?Number and distances of joistsPosition of butt joints and site jointsCorrosion protection acc. to ZTV-KOR or the requirements of the projectCheck geometry of the expansion joint’s cross sections with reference to the standard drawingsAre cover plates required for footways?

Movements Determination and/or check of quantity and direction of movement (DIN 1072, bearing).Within the range stated in the technical approval TL/TP-FÜ 92 the MAURER swivel-joist joint type STP admits structural movements laterally and longitudi-nally to the joint which are independent to each other. Thus a fixing of the direction of movement of the bridge’s end by bearing itself is not required, if the permissible movement is adhered to. Determination and/or check of movements per °C.Determination and/or check of reciprocal displacement of side wall and superstructure’s end when lifting to exchange the bearing acc. to DIN 1072 par. 3.6 and ZTV-K par. 9.1.1.Determination and/or check of possible combinations of movement. Have the permissable movements been obeyed?

Preadjustment State the required installation temperature and the required age of concrete on assembly. Determination and/or check of the expansion joint’s preadjustment for the assembly (dimensions “a” and “e”) for the required installation temperature and the required age of concrete.A change of the preadjustment “e” dependent on the measured structural temperature, necessary? If so, state and/or check the modified dimension of the preadjustment with reference to the structural temperature. If necessary state and/or check the required preadjustment in transversal bridge direction (in direction of the joint).

Recesses Observe the required recess acc. to the technical approval TL/TP-FÜ 92 – 3.3, 3.4 resp. 3.5. or to the approved workshop drawingsAdhere to the recesses for guide and parapet units.If necessary consider changes in the joint gap, dependent on the preadjustment “e”. Are clamping elements or their anchorages located at the edge of the recess? (To be considered in case of exchanging the expansion joints).

Reinforcement Minimum concrete cover 4.5 cm acc. to standard drawing for reinforcement.Position of the reinforcement to the front edge of the joist box. The connection to the existing reinforcement has to be established individually.

Structural edges Flush coatingObserve geometry (shuttering), the joint dimensions, longitudinal and lateral inclination as well as possible angular deviations on the recesses of the carriageway at the end of the bridge.Transmission of anchorage force and kinetic resistance in the structure must always be established individually.Adhere to the permitted movement of the final cross girder (see ZTV-K)Concrete quality (at least B 35 at the recess)Regarding steel bridges the superstructural bearing of the support bars has not been seized by the technical approval. Loadbearing capacity (acc. to DIN 18 809) and fatigue strength (corresponding to DS804) of the relevant elements must always be determined and/or checked individually. Geometry, material and enforcement of the final steel cross girder must be obeyed.

Design of the kerb unit(carriageway – footway)

For further information we

refer to the technical approvalsacc. to TL/TP-FÜ 92

for swivel-joist or girder grid

expansion joints


Scope

This instruction is applicable toMAURER expansion joints withstrip profile 80 made of EPDM. The quality assurance regulationscorrespond to the TL/TP-FÜ.

Normally site joints of the sealingelements have to be avoided. If asite joint becomes necessary fortechnical reasons, it must be execu-ted according to the existing regu-lation. The execution correspondsto the procedural testing in ac-cordance with test certificate GÜ26/96 of the ‘Prüfamt für Bau

10. Instruction for vulcanisation

von Landverkehrswegen’ of theTechnical University of Munich. Thevulcanisation joint has to be ar-ranged staggered to the associatedweld joints of the steel profiles.

Quality assurance

The site joint connection may be done only by specially trained personnel. The execution and eva-luation of the connections are tobe recorded.

1. Profiles to be cut off

rectangularly.

Description of the jobs

2. Roughen cuttingedges by means of awire brush or coarseemery paper.

3. Roughened cuttingedges to be painted with EPDM solution

(article code: 2.1259).

Ensure good ventilation!

Durability of the solution: 3 to 4 weeks.

Check expiry date!

Solution to be securelyclosed and put

into cold storage.

4. Use an extruded non-vulcanised profile, approx. 10 mm thick, as crude rubber

5. Adequately paint crude rubber with

solution (article code:2.1259).

Ensure good ventilation!Crude rubber to be

bonded to a profile end.

6. Put EPDM profileonto vulcanisingcore.

7. Assemble EPDMprofile and put it

into the preheated(100° to 120° C)

vulcanising mould(base part).

10. Put on upperpart of the mould.

11. Close heatingdevice.

9. Control of prestress by deformation of the strip

profile. The maximum deformation lateral to the

profile axis should be 2 to 3 mm.

Important!Pressure is absolutely

necessary for vulcanising.

13. Cooling process:Breaking of circuit.

Cooling to 70° - 80° C.

Open the mould.

Carefully separate andremove profile from the

heating mould.

Let it cool off toambient temperature.

12. Heat mould to160° C.

Starting time for vulcanisation whenreaching a tempera-ture of 160° C.

Duration of vulcanisation: 60 -80 minutes,depending on the ambient tem-perature at site.

The profile may only be installed tothe expansion joint when completelycooled down.

8. Clamp the profiles into tensioning deviceand solidly press the profile ends against each other.


11. Site joints 12. Product information MAURER Modular Expansion Joints

Site joint of the centre beam inthe carriageway

The site joints of the centre beamsin the carriageway are performedaccording to the welding system forcopper jaw sockets.

Site joint of the centre beam out-side of the carriageway

The site joints of the centre beamsoutside of the carriageway are welded at the joint side with sup-porting flange. Welding the otherprofiles is executed by means of fillet and butt welds.

Site joint of the edge beam in thecarriageway

Edge profiles in the carriageway are joined by tacking and weldingthe upper and lower flanges and welding the web. The fronts of thegirder’s top are to be ground flush.

Site joint of the edge beam outside of the carriageway

Edge profiles outside of the car-riageway are joined by tacking and welding the upper and lower flanges and welding the web. Thefronts of the girder’s top are to be ground flush.

For further information regarding the execution of the site joints seethe relevant documents of the tech-nical approval acc. to TL/TP-FÜ 92

MAURER girder grid expansion joints

Flexibly controlled, beared flexiblyand prestressed. This system isapplicable for concrete and steelbridges up to a maximum move-ment of 520 mm.

MAURER swivel joist expansion joints

Flexibly controlled, beared flexiblyand prestressed. Small number ofjoists, clearly static system. Compactbuilding method. Used for largermovements. So far installed formovement up to 2000 mm. Thissystem is applicable for concrete and steel bridges.

For further information see the relevant documents of the techni-cal approval acc. to TL/TP-FÜ 92

Cut A-A

copper jaws(secured bybrackets)

distance holder

centrebeam

without welding seam

without welding seambutt weldV-seam

workshopwelding

site welding

I-seamY-seamto be ground

to be ground

seal weld

withoutV-seamto be ground


14. Further instructions

For further detailed data concern-ing welding proofs, site joints aswell as notes for maintenance, preservation and the exchange of wearing see our technical approv-als according to TL/TP-FÜ 92:

13. Exchange of wearing parts

In case of MAURER modular expansion joints – girder grid expansion joints – swivel joist expansion joints wearing parts such as sliding bearingsand sliding springs as well as controlsprings and sealing elements can bereplaced with simple aids from abovethe carriageway or from beneath thestructural gap.

The bulbous shaped strip seal isfastened waterproof and securedagainst extraction in the claw-shapedcavities of the edge and/or centrebeams without additional clampingstrips. The sealing element is lowerthan the deck level and thus is protected against direct contact withvehicle tires and/or snow plough.

Insertion of thestrip profile intothe edge beam

Replacing the sliding bearingsfrom top of the

carriageway

Replacing the sliding springfrom top of thecarriageway

Disassembly of the centre beam MAURER swivel joist expansion joints

When using open stirrups the centre beam can be disassembledwithout destruction. The stirrups of the carriageway and guide barsmust be aligned parallel at leastfor each section. The guidance eyesof the guide units must be isolatedhalf laterally and welded lateragain. The eyes of the guide unitsmust be separated semi-sided andwelded again subsequently.

disassembly of sealing element, sliding bearings and sliding springs lateral shifting of approx. 150 mm and lifting of the centre beam installation of the new components

Replacing the sliding bearings

from beneath thecarriageway

Replacing the sliding spring from beneath the carriageway

a) girder grid expansion joints b) swivel joist expansion joints

type STP c) swivel joist expansion joints

type STW

centre beam

sliding bearing

sliding springstirrup

Site housing


Maurer Söhne Head Office:P.O. Box 44 01 45, D-80750 MünchenFrankfurter Ring 193, D-80807 MünchenTelephone (49)-(89) 3 23 94-0Fax (49)-(89) 3 23 94-306e-mail [email protected] Internet www.maurer-soehne.de

Maurer Söhne Main Branch Office:P.O. Box 63 40, D-44520 LünenZum Holzplatz 2, D-44536 LünenTelephone (49)-(231) 4 34 01-0Fax (49)-(231) 4 34 01-11

Maurer Söhne Subsidiary Plant:P.O. Box 55, D-02992 BernsdorfKamenzer Str. 4-6, D-02994 BernsdorfTelephone (49)-(3 57 23) 2 37-0Fax (49)-(3 57 23) 2 37-20

BA10

GB·

2000

·10.

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Airport Athens-Spata


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