Bridge Bearings

and Expansion Joints

CCL Bridge Bearings

CCL Bridge Bearings

CCL bearings are widely used in structural, marine and civil engineering applications, and particularly bridges, to transfer vertical forces from one structural member to another. They are also required to restrict or permit linear or rotational movement in the horizontal plane. Where horizontal movement is restricted the horizontal forces will be transferred through the bearing to the lower structure. Bearings are available in carbon steel as standard, and in stainless steel for applications where corrosion is a potential problem or life cycle costing benefits are sought. As standard CCL bearings are designed to meet the requirements of BS 5400 : Section 9.1 and 9.2: 1983 Design Due to the complexity of bridge bearing design CCL provide technical assistance on the selection of the most appropriate bearings. Our technical staff will be pleased to discuss individual applications. In order to facilitate the design process relevant information should wherever possible be supplied in accordance with BS5400 section 9.1 table 9. Special Bearings CCL can also manufacture bearings to suit loadings, rotational and movement requirements outside the scope of the standard range. These can include factors such as uplift, environmental conditions, seismic effects and temporary constructional requirements. Testing CCL has well equipped in-house facilities, which are regularly used for testing bearings. In-house testing is carried out in accordance with BS 5400: Section 9.2: 1983 and BS EN ISO 9001: 1994. Our compression test frame is one of the largest in the UK. An imposed rotation of the bearing can be accommodated when this is required. Tests can be observed by independent witnesses when this is required.

Selection of Bearings

Selection of Bearings
There are many factors to be considered before the most appropriate arrangement of bearings can be determined for a particular application. The table below provides an overall indication of the features of each type of bearing.
Direction of Force
Bearing Type Fixed Pot Free Sliding Pot Guided Sliding Pot Fixed Pin Uniguide Laminated Elastomeric Plain Pad & Strip Vertical Longitudinal Transverse

Rotation Permitted
Longitudinal Transverse

Movement Permitted
Longitudinal Transverse

Key

Suitable Not suitable Limited Indicates that either Longitudinal or Transverse loads/movements can be permitted, not both.

Mechanical Pot Bearings Mechanical pot bearings are available in three types; fixed, guided sliding and free sliding, and in a variety of capacities. All three types allow rotation. Fixed bearings provide restraint in all horizontal directions. Guided bearings allow movement in one horizontal direction and provide restraint in the other direction. Free Sliding bearings allow movement in all horizontal directions. Fixed Pin or Removable Dowel Bearings The Fixed Pin bearing provides restraint in all horizontal directions and can be used with Laminated Elastomeric bearings, the Elastomeric bearing supporting the vertical load and the Fixed Pin bearing taking the horizontal loads. Uniguide or Shear Key Bearings Uniguide bearings can be used at the opposite end to Fixed Pin bearings to allow expansion from the fixed end, but provide restraint in the other direction. Uniguide bearings can be used in conjunction with Laminated Elastomeric bearings, the Elastomeric bearings supporting the vertical load, the Uniguide bearing taking the lateral horizontal load. Laminated Elastomeric Bearings Laminated Elastomeric bearings allow horizontal movement by shear deflection, and allow rotation by angular deformation. Where horizontal movement needs to be controlled or large horizontal loads resisted, Laminated Elastomeric bearings should be used in conjunction with Fixed Pin or Uniguide bearings. If required laminated elastomeric bearings can be fitted with a vulcanised PTFE sheet and slider plate to accommodate large translations. Plain Pad and Strip Bearings Un-reinforced elastomeric pads and strips are used where low loads and small movements are expected. They are the simplest type of bearing, readily available and easy to install.

2 3

Arrangement of Bearings

Arrangement of Bearings
Mechanical Pot Bearings Elastomeric, Fixed Pin & Uniguide Bearings

Fixed Pot Bearing All translations are fixed, rotation possible Guided Sliding Bearing Horizontal movement in one direction, rotation possible. Free Sliding Bearing Horizontal movement in all directions, rotation possible. Elastomeric Bearing Rotation and movement possible in all directions. Uniguide Bearing Movement allowed in one direction only, no vertical load. Fixed Pin Bearing All translations are fixed, rotation possible, no vertical load. 4

PF Fixed Pot Bearing

PF Fixed Pot Bearing

Fixed bearings carry vertical load whilst providing restraint in all horizontal directions. There are three types of mechanical pot bearings, all of which are available in a range of capacities and sizes. Each type utilises a piston, rubber disc and pot base, with variations to suit.

The projecting piston of the top plate is fully retained by the metal pot of the bottom plate to provide full restraint in the horizontal plane. The deformation of the elastomeric disc allows multi-directional rotation to take place.
f h

Top Plate a Seal Elastomeric Disc Pot Base d b

PF Fixed Pot Bearing

Indicative Table of Dimensions
PF 50 SLS Permanent Vertical Load (kN) SLS Total Vertical Load (kN) SLS Horizontal Load (kN) ULS Vertical Load (kN) ULS Horizontal Load (kN) Overall Height a Base Length and Width b Base Bolt Ctrs (Square) d Top Plate Length and Width f Top Bolt Ctrs (Square) h Bolt Size 330 500 110 650 140 54 180 145 180 145 M12 PF100 670 1000 210 1300 270 71 245 200 245 200 M16 PF150 1000 1500 225 2000 300 84 300 255 300 255 M16 PF200 1330 2000 255 2660 330 89 350 305 350 305 M16 PF250 1660 2500 350 3330 470 103 385 320 385 320 M20 PF300 2000 3000 380 4000 500 115 415 360 415 360 M20 PF400 2670 4000 545 5330 710 131 485 420 485 420 M24 PF500 3330 5000 810 6500 1050 140 545 460 545 460 M30 PF750 PF1000 PF1500 PF2000 5000 7500 930 9750 1200 166 670 590 670 590 M30 6660 10000 1300 13000 1690 202 770 675 770 675 M36 10000 15000 1850 19500 2400 247 940 830 940 830 M42 13330 20000 2100 26000 2700 282 1085 975 1085 975 M42

Assumptions: 1. Minimum load is at least 20% of total load 2. 30% of minimum load is used as frictional resistance to horizontal load 3. Total rotations are up to 0.015 rads 4. Lower and upper seating pressures approach 20N/mm2 at SLS 5. Lower and upper seating pressures approach 30N/mm2 at ULS 6. 25mm mortar under base. 5

PS Free Sliding Pot Bearing

PS Free Sliding Pot Bearing

Free sliding bearings carry vertical loads whilst allowing horizontal movement and rotation in all directions. Within the base plate a rocker is fully retained in the pot. This rocker has a lubricated, dimpled PTFE disc, which slides against the stainless steel plate. The high quality, polished stainless steel plate is fitted to the machined top plate allowing free horizontal movement between the two sections of the bearing. The deformation of the elastomeric disc under the rocker plate allows multi-directional rotation to take place.
g/f h/j Top Plate Stainless Steel Slider PTFE Disc Rocker Plate Seal Elastomeric Disc d b Pot Base

PS Free Sliding Bearing

Indicative Table of Dimensions
PS 50 SLS Permanent Vertical Load (kN) SLS Total Vertical Load (kN) ULS Vertical Load (kN) Overall Height a Base Length and Width b Base Bolt Ctrs (Square) d Top Plate Length f Top Plate Width g Top Plate Bolt Ctrs longitudinally h Top Plate Bolt Ctrs Transversely j Bolt Size 330 500 650 62 180 145 210 290 175 255 M12 PS100 670 1000 1300 85 245 200 260 370 215 325 M16 PS150 1000 1500 2000 95 300 255 300 425 250 380 M16 PS200 1330 2000 2660 101 350 305 335 475 290 430 M16 PS250 1660 2500 3330 113 385 330 365 530 310 475 M20 PS300 2000 3000 4000 128 415 360 385 560 330 505 M20 PS400 2670 4000 5330 144 485 430 440 630 375 575 M20 PS500 3330 5000 6500 158 550 470 480 700 425 645 M20 PS750 PS1000 PS1500 PS2000 5000 7500 9750 190 665 600 570 825 505 760 M24 6660 10000 13000 208 775 650 720 960 640 880 M30 10000 15000 19500 253 940 840 890 1160 790 1060 M36 13330 20000 26000 296 1190 995 960 1300 865 1205 M36

Assumptions: 1. Minimum load is at least 20% of total load 2. Total rotations are up to 0.015 rads 3. Lower and upper seating pressures approach 20N/mm2 at SLS 4. Lower and upper seating pressures approach 30/mm2 at ULS 5. 25mm mortar under base. 6. Movements +/- 25mm SLS. 6

PG Guided Sliding Pot Bearing

PG Guided Sliding Pot Bearing

Guided sliding bearings carry vertical loads whilst allowing movement in one direction and providing restraint perpendicular to this movement. They also allow rotation in all directions. Within the base plate a rocker is fully retained in the pot. This rocker has a lubricated, dimpled PTFE disc, which slides against the stainless steel plate. The high quality, polished stainless steel plate is fitted to the machined top plate between two guide rails, which resist the horizontal load in one direction. Horizontal movement occurs along the length of the guide rails. The deformation of the elastomeric disc under the rocker plate allows multi-directional rotation to take place.
g/f h/j Top Plate Stainless Steel Slider PTFE Disc Guide Bar Rocker Plate Seal d b Elastomeric Disc Pot Base

PG Guided Sliding Pot Bearing

Indicative Table of Dimensions
PG50 SLS Permanent Vertical Load (kN) SLS Total Vertical Load (kN) SLS Horizontal Load (kN) ULS Vertical Load (kN) ULS Horizontal Load (kN) Overall Height a Base Length and Width b Base Bolt Ctrs (Square) d Top Plate Length f Top Plate Width g Top Plate Bolt Ctrs Longitudinally h Top Plate Bolt Ctrs Transversely j Bolt Size 330 500 100 650 130 100 180 145 225 315 190 280 M12 PG100 660 1000 200 1300 250 114 245 200 275 380 230 335 M16 PG150 1000 1500 220 2000 280 122 300 255 315 415 270 370 M16 PG200 1330 2000 240 2660 310 134 350 305 350 470 305 425 M16 PG250 1660 2500 350 3330 440 149 385 330 380 515 325 460 M20 PG300 PG400 2000 3000 380 4000 475 159 415 360 410 545 355 490 M20 2670 4000 510 5330 670 175 485 420 460 615 395 550 M24 PG500 3330 5000 610 6500 790 89 545 460 500 690 420 610 M30 PG750 PG1000 PG1500 PG2000 5000 7500 890 9750 1120 227 670 590 600 810 520 730 M30 6660 10000 1350 13000 1580 270 770 675 720 935 625 840 M36 10000 15000 1700 19500 2200 306 940 830 900 1140 790 1030 M42 1333 20000 2100 26000 2550 360 1085 975 1000 1280 890 1170 M42

Assumptions: 1. Minimum load is at least 20% of total load 2. 30% of minimum load is used as frictional resistance to horizontal load 3. Total rotations are up to 0.015 rads 4. Lower and upper seating pressures approach 20N/mm2 at SLS 5. Lower and upper seating pressures approach 30N/mm2 at ULS 6. 25mm mortar under base. 7. Movements +/- 25mm SLS. 7

FP Fixed Pin Bearing

FP Fixed Pin Bearing

The Fixed Pin bearing has a central pin located in the base plate. The top plate of the bearing is recessed to accept the pin and will provide restraint in all horizontal directions. Fixed Pin bearings will not transfer any vertical load. The vertical load would generally be taken by Laminated Elastomeric bearings positioned each side of the Fixed Pin bearing. In situations where space is restricted the bolting of the top plate can prove difficult. Uniguide and Fixed Pin bearings can be supplied with an optional tang plate to overcome this problem. This provides a permanent anchor for the bearing within the concrete.

b d Top Plate Silicone Seal Base Plate Centre Pin e c

FP Fixed Pin Bearing

Indicative Table of Dimensions
FP25 SLS Horizontal Load (kN) ULS Horizontal Load (kN) Overall Height a Top Plate & Base Plate Width b Top Plate & Base Plate Length c Top & Base Plate Bolt Ctrs - Transversely d Top & Base Plate Bolt Ctrs Longitudinally e Bolt Size No. of Bolts (Top & Base) 250 350 90 175 285 110 220 M24 4 FP50 500 700 120 245 425 150 330 M36 4 FP75 750 1050 140 310 530 200 420 M42 4 FP100 1000 1300 140 390 610 280 480 M42 4 FP125 1250 1565 150 450 650 340 540 M42 6 FP150 1500 2100 160 530 730 420 620 M42 6 FP200 2000 2800 170 670 890 560 770 M42 10

UG Uniguide Bearings

UG Uniguide Bearings
Uniguide bearings allow movement in one direction to allow expansion from the fixed end, but provide restraint in the oposite direction.

The Uniguide bearing has a central guide bar recessed into the top plate. This guide bar is located between two other guide bars recessed into the bottom plate.

Uniguide bearings will not transfer any vertical load. Laminated Elastomeric bearings would usually be positioned each side of the Uniguide to take the vertical load.
f/g j/h Top Plate Guide Bar Shear Key Base Plate e/d c/b

UG Uniguide Bearings
Indicative Table of Dimensions
UG200 UG300 UG400 UG500 UG750 UG1000 UG1500 UG1500 SLS Horizontal Load (kN) ULS Horizontal Load (kN) Overall Height a Base Plate Length b Base Plate Width c Base Plate Bolt Ctrs - Longitudinally d Base Plate Bolt Ctrs - Transversely e Top Plate Length f Top Plate Width g Top Plate Bolt Ctrs Longitudinally h Top Plate Bolt Ctrs Transversely j Top Bolt Size Base Bolt Size Clearance m 200 280 110 180 255 80 200 325 255 270 200 M20 M20 8 300 415 120 255 270 90 205 350 270 285 205 M24 M24 10 400 560 140 280 330 100 250 420 330 340 250 M30 M30 10 500 700 158 320 360 120 280 440 360 360 280 M30 M30 10 750 1030 185 350 470 130 375 495 470 400 375 M36 M36 10 1000 1400 220 400 560 140 450 550 560 440 450 M42 M42 10 1500 2100 239 510 560 400 450 600 750 490 640 M42* M42* 12 2000 2800 249 670 560 560 450 760 750 650 640 M42** M42** 12

Assumptions: 1. Movements are +/- 25mm SLS and +/- 40mm ULS * 6 Bolts ** 8 Bolts 9

Stainless Steel Bearings

Stainless Steel Bearings

For applications where corrosion is a potential problem, bearings can be designed and manufactured in the appropriate grade of stainless steel to ensure that both performance and corrosion resistance criteria are met. Stainless steel has been used by the construction and civil engineering industries for over fifty years. Its use continues to increase rapidly as the benefits of stainless steel over more traditional materials have become more widely recognised. Stainless steel offers many advantages to the specifier: Excellent corrosion resistance Life cycle costing benefits Resistance to unsightly staining High ductility and strength Excellent high and low temperature properties Non-magnetic

Material Specification There are many grades of stainless steel. The grade used in the manufacture of CCL Bridge Bearings is usually 316. This is recommended for highly corrosive areas such as marine locations or heavily polluted industrial environments.

Custom Bearings In addition to the standard range of mechanical bearings, CCL designs and manufactures bearings to suit loadings, movement requirements or space limitations which are outside the scope of the standard range.

CTRL 430 Courtesy of Rail Link Engineering 10

Elastomeric Bearings

Elastomeric Bearings
CCL Stressing Systems has been supplying a comprehensive range of Elastomeric Bridge Bearings for both the UK and overseas markets for many years.

The range of bearings includes elastomeric plain pad & strip bearings and laminated bearings which are currently utilised on hundreds of structures such as road and motorway bridges, water reservoirs and more recently for pre-stressed concrete pressure vessels at nuclear power stations.

Rubber Laminations Steel Plates

CCL Elastomeric Bearings are usually designed and manufactured to British Standard BS 5400: Part 9 :1983 and if required, calculations can be prepared to take into account the Department of Transport requirements listed under their Departmental Standard BD20/92. The basis of an elastomeric bearing is a natural rubber pad to which steel plates are vulcanised on both sides. The bearing can be built up by adding a number of steel and rubber layers, this number being limited by considerations of stability. The resulting bearing is then enclosed by a rubber outer layer, which increases the bearings resistance to ageing caused by external influences, in particular, ozone. CCL standard bearings have natural rubber laminates in thicknesses of 5, 8 and 11 mm and steel plates in thicknesses of 2, 3 and 4mm. Other thicknesses of rubber laminations & steel plates can be produced by manufacture of a new mould. If required, CCL Stressing Systems can design and manufacture special bearings. These could involve using a different rubber hardness, chloroprene as opposed to natural rubber, or non standard sizes which can be produced by manufacture of a new mould. For details of CCL Stressing Systems full range of bearings please contact the CCL Design department. For additional data or special requirements please do not hesitate to contact our Design Engineers. Details of testing facilities, charges and cost of certification are available on request from CCL Stressing Systems.

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Elastomeric Bearing Codes

Elastomeric Bearing Codes

2520-04-08ENR3

a a= b= c= d= e= Overall length in centimetres Overall breadth in centimetres Number of rubber laminations

Thickness of individual rubber laminations in millimetres Grade and Type of rubber.

f= Thickness of steel plate in millimetres standard sizes 2,3 and 4mm Note: The number of plates = the number of laminates + 1 Top and bottom cover thickness = 2.5mm Side cover thickness = 4.5mm

To calculate the total thickness of the bearing: T = Top and bottom cover thickness + total thickness of rubber laminations + total thickness of plates

Example: Bearing reference 2520-04-08ENR3 Number of rubber laminations = 4 Thickness of laminations = 8mm Number of plates = 4+1 = 5 Thickness of plate = 3mm T = (2.5 + 2.5) + (4 x 8) + (5 x 3) = 52mm

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Elastomeric Bearing Range

Elastomeric Bearing Range

Zero Shear No Rotation Max. Shear With Zero Rotation Zero Shear With Rotation Maximum Shear With Rotation Rotational Capacity (Rads) 0.0090 0.0167 0.0240 0.0309 0.0083 0.0153 0.0219 0.0281 0.0338 0.0080 0.0146 0.0208 0.0266 0.0038 0.0070 0.0102 0.0132 0.0161 0.0189 0.0080 0.0153 0.0222 0.0287 0.0347 0.0048 0.0093 0.0135 0.0176 0.0216 0.0047 0.0090a 0.0131 0.0170 0.0208 0.0032 0.0061 0.0089 0.0117 0.0144 0.0170 0.0195 0.0031 0.0059 0.0086 0.0112 0.0137 0.0162 0.0186 0.0022 0.0043 0.0063 0.0083 0.0102 0.0120 0.0139 0.0156 0.0029 0.0057 0.0083 0.0109 0.0135 0.0159 0.0183 0.0023 0.0045 0.0066 0.0086 0.0106 0.0126 0.0145 0.0164 0.0019 0.0036 0.0053 0.0070 0.0086 0.0102 0.0117 0.0133 0.0148 Plan Bearing Reference Dimension (mm) 1010-01-05ENR2 1010-02-05ENR2 1010-03-05ENR2 1010-04-05ENR2 1510-01-05ENR2 1510-02-05ENR2 1510-03-05ENR2 1510-04-05ENR2 1510-05-05ENR2 2010-01-05ENR2 2010-02-05ENR2 2010-03-05ENR2 2010-04-05ENR2 2015-01-05ENR2 2015-02-05ENR2 2015-03-05ENR2 2015-04-05ENR2 2015-05-05ENR2 2015-06-05ENR2 2515-01-08ENR3 2515-02-08ENR3 2515-03-08ENR3 2515-04-08ENR3 2515-05-08ENR3 2520-01-08ENR3 2520-02-08ENR3 2520-03-08ENR3 2520-04-08ENR3 2520-05-08ENR3 3020-01-08ENR3 3020-02-08ENR3 3020-03-08ENR3 3020-04-08ENR3 3020-05-08ENR3 3025-01-08ENR3 3025-02-08ENR3 3025-03-08ENR3 3025-04-08ENR3 3025-05-08ENR3 3025-06-08ENR3 3025-07-08ENR3 4025-01-08ENR3 4025-02-08ENR3 4025-03-08ENR3 4025-04-08ENR3 4025-05-08ENR3 4025-06-08ENR3 4025-07-08ENR3 4030-01-08ENR3 4030-02-08ENR3 4030-03-08ENR3 4030-04-08ENR3 4030-05-08ENR3 4030-06-08ENR3 4030-07-08ENR3 4030-08-08ENR3 4535-01-11ENR4 4535-02-11ENR4 4535-03-11ENR4 4535-04-11ENR4 4535-05-11ENR4 4535-06-11ENR4 4535-07-11ENR4 5040-01-11ENR4 5040-02-11ENR4 5040-03-11ENR4 5040-04-11ENR4 5040-05-11ENR4 5040-06-11ENR4 5040-07-11ENR4 5040-08-11ENR4 6045-01-11ENR4 6045-02-11ENR4 6045-03-11ENR4 6045-04-11ENR4 6045-05-11ENR4 6045-06-11ENR4 6045-07-11ENR4 6045-08-11ENR4 6045-09-11ENR4 100 x 100 100 x 100 100 x 100 100 x 100 150 x 100 150 x 100 150 x 100 150 x 100 150 x 100 200 x 100 200 x 100 200 x 100 200 x 100 200 x 150 200 x 150 200 x 150 200 x 150 200 x 150 200 x 150 250 x 150 250 x 150 250 x 150 250 x 150 250 x 150 250 x 200 250 x 200 250 x 200 250 x 200 250 x 200 300 x 200 300 x 200 300 x 200 300 x 200 300 x 200 300 x 250 300 x 250 300 x 250 300 x 250 300 x 250 300 x 250 300 x 250 400 x 250 400 x 250 400 x 250 400 x 250 400 x 250 400 x 250 400 x 250 400 x 300 400 x 300 400 x 300 400 x 300 400 x 300 400 x 300 400 x 300 400 x 300 450 x 350 450 x 350 450 x 350 450 x 350 450 x 350 450 x 350 450 x 350 500 x 400 500 x 400 500 x 400 500 x 400 500 x 400 500 x 400 500 x 400 500 x 400 600 x 450 600 x 450 600 x 450 600 x 450 600 x 450 600 x 450 600 x 450 600 x 450 600 x 450 Height (mm 14 21 28 35 14 21 28 35 42 14 21 28 35 14 21 28 35 42 49 19 30 41 52 63 19 30 41 52 63 19 30 41 52 63 19 30 41 52 63 74 85 19 30 41 52 63 74 85 19 30 41 52 63 74 85 96 24 39 54 69 84 99 114 24 39 54 69 84 99 114 129 24 39 54 69 84 99 114 129 144 Weight (kg) 0.38 0.57 0.76 0.95 0.58 0.87 1.16 1.45 1.73 0.78 1.17 1.56 1.95 1.19 1.78 2.38 2.97 3.57 4.16 2.16 3.30 4.45 5.59 6.73 2.91 4.45 5.99 7.52 9.06 3.50 5.36 7.21 9.06 10.92 4.41 6.74 9.07 11.40 13.72 16.05 18.38 5.90 9.03 12.15 15.27 18.39 21.51 24.63 7.11 10.87 14.63 18.39 22.15 25.91 29.67 33.42 12.27 18.93 25.60 32.26 38.93 45.59 52.26 15.64 24.13 32.61 41.10 49.59 58.08 66.57 75.06 21.19 32.69 44.19 55.69 67.19 78.69 90.19 101.69 113.19 Kc (kN/mm) 115 65 45 34 255 144 100 77 62 418 237 165 127 1032 592 415 320 260 219 503 263 178 135 108 939 494 335 254 204 1298 686 466 353 284 2045 1088 741 562 452 379 326 3339 1788 1221 927 747 626 538 4771 2574 1763 1340 1081 906 780 684 3691 1922 1299 981 789 659 566 5721 2998 2032 1536 1235 1033 887 778 9658 5107 3471 2629 2116 1770 1522 1334 1188 Ks (kN/mm) 0.90 0.60 0.45 0.36 1.35 0.90 0.68 0.54 0.45 1.80 1.20 0.90 0.72 2.70 1.80 1.35 1.08 0.90 0.77 2.60 1.61 1.16 0.91 0.75 3.46 2.14 1.55 1.22 1.00 4.15 2.57 1.86 1.46 1.20 5.19 3.21 2.33 1.82 1.50 1.27 1.11 6.92 4.29 3.10 2.43 2.00 1.70 1.48 8.31 5.14 3.72 2.92 2.40 2.04 1.77 1.57 8.86 5.25 3.73 2.89 2.36 2.00 1.73 11.25 6.67 4.74 3.67 3.00 2.54 2.20 1.94 15.19 9.00 6.39 4.96 4.05 3.42 2.96 2.61 2.34 Max. Shear Max. Shear SLS SLS Vertical Movement- Movement- SLS Vertical Vertical Located Unlocated Load (kN) Load (kN) Load (kN) (mm) (mm) 90 90 90 82 170 170 170 154 129 257 257 257 233 524 524 524 524 524 524 453 453 453 431 355 735 735 735 735 735 961 961 961 961 961 1386 1386 1386 1386 1386 1386 1369 2107 2107 2107 2107 2107 2107 2081 2847 2847 2847 2847 2847 2847 2847 2847 3155 3155 3155 3155 3155 3155 3155 4559 4559 4559 4559 4559 4559 4559 4559 7181 7181 7181 7181 7181 7181 7181 7181 7181 3.5 7.0 10.5 14.0 3.5 7.0 10.5 14.0 17.5 3.5 7.0 10.5 14.0 3.5 7.0 10.5 14.0 17.5 21.0 5.6 11.2 16.8 22.4 28.0 5.6 11.2 16.8 22.4 28.0 5.6 11.2 16.8 22.4 28.0 5.6 11.2 16.8 22.4 28.0 33.6 39.2 5.6 11.2 16.8 22.4 28.0 33.6 39.2 5.6 11.2 16.8 22.4 28.0 33.6 39.2 44.8 7.7 15.4 23.1 30.8 38.5 46.2 53.9 7.7 15.4 23.1 30.8 38.5 46.2 53.9 61.6 7.7 15.4 23.1 30.8 38.5 46.2 53.9 61.6 69.3 7.0 10.5 14.0 17.5 7.0 10.5 14.0 17.5 21.0 7.0 10.5 14.0 17.5 7.0 10.5 14.0 17.5 21.0 24.5 9.1 14.7 20.3 25.9 31.5 9.1 14.7 20.3 25.9 31.5 9.1 14.7 20.3 25.9 31.5 9.1 14.7 20.3 25.9 31.5 37.1 42.7 9.1 14.7 20.3 25.9 31.5 37.1 42.7 9.1 14.7 20.3 25.9 31.5 37.1 42.7 48.3 11.2 18.9 26.6 34.3 42.0 49.7 57.4 11.2 18.9 26.6 34.3 42.0 49.7 57.4 65.1 11.2 18.9 26.6 34.3 42.0 49.7 57.4 65.1 72.8 68 65 63 60 129 124 118 113 99 195 187 179 171 411 400 389 378 368 357 349 335 320 305 275 578 560 542 524 506 755 732 708 685 662 1100 1074 1047 1021 994 967 941 1673 1632 1592 1551 1511 1471 1430 2275 2230 2185 2140 2094 2049 2004 1959 2517 2458 2399 2340 2282 2223 2164 3653 3579 3505 3430 3356 3282 3208 3134 5773 5670 5566 5463 5359 5256 5152 5049 4946 39 42 43 43 81 86 88 89 89 128 136 139 140 229 247 253 257 259 260 239 244 246 247 247 358 368 371 373 374 482 495 500 502 503 646 667 674 678 680 681 682 1020 1055 1067 1074 1077 1080 1082 1284 1337 1355 1365 1370 1374 1377 1379 1515 1546 1557 1562 1566 1568 1569 2114 2166 2184 2193 2199 2202 2205 2207 3240 3337 3371 3388 3399 3405 3410 3414 3417 Max. Shear Max. Shear SLS Rotational Movement Movement- Vertical Capacity -Located Unlocated Load (kN) (Rads) (mm (mm) 0.0113 0.0215 0.0316 0.0417 0.0105 0.0198 0.0290 0.0383 0.0475 0.0101 0.0189 0.0277 0.0365 0.0047 0.0089 0.0130 0.0171 0.0212 0.0253 0.0101 0.0198 0.0294 0.0390 0.0486 0.0060 0.0117 0.0174 0.0231 0.0287 0.0058 0.0113 0.0168 0.0223 0.0278 0.0039 0.0076 0.0113 0.0150 0.0187 0.0224 0.0261 0.0038 0.0073 0.0109 0.0144 0.0179 0.0215 0.0250 0.0028 0.0053 0.0079 0.0105 0.0131 0.0156 0.0182 0.0208 0.0036 0.0071 0.0105 0.0140 0.0175 0.0209 0.0244 0.0028 0.0055 0.0082 0.0109 0.0137 0.0164 0.0191 0.0218 0.0023 0.0044 0.0066 0.0088 0.0109 0.0131 0.0152 0.0174 0.0196 3.5 7.0 10.5 14.0 3.5 7.0 10.5 14.0 17.5 3.5 7.0 10.5 14.0 3.5 7.0 10.5 14.0 17.5 21.0 5.6 11.2 16.8 22.4 28.0 5.6 11.2 16.8 22.4 28.0 5.6 11.2 16.8 22.4 28.0 5.6 11.2 16.8 22.4 28.0 33.6 39.2 5.6 11.2 16.8 22.4 28.0 33.6 39.2 5.6 11.2 16.8 22.4 28.0 33.6 39.2 44.8 7.7 15.4 23.1 30.8 38.5 46.2 53.9 7.7 15.4 23.1 30.8 38.5 46.2 53.9 61.6 7.7 15.4 23.1 30.8 38.5 46.2 53.9 61.6 69.3 7.0 10.5 14.0 17.5 7.0 10.5 14.0 17.5 21.0 7.0 10.5 14.0 17.5 7.0 10.5 14.0 17.5 21.0 24.5 9.1 14.7 20.3 25.9 31.5 9.1 14.7 20.3 25.9 31.5 9.1 14.7 20.3 25.9 31.5 9.1 14.7 20.3 25.9 31.5 37.1 42.7 9.1 14.7 20.3 25.9 31.5 37.1 42.7 9.1 14.7 20.3 25.9 31.5 37.1 42.7 48.3 11.2 18.9 26.6 34.3 42.0 49.7 57.4 11.2 18.9 26.6 34.3 42.0 49.7 57.4 65.1 11.2 18.9 26.6 34.3 42.0 49.7 57.4 65.1 72.8 31 32 32 32 64 66 66 65 64 101 105 104 102 185 196 198 198 196 194 190 190 186 181 176 289 291 289 285 280 388 392 388 383 376 523 533 532 528 522 516 509 826 843 841 834 825 815 804 1045 1076 1080 1075 1068 1059 1049 1038 1230 1240 1233 1221 1207 1192 1176 1721 1745 1741 1729 1714 1698 1679 1660 2643 2698 2700 2688 2671 2650 2627 2602 2577

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Elastomeric Bearing Installation

Elastomeric Bearing Installation

Positive Fixity Method Base Fixity A Cast into recess in concrete with bedding mortar fill

B Cast onto bedding mortar and built up around the edges

C Glued onto smooth mortar plinth *(Standard method)

TOP FIXITY D Cast into in-situ concrete deck

E Glued to beam soffit *(Standard method)

TOP & BASE FIXITY F Fixed using auxiliary steel plates *(Extreme cases only)

Please Note: Bearing must be fixed on the top and bottom faces if positive fixity is required.

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CCL Masterflex Expansion Joints

CCL Masterflex Expansion Joints

CCL MASTERFLEX elastomeric expansion joints satisfy the requirements of bridge deck movements as caused by temperature variations, shrinkage, creep, traffic loads and other structural constraints. The expansion joints permit movement of the structure by shear deformation of the rubber element. The joints are waterproof and capable of withstanding vertical loads and horizontal forces from vehicle acceleration and braking. MASTERFLEX joints are based on a successful design, which has been in use since 1969. Product Description MASTERFLEX joints consist of moulded neoprene rubber mats, reinforced by steel plates and profiles. The rubber material has been specially formulated and is highly resistant to oil, grease, petrol, salt, sand, weather and abrasion. These properties together with the corrosion-proof metal components ensure high integrity and longevity of the joints. MASTERFLEX joints are supplied in standard 2-metre length units (1 metre for M330 type) and are jointed to form a continuous line using inter-locking tongue & groove connections. Key Benefits of MASTERFLEX joints Smooth, shock-free vehicle drive Silent Water-tight High skid resistance Durable Complete neoprene encapsulation ensures that steel inserts remain free of corrosion Compact design Accommodation of movement in both longitudinal and transverse direction Easy and quick installation Steel inserts are manufactured to ASTM Type A36. The rubber compound is based on Neoprene rubber compound with the following properties:

Physical Properties Hardness ( Shore A ) Tensile Strength ( MPa ) Elongation at Break ( % ) Low Temperature Brittleness (30 Min at 40o C) Compression Set (After 33 Hours at 70o C) Ozone Resistance After 48 Hours at 40o C 20 % strain 50 pphm Oil Resistance ASTM No.3 Oil (168 Hours at 25o C, Volume Change) Flame Resistance

Test Method ASTM D D D D 2240 412 412 746

Required Specification 50 +/- 5 13 min. 400 min. No Brittle 30 % max. No Crack 18 % max. No Propagation

D 395 D 1149 D 471 C 542

MASTERFLEX joints are available in a range of sizes to accommodate movements from 50mm to 330mm. Note we can also comply to specific customer requests by producing joints based on natural rubber compound.

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CCL Masterflex Specification

CCL Masterflex Specification

M50-M160
G

M200-M300
G

Section A-A

Section A-A

MASTERFLEX Dimensions (mm)

Joint Type M50 M80 M100 M140 M160 M200 M260 M330

Total Movement ( mm ) 51 80 102 140 165 200 260 330

Width A 271 357 391 410 454 800 890 1105

Thickness D 32 44 53 71 82 69 78 100

Length L 2000 2000 2000 2000 2000 2000 2000 1000

Anchors (mm) Dia / E 12 / 200 16 / 250 16 / 250 16 / 250 16 / 250 20 / 250 20 / 250 20 / 250

Anchors (mm) G 220 280 300 330 370 700 790 980

Weight (Kg/m ) 22 49 59 81 96 185 210 307

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Expansion Joint Selector

Expansion Joint Selector

The selection of the type of MASTERFLEX joint depends on the calculated movement of the structure. However, when the movement direction is neither parallel or perpendicular to the direction of the joint, the choice of joint type can be easily obtained using the following graph.

Example Vx = 48mm =30 = required type = M140

Longitudinal Axis of Structure = Direction of Movement

Joint Type

Movement in the Direction of Movement (Vx) 90 130 80 70 60 50 100

M330

M260 120

110
M200 Angle B

90 80

M160 M140 M100 M80

40

70 60 50 40 30 20 20 10 30

M50

10 20 70 80 10 40 50 60 30 90

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Lo ng itu di na lA xi s

Transversal Axis of Structure

of M AS TE R FL EX

CCL Masterflex Installation

CCL Masterflex Installation

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

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Installation Procedure

Installation Procedure
Method Statement for Installation. Step 1. Straight cut and remove the asphalt to obtain the recess of the required width and depth for each respective MASTERFLEX joint type. Clean thoroughly all the recessed substrate surface by compressed air Step 2. Prime the substrate surface with SIKAFLOOR 156, at a consumption rate of 0.3 Kg/m2. Then apply and trowel SIKAFLOOR 156 filled with sand at a ratio of 1:10 in the recess to form a layer of level bedding for the expansion joint (1 unit SIKAFLOOR 156 at 2.5 Kg, mixed with 25.0 Kg of sand, yielding approx. 1.4 Litre). Step 3. Drill the substrate to form bolt holes at the required spacing and diameter for each respective MASTERFLEX joint type. Holes are to be flushed thoroughly with compressed air Step 4. Insert anchor bolts vertically down into boltholes. The boltholes having been filled with SIKADUR 42 fast curing pourable epoxy grout prior to insertion Step 5. Lay the first MASTERFLEX element, apply SIKAFLOOR 11FC polyurethane sealant on the epoxy bedding at the tongue & groove interface before installing the adjoining element in order to achieve a waterproof connection Step 6. Anchor bolts are tightened to the required torque. Transition nosing between joint elements and asphalt are made by filling gaps with a pourable mix of SIKAFLOOR 156 filled with sand at a ratio of 1:1 (1 unit SIKAFLOOR 156 at 10.0 Kg, mixed with 10.0 Kg of sand, yielding approx. 23.2 Litre). Step 7. Adequate torquing of anchor bolts is checked. Bolt hole cavities in MASTERFLEX elements to be plugged using BOSTIK PU sealant.

Note The sand used should be kiln dried quartz sand, size range 0.1mm 2.0mm. CCL recommend that local sands are subjected to practical trial mixes with SILKAFLOOR 156 to confirm practicality.

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Telephone: +44 (0)113 270 1221 Fax: +44 (0)113 277 8977 Postal Address: Unit 4, Park 2000 Millennium Way, Westland Road, Leeds, LS11 5AL, England Email: sales@cclstressing.com Website: www.cclstressing.com