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EXPANSION JOINTS June 14 Page 1

Expansion Joints
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This presentation contains certain forward looking statements concerning future business prospects and profitability of HCC, which are subject to a
number of risks and uncertainties and actual results could materially differ from those in such forward looking statements, important developments
that could affect the company's operations include a downtrend in the infrastructure sector, significant changes in political and economic environment
in India, tax laws, labor relations, litigation etc. The company does not undertake to make any announcement in case any of these forward looking
statements become materially incorrect in future or update any forward looking statements made from time to time by or on behalf of the company.
DISCLAIMER
What is an expansion joint?
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An expansion joint is defined as a structural discontinuity between deck and other
element of a bridge superstructure designed to permit relative translation and/or
rotation between the two.

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The components of the joint must accommodate the translation and rotation
of the structure at the joint.
In order to provide smooth traversing over the expansion joint the gap
between adjacent sides of the joint should be bridged.The joint must provide
for the passage of traffic across the joint without significantly impairing the
riding quality of the pavement surface.
Deck joints must be constructed and detailed such that they prevent damage
to the deck, bearings piers and abutment from the water borne chemicals and
other foreign materials, either by preventing water from leaking through the
joint or by permitting water to drain through the joint in such a manner that
damage to the deck bearing piers or abutment does not occur.
Functional Requirements of a bridge Expansion Joint
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Sl.
No
.
Type of Exp.
Joint
Suitability for adoption of joint Expected
Service Life
1 Buried Joint Simply supported span up to 10m 10 Years
2 Filler Joint Fixed end of simply supported spans with insignificant
movement of simply supported spans not exceeding 10m.
10 Years
3 Asphaltic Plug
Joint
Simply supported spans for right or skew(up to 20 degree)
moderately curved or wide deck with maximum horizontal
movement not exceeding 25mm. Ambient temperature should
be in the range of 5 to 50 degree Celsius.
10 Years
4 Compression
Seal Joint
Simply supported or continuous spans right or skew (up to 30
Degrees), Moderately curved with maximum horizontal
movement not exceeding 40 mm.
10 Years
5 Elastomeric
Slab seal Joint
Simply supported or continuous spans. Right or Skew(Less
than 20 degrees),moderately curved with maximum horizontal
movement up to 50mm.
10 Years
Suitability Criteria
for
Adoption of different types of Expansion Joints
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Sl.
No
.
Type of Exp.
Joint
Suitability for adoption of joint Expected
Service Life
6 Single strip seal
Joint
Moderate to large simply supported cantilever/ continuous
construction having right skew or curved deck with maximum
horizontal movement up to 70 mm.
25 Years
7 Modular strip
Seal
Large to very large continuous/cantilever construction with
right deck having maximum horizontal movement in excess of
70mm
25 Years
8 Special Joints For bridges having wide and large span length involving
complex movements/rotations in different
directions/planes,provision of special type of modular
expansion joints .
25 Years
Suitability Criteria
for
Adoption of different types of Expansion Joints
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MODULAR EXPANSION JOINT
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COMPRESSION SEAL EXPANSION JOINT
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Steel plate sliding expansion joints
Filler joints
Elastomeric slab seal expansion joint
Strip seal expansion joint.no the gap
Types of Expansion Joints
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Steel plate sliding expansion joints
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The exposed metallic components shall be galvanized or coated with approved anti
corrosive paint.

The thickness shall be 20 mm or so for obtaining satisfactory performance.

Any temporary bolts or other fixings which prevent relative movement of the adjacent
parts of the joint shall be removed as soon as the concrete has set sufficiently to hold
the expansion plates in their correct positions.

Plates shall be free of oil,rust, loose paint or other similar material before coating.
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Filler joint
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The components of this type of joint shall be at least 2 mm thick corrugated
copper plate placed slightly below the wearing coat, 20 mm thick compressible
fiber board to protect the edges, 20 mm thick pre molded joint filler filling the
gap up to the top level of the wearing coat.
The material used for filling expansion joint shall be bitumen impregnated felt,
elastomer or any other suitable material.
Impregnated felt shall conform to the requirements of IS: 1838.
The joint filler shall consists of large pieces and assembly of small pieces to
make up the required size shall be avoided.
Sealants shall be finished approximately 3 mm below the upper surfaces of
the joint.
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Elastomeric slab seal expansion joint
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Materials:
1. Steel inserts shall conform to IS: 226.
2. Elastomer for elastomeric slab unit (ESU) shall conform to IRC:83(Part II) ,
compounded to give hardness IRHD 605, subject to the following additional
stipulations:
Chloroprene only shall be used in the manufacture of elastomeric expansion
joints.
The chloroprene material used in the manufacture of elastomeric shall be
Neoprene WRT, Bay prene 110, Skyprene B5 or Denka S 40V.
Chloroprene content of the compound shall not be lower than 60 percent by
weight. The ash content shall not exceed 5 percent.
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Installation:
All bearing surfaces and recesses which are in contact with the joint
assembly shall be checked with a straight edge to ensure flatness of profile.
No holes shall be drilled for fixing bolts within seven days of concreting.
Sections of the jointing making the completed joint shall follow a straight line.
The fixing bolts shall not be placed in position un till at least 4 weeks after
stressing is completed in post tensioned box or beam and slab structures.
Prior to placing sections of jointing, contact surfaces shall be cleaned to
remove all grease , tar, paint, oil, mud or any other foreign material that may
affect adhesion of the sealant.
Sealant shall only be applied to dry contact surfaces
Final sealing of the finished expansion joint shall be completed immediately
after the completion of installation.
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Acceptance test:
The properties of the elastomer shall conform to IRC Table 1 of clause
915.2.
The acceptance testing for elastomer material shall conform to clause
918.4.1.2 of IRC :83 (Part II).
For severe environment, ozone resistance test as per clause 915.2.3 of IRC
:83 (Part II) shall be carried out for the elastomer.
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Acceptance test for the fabricated expansion joint
Routine test:
Each expansion joint shall be tested for at least 100 cycles for a test
movement which shall be 10 percent more than the design
expansion/contraction movement.
In addition to the routine test, one out of every 20 expansion joints shall be
subjected to the test movement for 400 cycles.
The lot shall be rejected if the elastomer material shows signd of fatigue or
permanent set or distress in the test.The test piece shall not be used in the
bridge.
The type test for abrasion resistance shall be carried out for one joint out of
every 20 nos. as per IS: 3400 (Part 3) and the standard deviation shall be
within 20 percent.
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STRIP SEAL EXPANSION JOINT
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COMPONENTS
1. Edge Beams: This special claw leg profiled member shall be of extruded
rolled steel section combining good weld ability with notch toughness.
2. Strip Seal: This shall be of chloroprene with high tear strength, insensitive to
oil, gasoline and ozone. It shall have high resistance to aging.This
component provided to ensure water tightness, shall have bulbous shape of
the part of the seal which is inserted into the groove, provided in the edge
beam. The seal should be vulcanized in single operation for minimum full
length of joint.
3. Rigid Anchorage: This shall be welded to the edge beam at staggered
distance.
4. Anchor loops: This shall be made of weld able steel connecting the rigid
anchorage with deck reinforcement.
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Strip Seal Expansion Joint
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strip seal expansion joint
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Property Specified Value
Hardness 635 Shore A
Tensile Strength Min 11 Mpa
Elongation at fracture Min 350 per cent
Tear propagation Strength
Longitudinal Min 10 N/mm
Transverse Min 10 N/mm
Shock Elasticity Min 25 Percent
Abrasion Min 220 mm
Residual Compressive strain(22 h/70 deg
C/ 30 percent Strain)
Max 28 Percent
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Property Specified Value
Ageing in hot air (14 days/70 deg C)
Change in hardness Max + 5 shore A
Change in Tensile Strength Max + 20 percent
Change in Elongation at Fracture Max + 20 percent
Ageing in Ozone(24 h/50 pphm/25 deg
C/20 percent strain)
No Cracks
Swelling behaviour in oil(116h/25 percent
C) ASTM OIL NO.
Volume Change Max 5 percent
Change in hardness (ASTM OIL NO. 3) Max 10 Shore A
Volume Change Max 25 Percent
Change in hardness Max 20 Shore A
Cold Hardening Point Min 35 Deg C
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Pre-Installation:
Rolled steel profiles for edge beams shall be long enough to cater for the
carriage way width.
Anchor plates shall be cut to the required size by gas cutting. These shalll be
welded to the edge beams.
Anchor loops shall be bent to the required shape and welded to anchor
plates.
The finally assembled joint shall then be clampled and transported to the
work site.
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Installation:
The surfaces of the recess shall be thoroughly cleaned and all dirt and
debris removed.
The exposed reinforcement shall be suitably adjusted to permit unobstructed
lowering of the joint in to the recess.
The recess shall be shuttered in such a way that dimensions are correct as
per the drawing.
The joint shall be lowered in a pre determined position, leveled and finally
aligned and the anchor loops on one side of the joint welded to the exposed
reinforcement bars of the structure.
With the expansion joint finally held at both sides, the auxiliary brackets shall
be released, allowing the joint to take up the movement of the structure.
High quality concrete (not less than M35) shall then be filled into the recess.
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Acceptance test:
All steel elements shall be finished with corrosion protection system.
For neoprene seal, the acceptance tests shall be conducted.
The fatigue strength of the built up edge beams to withstand 2 x 10
6
load
change cycles without showing signs of damage will be required.
Anchorage system should be tested to determine optimum configuration
under dynamic loading.
Water tightness test should be carried out to check the water tightness under
a water pressure of 4 bars.
Evidence of satisfactory performance of the joint shall be required.
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Based on the GA drawing of the expansion Joint and Detailed plan/X-section
of individual bridge, prepare an enquiry for supplier.b Drawing should show full
width of the carriageway with kerb / crash barrier/camber/ skew angle etc.
Ask the supplier to make working drawings to meet technical specifications,
MoRT & H guidelines( As per latest circulars).
On receipt of drawings from supplier, get it approved from client/engineer
before asking the suppler to go ahead with fabrication.
Ask supplier to offer QA Plans and dates for inspection.
Get QA Plan approved.
Inspect
Ask for extra paint along with supplies for any touch work required during
installation.
Packing Details
Steps to be followed for Procurement and Installation of
Expansion Joints