INSTALLATION MANUAL

FOR
MODULAR EXPANSION JOINT
(LG SYSTEM)
TABLE OF CONTENTS
1. INTRODUCTION TO THE MODULAR EXPANSION JOINT
1.1 Purpose
1.2 How They Work
1.3 Movement Capacity
1.3.1 Longitudinal Direction - ex:
1.3.2 Transverse Direction - ey:
1.3.3 Vertical Direction - ez:
1.3.4 Rotation ΦX, ΦY, ΦZ
1.4 Design Drawing

2. TRANSPORTATION AND STORAGE

2.1 Transportation and Handling
2.2 Storage

3. INSTALLATION
3.1 Inspection
3.2 Preparation of the Recess
3.3 Shuttering
3.4 Placing in the Recess
3.5 Connecting
3.5.1. The 1st Side
3.5.2. The 2nd Side
3.6 Concreting
3.7 Asphalt Surfacing

APPENDIX – INSTALLATION RECORD SHEET

1. INTRODUCTION TO THE MODULAR EXPANSION JOINT
1.1 Purpose

A modular expansion joint forms the load-carrying link between the abutment and the
deck or between individual decks of a bridge. Their purpose is to create a transition that
maintains a high level of riding comfort for the vehicles and limits noise output from this
traditionally problematic part of a bridge structure. To achieve this the expansion joint
accommodates movements resulting from settlement of piers and abutments,
temperature variation, traffic load and from creep and shrinkage of the concrete.

1.2 How They Work

The total longitudinal movement capacity is divided into individual, smaller gaps by the
lamellas. These gaps are made watertight with locked in elastomeric profiles (lock seal).

Absorbing Impact:
1. The Connection Between our center beam & support beam is an elastic connection
2. Therefore impact energy is dampened by the connection

The lamellas are connected to joists (support beams) via a pre-stressed free-sliding
system. The joists themselves are supported by a similar system in the joist boxes. The
elastomeric control springs coordinate individual movements (spacing) of the lamellas in
conjunction with the elastomeric profiles. This forms a dynamic system that can absorb
any combination of braking or accelerating forces applied by the traffic. This elastic
system heavily reduces the forces acting directly on the other expansion joint
components and also on the adjacent bridge structure, thus extending the life span of
the entire system.
The residual horizontal loads are transmitted through the L-shaped edge profile and anchorage
system into the bridge deck. Vertical loads are transmitted from the lamellas and sliding
bearings to the joist beams and from there through sliding bearings (situated in the joist box)
into the adjacent bridge structure.

1.3 Movement Capacity

The advantage given by the elastic support system and the free-sliding lamellas is the 3-
dimensional movement and rotational capacity of the expansion joint. Combinations of any
translations (ex, ey, eZ) and rotations (x, y, Z) around all 3 axes are possible

The Modular Expansion Joint is especially suited to accept movement in longitudinal direction.
The total movement capacity depends on the number of lamellas.

Type b1 b2 h fmin f60 f70 f80 G(Wt)

mm in mm in mm in mm in mm in mm in mm in Kg/m Lbs/ft
LG2 400 15.7 400 15.7 400 15.7 150 5.9 260 10.2 280 11.0 300 11.8 150 99
LG3 480 18.9 300 11.8 400 15.7 220 8.7 400 15.7 430 16.9 460 18.1 210 139
LG4 560 22 300 11.8 400 15.7 300 11.8 540 21.3 580 22.8 620 24.4 250 165
LG5 640 25.2 300 11.8 400 15.7 380 15.0 680 26.8 730 28.7 780 30.7 290 195
LG6 720 28.3 300 11.8 400 15.7 460 18.1 820 32.3 880 34.6 940 37.0 410 275
LG7 800 31.5 300 11.8 420 16.5 540 21.2 960 37.8 1030 40.5 1100 43.3 500 335
LG8 880 34.6 300 11.8 440 17.3 620 24.4 1100 43.3 1180 46.5 1260 49.6 596 400
LG9 960 3708 300 11.8 450 17.7 700 27.5 1240 48.8 1330 52.4 1420 55.9 745 500
LG10 1040 41.0 300 11.8 460 18.1 780 30.7 1380 54.3 1480 58.26 1580 62.2 1060 713
LG12 1200 47.2 300 11.8 500 19.7 940 37.0 1660 65.4 1780 70.0 1900 74.8 1340 900

Standard Dimensional Details of Modular Expansion Joint

1.3.1 Longitudinal Direction (ex):

Joint type Movement capacity ex (mm)

UNITARY 1x80 = 80 mm
LG2 2x80 = 160 mm
LG3 3x80 = 240 mm
LG4 4x80 = 320 mm
LG5 5x80= 400 mm
LG6 6x80 = 480 mm

1.3.2 Transverse Direction (ey):

Condition:Max rotation angle of the joist relative to the x-axis;

Z = <3%)

1.3.3. Vertical Direction (ez):

Condition y = < 3%

1.3.4. Rotations (x ,y, z):

x : determined by y max.

y: y < 3%

z: determined by the degree of expansion/contraction of the bridge.

1.4 Design Drawing

Typical Cross section at Stirrup Box:

2. TRANSPORTATION AND STORAGE
2.1 Transportation and Handling
Expansion joints are long and relatively slim steel constructions with a considerable
weight and require careful handling to avoid damages at unloading.

Lifting points for straps and chains are generally marked in yellow. If a single crane only
is used for lifting and lowering into position, then the angles between the two straps
must not exceed 45°. Otherwise, the use of a lifting-beam is recommended

N.B. Never use the pre-setting brackets as lifting points.

2.2 Storage
The expansion joint must be stored on wooden beams (approx. 12 cm x 12 cm) placed
under the joist boxes, if installation is not immediately made after unloading. The
wooden beams must be laid horizontally to avoid tensions and torsion within the
expansion joint.
3. INSTALLATION
3.1 Inspection

The modular expansion joint should be

thoroughly inspected to see if damage occurred
during shipment.

In case of damage, silicone caulk is applied to

seal any gaps between the bulkhead and joint,
or in the support bar boxes to ensure that no
concrete can enter the joints during the pour.

Cold galvanizing paint is applied to any

blemishes that may occur during the shipment
of the joint.
3.2 Preparation of the Recess/Block-out.

The recess must suit in size and form to the geometry of the expansion joint. In order to
avoid difficulties during installation, the following points must be checked and
considered.

 Dimension check of recess/Block-out

 Check of the levels
 Check of the skew and slope
 Check of the designed gap between bridge deck and abutment and/or
between adjoining decks.
 Checking of the existing structural reinforcement according to the drawings.

Usually, the rebars should be placed at 150 mm intervals. Missing rebars must be
replaced by insertion bars penetrating sufficiently deep into the concrete. Otherwise
make drill holes in the block-out and fix by epoxy short weldable reinforcement bars to
fix the anchor lugs of MEJS.

Rebars that would obstruct the installation of the expansion joint should be bent to
accommodate the expansion joint anchorages. Larger diameter rebars should be heated
prior bending to avoid fractures.

If required, removing or cutting off interfering reinforcing shall only be done after
consultation with the engineer-in-charge.

The recess must be cleaned thoroughly. If necessary the surface should be roughened.
All loose debris must be removed with pressurized air.
3.3 Shuttering

Shuttering plates must be used to seal the space between the undersides of the joint and the
vertical face of the recess.

The expansion joint is laid on transversally

placed wooden beams approx. 40 -60 cm above
the recess. Shuttering plates of 3 mm thickness
are then welded to the underside of the joint
Gaps, resulting from the wooden beams, are to
be sealed prior lowering the joint into the
recess.

The shuttering must be fitted in such a way that

it forms an appropriate seal against the edge of
the recess. If required, the shuttering plates can be tensioned by connecting to the
reinforcement bars with fixing wires. Otherwise props can be also used between two shuttering
plates.

3.4 Placing in the Recess/Block-out

Level marks must be set next to the recess by the installation engineer. This enables a controlled
leveling of the expansion joint.

Lowering the expansion joint into the recess

with a crane alone is not recommended. With
hand-operated jacks, the entire length of the
joint can be evenly lowered into the recess.
(The number of jacks depends on the joint
length).

As soon as the joint is accurately placed, the

engineer in charge shall provide a written
confirmation of the correct placement of the
joint.
3.5 Connecting

3.5.1 The 1st Side

The side where the least longitudinal movement is
expected (either the abutment of the bridge deck
side) is designated the 1st side for connecting the
joint. If required, the preliminary fixing is made by
evenly placing then welding of rebars over the entire
length between the stud and the deck
reinforcement. Otherwise make drill holes in the
block-out and fix by epoxy short weldable
reinforcement bars to fix the anchor lugs of MEJS.

To facilitate concreting, it is recommended that the

gap between recess and shuttering sealed by a grout
seam of approx 80 X 80 mm. The seam must be left
to dry prior to final concreting.

After this, if required, additional rebars are welded until all studs are firmly connected to the
deck reinforcement. The expansion joint is sufficiently fixed when no vibrations are noted when
lightly bouncing on the joint.

N.B. The extent of the fixing of the expansion joint described above is not designed to accept
dynamic loads from traffic. It serves only to firmly pin the expansion joint in the recess until the
concrete has been poured and sufficiently cured. It is, therefore, vital that the expansion joint is
not subject to any loads that could in any way displace the precise location of this fixing.

3.5.2 The 2nd Side

Depending on the size of the expansion joint and the expected movement during the
installation, the most suitable time must be determines for the fixing of the 2nd (opposite) side
(Please refer to the gap setting chart as mentioned in the particular drawing of MEJS). Usually
this is the early morning hours with the smallest temperature deviations.

The procedure is identical to that at the 1st side. As fast as possible, preferably with several
fitters at the same time, the joint is provisionally fixed to the reinforcement.

N.B. Immediately afterwards, the fixation brackets must be removed. The expansion joint can
now follow the longitudinal movement of the bridge.

Thereafter, seal the gap between recess and shuttering with an 80 mm x 80 mm grout seam and
weld the remaining rebars, as described previously.

Thereafter, the joint is precisely 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.
3.6 Concreting

Reinforcement
Once the modular expansion joint is placed in the
block-out, the remainder of the reinforcing steel can
be inserted. The rebar needs to be high enough in the
block-out, close to the top of the anchorage.

Joint Release
Once the joint is deemed to be straight and at the
right grade the joint can be released. Please refer the
specific shop drawing of MEJS regarding gap-presets.
This is done by welding the edges of the joint to the
reinforcement bars and removal of the gap width bars
on top of the joint. Otherwise make drill holes in the
block-out and fix by epoxy short weldable
reinforcement bars to fix the anchor lugs of MEJS.

Concrete Protection
After all reinforcing steel is in place, the top surface of
the modular expansion joint should be protected. This
can be accomplished by placing plywood, bit board,
Masonite or plastic across the top and secured with
duct tape.

Gaps in the bulkhead should be filled with foam or bit

board.
Prior to the concrete pour, the contractor must check
to determine that no concrete can protrude into the
support bar boxes

Concrete Pour
The concrete must be poured to the exact level
surface of the roadway to assure a smooth transition
between the roadway and the modular expansion
joint.

A vibrator should be used to ensure that concrete is

sufficiently placed underneath the support bar boxes.

The concrete should be leveled out at least 3mm

above grade to protect the expansion joint and allow
for the setting of the concrete which reduces the total
height.
3.7 Asphalt Surfacing

If required, an insulation sheet is clued to the horizontal flange of the edge profile prior to
asphalting.

In order to get a smooth transition, the asphalt must be leveled precisely to the joint. It is
common that the top surface of the asphalt is approx. 2 -4 mm higher than the edge profile of
the joint.

As the connecting surface to the joint is subject to heavy load impact it is recommended to
install a transition strip of mastic asphalt on both sides of the joint.
Appendix – Installation Record Sheet

Contractor: Manufacturer :
Order-No.: Engineer (Name):
Drawing-No. Date :
Type of Expansion Joint:
1. Place of Installation (Abutment, Piers)
2. Date of Delivery
3. Presetting brackets firm and fixed
4. Presetting value acc. Drawings or instruction
5. Corrosion protection and cleanliness
6. Regularly unloaded, stored, protected
7. Installation manual available, complete
8.
9.
10.
11 Temperature Air / Structure (°C)
12 Presetting value changed / corrected
13. Presetting brackets released, removed
14. Distance between inner side of edge profile after
connecting with the structure
15. Installation levels, directions, checked
16. Approved for concreting, Date
17. Delivery Sheet No. of the concrete
18. Concreting done, Date
19.
20.
21.
22. Remarks, Notes

Recorded : ________________________ Signature : ________________________

Place: Date: Place : Date :

Contractor
Client