Fosflex constructive solutions

Steel / elastomer module bridge deck joint

Uses
Each model incorporates steel angels designed to be
Fosflex bridge joints are designed for movement joints in
bolted to the structural deck and a steel bridging plate
elevated structure including:
system which spans the open joint gap.
Highway bridge decks
The corrosion resistant elastomer case is highly resistant
Trafficked access decks in elevated structures
to oils and solvent spillage and the trafficked surface
Ramps
includes and anti-skid pattern for safety. Each model is
Overpasses
specifically designed to accommodate horizontal and skew
movement and will also accommodate vertical movement
due to rotation of up to 6mm.
Advantages
Special steel clipped washers are provided with each unit,
Provides high movement accommodation up to designed specifically for the Fosflex joint. Stainless steel
330mm washers to the same high specification can be supplied to
Corrosive resistant elastomer casing special order.
Smooth wear resistant surfacing
Accommodates skew movement It is important that the correct washer is used in each
case.
Description
Rebond Profiles
Fosflex bridge joints comprise steel angels and a steel
bridging plate system encased in a flexible elastomer. During installation it is sometimes necessary, for practical
reasons, to cut a Fosflex unit on-site. In order to maintain
They are supplied in module lengths designed to be bolted the integrity of the joint between each module, male and
to the structural deck on either side of the expansion joint female rebond profiles are available for each unit to
in the structure. reinstate the end configuration as required.
A range of models are available to accommodate The profiles are available in lengths for cutting on-site
movement up to 330mm, and skew angels, providing a together with the recommended adhesive, Locite 495, or
substantially waterproof joint and a smooth, wear resistant equivalent.
surface.

The Fosflex bridge joint system comprises six standard by

shear deformation of the elastomer between the steel
components.

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Fosflex

Technical Support

Fosroc offers a comprehensive range of high performances, high quality technical products, manufactured in accordance with
BS 5750 registered quality scheme. In addition Fosroc offers a technical support package to specifiers and contractors which
includes computer aided design (CAD), standard details as well as on site technical advice from staff with unrivalled
experience in the industry.

Design Criteria

Fosflex bridge joint F200 and F250 Fosflex bridge joint F400,F650,F900 AND F1300

Typical Cross Sections Through carriageway joint

Fosroc's Fosflex bridge joint models

Model Movement Module Module Module Stud Module
Accommodation Length Width Depth Diam. Weight
B A D
50 mm 1830 mm 274 mm 40 mm 12 mm 48 kg

F200
65 mm 1830 mm 356 mm 46 mm 16 mm 68 kg

F250
102 mm 1830 mm 590 mm 54 mm 20 mm 150kg

F400
165 mm 1830 mm 724 mm 75 mm 24 mm 272 kg

F650
230 mm 1830 mm 890 mm 93 mm 24 mm 375 kg

F900
330 mm 1220 mm 1207 mm 127 mm 30 mm 451 kg

F1300

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Design Criteria

Models F200 and F250

Max stud Max joint End of

Bolt hole
height Bolt width at Max joint Recess Transition Bolt hole unit to
centre
above torque mid-deck width depth strip width centres first bolt
along unit
shelf temp hole

M N O R W C CL CE

32 mm 45 Nm 51 mm 76 mm 46 mm 100 mm 220 mm 305 mm 152 mm

40 mm 100 Nm 67 mm 98 mm 52 mm 100 mm 279 mm 305 mm 152 mm

42 mm 175 Nm 102 mm 152 mm 60 mm 100 mm 498 mm 305 mm 152 mm

51 mm 190 Nm 121 mm 203 mm 81 mm 125 mm 618 mm 305 mm 152 mm

60 mm 275 Nm 158 mm 273 mm 99 mm 150 mm 787 mm 305 mm 152 mm

70 mm 300 Nm 216 mm 381 mm 133 mm 175 mm 1080 mm 305 mm 152 mm

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Technical Data - Materials

Requirements Test Method

Neoprene
Hardness 500 shore A+5 ASTM D2240
Tensile strength 130 kgs/cm2 MIN ASTM D412
Elongation at break 400% MIN ASTM D412
0
Low temperature -40 C (Not brittle) ASTM D746
0
Ozone resistance After 48 hours at 38 C exposure to 50 ASTM D1149
PPHM in air sample under 20% strain
(No cracks)
Resistance to permanent set After 70 hours at 1000 + 31% ASTM D395
Oil resistance immersion ASTM No.3 approximately DIN 53531
0
168 hours at 25 C + 18% change in
volume
Steel Steel components manufactured to: Type ST 37-2 ASTM Type A36
Steel clipped washers Manufactured to DIN 37-2

a b d t
F200 34mm 27mm 14mm 3.0mm
F250 45mm 35mm 17mm 3.7mm
F400 60mm 50mm 21mm 4.0mm
F650 65mm 55mm 25mm 4.5mm
F900 72mm 51mm 25mm 6.0mm
F1300 70mm 60mm 31mm 6.0mm

On-site modification to standard units

It may be necessary to modify standard units on-site to

accommodate changes of level from road to footway.

This is achieved by cutting and notchilng the steel

bridging system and steel angels and lbending thel; units
0
through 30 . The point pf change of leel from road to
footway taking place behind the kerb line. The void in the
kerb line being protected with a galvanized steel cover
plate.

Detail on change of level modifications available from the

Technical Service Department.

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Technical Data - Performance
The graphs illustrated below are an indication of the
Fosflex bridge joints are designed to accept both horizontal load required to deflect Fosflex joint model
horizontal and vertical loads due to traffic in accordance manufactured using the 500 Shore A Neoprene.
with the UK Dot Technical Memorandum BE 3/72 Clause 4
and BS 5400 Part II 1978.

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Fosflex
Fosflex temperature adjustment guide 4. Hence the new bolt hole centres “C” to be drilled in the
structural concrete will be 199mm instead of
It will often be necessary to pre-compress or pre-extend 219mm.
the Fosflex joint to pre-set joint unit to suit the relative
position of the structural expansion joint in the bridge deck. 5. Maximum movement of joint module + and -25mm.

At the time of the installation therefore knowing the mean 6. Actual movement required + and -25mm.
deck temperature range and the movement to be
accommodated, the amount of pre-compression or pre-
extension can be taken off a graph prepared in the manner Key:
of the example illustrated. a Maximum compression
274 -25 = 249mm
NB:1.Example based on model 200 (274mm wide).
b Compressed width
2. The example assumes a total design movement for installation 254 mm
accommodation requirement of + and -25 mm from
the mid point position. c Actual module width 274mm

3. The installation temperature requires that the joint d Maximum extension

be compressed to 254 mm overall width – prior to 274 + 25 = 299mm
installation.

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Fosflex
Application Instructions The fixing nuts should be torqued to the rate indicated for
For concrete decks finished slightly higher(3mm) than that of the top of the
bridge joint module.
A flat and monolithic haunch or recess should be
formed in the structural deck to accommodate the Fosflex Following final torque checks on the fixing nut, the bolt
joint and the transition strips. hole pocket shall be filled with composition of plastic and
fine quartz sand (ratio 1.3) or approved equivalent to
At the design stage care should be taken to locate the protect the stud against corrosion.
reinforcement avoiding the position of the bridge joint
anchor studs. Note: Avice on, or the supply of, BJ Transition strip
materials is available from Fosroc.
In the interest of achieving a smooth traffic ride over the
joint, the wearing course should be machine laid Further information – Fosflex Installation
continuously over the structural joint and subsequently Manual
removed by sawing just prior to installing the bridge joint.
1. The detailed installation Guide sets out the
The removal of the surfacing over the joint in the deck is recommended installation procedure for Fosflex
facilitated by the location of a hardboard bond breaker of a bridge joints.
width just under the combined width of the joint and the
transition strips prior to the surfacing being laid. 2. Fosflex Product ScheduleDetailed product schedules
for each joint modules sets out the components
At the time of installation dependent upon mean deck available against each Fosflex model type.
temperature it may be necessary to pre-compress or pre-
extend the Fosflex joint unit to suit the relative position of Ancillary materials and equipment
the structural expansion joint in the bridge deck.
Materials:
The installation width of the joint may be determined using Studs See chart under the
graphical means illustrated in the example under the heading "Description for
heading “Temperature Adjustment Guide." Once the Hexagon head high recommended diameter
Fosflex module installation width and the new bolt hole Tensile rainbow coated bolt and type"
centres have been determined the joint module can be
adjusted in width accordingly. Conbextra EP150 for bolt anchoring

The surfacing may then;the sawn and removed to the Nitoseam MS 600 for sealing bolt holes.
dimension equivalent to the installation width of the joint
plus the two transition strips. Nitomortar B /BJ Transitional Strips epoxy mortar for use as a
leveling screed or bed.
The exposed concrete should be scrabbled land the finall;
level of the bed adjusted using a polymer modifier mortar BJ Transitional Strips for forming transition strips between road
approximately 20mm thick maintaining the recess depth wearing surfaces and the module joint
“R” i.e 46mm in case of model F200.
Equipment
The bridge joint modules centered over the expansion joint
in the deck may then be used as templates for the pilot Extension/compression tool for adjusting and pre-setting the
holes thus determining the final position of the bolt holes or module joint to suit temperature/joint gap at time of installation.
by use of a prepared template.
Rotary percussion drill
The final bolt holes should be drilled and studs installed Cretangle mixer
using Conbextra EP150 or equivalent. Each bridge joint Fosroc “G” Gun
unit may then be laid into position on beads of Nitoseam Torque spanner
MS One/600 sealant, plant clipped washers supplied with Jacking equipment
each unit located and the assembly bolted down.
Health and safety
Subsequent modules should then be located and fixed in
the same way, the sealant first being applied to the tougue
and groove edges of each unit prior to jacking into position Fosflex
to ensure a substantially waterproof junction.
There are no health hazards associated with Fosflex in
normal use.

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Ancillialry materials

Health and safety data sheets for Nitoseam MS 600 and

Nitoseam MS One are available separately from Technical
Service.

Important note:
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard Conditions
for the Supply of Goods and Services, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that
any advice, recommendation, specification of information it may give is accurate and correct, it cannot, because it has no direct
or continuous control over where or how its products are applied, accept any liability either directly or indirectly arising from the
use of its products, whether or not in accordance with any advice, specification, recommendation of information given by it.

Fosam Company Limited

Telephone: +966 2 637 5345 Fax: +966 2 637 5891 email: fosam@fosroc.com
Head Office
Post Box 11081 Regional Offices
Jeddah Sales Office Tel: (02) 6080999 Fax: (02) 635 3330 Yanbu Tel: (04) 322 4280 Fax: (04) 391 2980
Jeddah – 21453
Jeddah Showroom Tel: (02) 665 0787 Fax: (02) 667 4884 Makkah Tel: (02) 542 0869 Fax: (02) 542 0869
Saudi Arabia Riyadh Tel: (01) 482 9303 Fax: (01) 482 7562 Medinah Tel: (04) 845 1767 Fax: (04) 846 3195
Dammam Tel: (03) 814 1282 Fax: (03) 814 1581 Jubail Tel: (03) 362 3904 Fax: (03) 362 3875

www.fosroc.com Khamis Mushayt Tel: (07) 250 0469 Fax: (07) 250 0469
Registered Office: Industrial Area, Phase 4, Road No. 414, Street No. 407
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