WORKING PROCEDURE

Wd EXPANSION JOINT

Rev

WORKING PROCEDURE

EXPANSION JOINT

Wd

J-Wd000-PR-A.001
Rev C

JUNE 2003

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INTRODUCTION NOTE
This document is the property of FREYSSINET INTERNATIONAL & Cie.
It is confidential and may not be used, reproduced or circulated, even partially, under any form
and in any way whatsoever, without the prior written approval of FREYSSINET
INTERNATIONAL & Cie.

FOLLOW-UP OF REVISION INDEXES

H
G
F
E
D
C 05/06/03 New reference [Link] [Link] [Link]
B 05/01/95 Updated [Link] [Link] [Link]
Rev Date Modification Drafted by Checked by Approved by

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TABLE OF CONTENTS

1-SAWING OF BITUMINOUS CONCRETE................................................................................ 4

2-CLEARING THE BLOCK-OUT ................................................................................................ 5

3-INSTALLATION OF ADDITIONAL REINFORCEMENT ........................................................... 7

4- INSTALLATION OF DRAIN.................................................................................................... 8

5-INSTALLATION OF SPACING FORMS .................................................................................. 9

6-FIXING THE JOINT’S COMPONENT ON THE INSTALLATION ARMS ................................ 10

7-INSTALLATION OF THE FIRST ROW OF COMPONENTS.................................................. 11

8- INSTALLATION OF THE ELASTOMERIC PROFILE ........................................................... 12

9- INSTALLATION OF THE SECOND ROW AND ADJUSTMENT ........................................... 13

10- INSTALLATION OF ANCHORAGES.................................................................................. 14

11-PREPARATORY WORKS BEFORE CONCRETING........................................................... 15

12- CONCRETING ................................................................................................................... 17

13- FINISHING ......................................................................................................................... 18

14- CONCRETE CURING ........................................................................................................ 19

15- TENSIONING OF ANCHORAGES..................................................................................... 19

15.1. TIGHTENING USING A TORQUE SPANNER..................................................................... 20

15.2. TENSIONING USING A JACK .............................................................................................. 21

16- FINITION............................................................................................................................ 22

17- CUTTING AND INSTALLATION OF UPTURNS................................................................. 23

18-TREATMENT OF SIDEWALKS........................................................................................... 24

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1-SAWING OF BITUMINOUS CONCRETE

- Survey the structure and mark the joint line (check for the presence of an existing joint, cracks,
etc...)
- Mark the edges of the rabbet by means of a spot check carried out at the extremities of the joint
line, using a moil-point and record the thickness of bituminous concrete.
- Indicate the outline to be cut using a chalk line according to the distance « S » specified below:
Wd60 S (mini) =210 S (mean value) =285
Wd80 S (mini) =210 S (mean value) =295
Wd110 S (mini) =270 S (mean value) =370
Wd160 S (mini) =325 S (mean value) =455
Wd230 S (mini) =385 S (mean value) =585
-Saw the road surface using a concrete cutter to a depth of 50 mm to 100 mm (if the thickness of
the road surface is below these values, saw down to the concrete without penetrating it).

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2-CLEARING THE BLOCK-OUT

- Break up and loosen the road surface material using a pneumatic hammer fitted with a spade
bit.
- Clear the filling material from the block-out.
- Refurbish the concrete faces by means of light bush hammering or light moil-point scalping.
- Blow off all debris and clean the block-out and the cavity between concrete structures.

Type\distance B mini C H mini e

Wd 60 200 20 to 80 200 20
Wd 80 200 30 to 110 200 20
Wd 110 250 40 to 150 250 20
Wd 160 300 50 to 210 280 20
Wd 230 350 70 to 300 280 20

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CRITICAL POINT
VERIFICATIONS ACTION TO BE TAKEN

1- Check the dimensions of the block-outs. 1- If the dimensions do not comply, alert the
FREYSSINET site agent and the Client
representative and complete a non-conformity
form.

2- Verification of the water-tightness of the 2- If the waterproofing is non existent or

structure : defective, immediately contact the
- type of waterproofing FREYSSINET officer and the Client
- location representative and complete a non-conformity
- thickness form.

3- Verification of stirrups : 3- If the reinforcement does not comply, alert the

- diameter of bars FREYSSINET agent and the Client
- intervals representative and complete a non-conformity
- cover form.

4- Check the distance between concrete 4-If the distance between concrete faces does not
faces and make sure the spacing forms have comply an/or if a foreign body prevents the joint
been removed. from functioning properly, alert the
FREYSSINET agent and the Client
representative and complete a non-conformity
form.

5-Check the condition of the block-out 5-If the concrete faces do not seem sound, alert
concrete. the FREYSSINET agent and the Client
representative.

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3-INSTALLATION OF ADDITIONAL REINFORCEMENT

The stirrups – 5 units per linear metre - are commonly located too deep in relation to the fixing
accessories of the joint to be installed ; this is why additional reinforcement is installed to
« link » the joint to the structure This reinforcement is installed with a minimum cover of 20
mm, at a distance « H » from the road surface, specified as follows :

Wd60 H=70 mm
Wd80 H=85 mm
Wd110 H=95 mm
Wd160 H=115 mm
Wd230 H=140 mm

The following stirrups have to be used according to the recesses sizes:

100x150 Æ8 at 20 cm intervals+ longitudinal bars Æ10
150x150 Æ8 at 20 cm intervals+ longitudinal bars Æ10
150x200 Æ8 at 20 cm intervals+ longitudinal bars Æ10
150x350 Æ8 at 20 cm intervals+ longitudinal bars Æ10

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4- INSTALLATION OF DRAIN
20 mm

Plank

Type 40 alu 16/100 flashing

1- INSTALLATION OF THE ALUMINIUM FLASHING

a) Brush over the concrete support using

a VERAL type priming coat
VERAL priming coat
b) Assemble the type 40 alu 16/100 flashing by
thermo-welding, in strips 1 meter long, 100 mm wide,
overlapping by at least 50 mm

Pure asphalt
2- WATERPROOFING - ALUMINIUM SHEET JUNCTION
Pour the pure asphalt to a thickness
at least equal to that of the waterproofing complex

3- INSTALLATION OF THE DRAIN

Set the drain onto the asphalt bedding

and push back the aluminium sheet.
(The asphalt bedding w ill be topped by a Kraft
paper w hen the block-out is filled w ith asphalt)

4- EXTREMITY OF THE DRAIN

Exit the drain w hen it reaches the

low est level of the joint line and
if possible, connect it to a w ater
outlet duct. To achieve this:
.drill a hole in the aluminium flashing
.install a flexible plastic tube on the
drain along its length of passage
through the concrete (or w rap it
w ith sealing tape) + 200 mm above the flashing

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CRITICAL POINT
VERIFICATIONS ACTION TO BE TAKEN
1- Check the necessary documents for the adjustment 1- In the absence of precise
of the joint (installation diagram, thickness of the information, notify the construction
form between concrete faces, etc ...) engineer.

5-INSTALLATION OF SPACING FORMS

Install a polystyrene form (or plywood-polystyrene-plywood sandwich, according to the

thickness of the form, when e > 65 mm) and carefully cut off following the cross section outline
at a distance « P » from the level of the road surface.

Wd60 P = 45 mm 20 mm < e > 80 mm

Wd80 P = 48 mm 30 mm < e > 110 mm
Wd110 P = 68 mm 40 mm < e > 150 mm
Wd160 P = 83 mm 50 mm < e > 210 mm
Wd230 P = 105 mm 70 mm < e > 300 mm

When plywood sheets are used, these must be first brushed over with a form oil.

The lower part of the form must be securely wedged between the concrete faces, in order to
prevent any sinking during concreting.

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6-FIXING THE JOINT’S COMPONENT ON THE INSTALLATION

ARMS

The joint’s components are exactly levelled with the road surface thanks to installation arms
which are set on each side of the joint, on the road surface.
Each joint segment is installed using two installation arms.
An installation arm is screwed onto two successive segments. These screws are tightened but not
blocked, in order to allow for the adjustment of the joint line.

Screw Æ8 Lg :
70 for Wd60
Installation arm Lg 1.2 ml 80 for Wd80 et Wd110
(=1.5 ml for Wd230) 90 for Wd160
Screw Æ10 Lg 120 for Wd230

Plate 35x5 + wedge 60x30

(100x50 for Wd230)

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7-INSTALLATION OF THE FIRST ROW OF COMPONENTS

The joint, fitted with its installation arms, is placed in the recess, segment after segment (or in a
complete row). The joint’s segments are brought into contact with the form located in the gap
between concrete faces. The installation arms are linked to the stirrups (on one side of the joint
only), in order to maintain the geometry of the ensemble.
The end segments are cut to length, then prepared to suit the upturns (see 23)

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8- INSTALLATION OF THE ELASTOMERIC PROFILE

Stick the 3M type double side mastic tape on both edges of the elastomeric profile ; do not
remove the paper protection.
Place the profile under the installation arms, close to the joint’s segments.
Remove the paper protection in accordance with the rate of installation and insert the elastomeric
profile in the first row of segments and in the upturns.

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9- INSTALLATION OF THE SECOND ROW AND ADJUSTMENT

Install the second row of metal segments.

Tighten the second row to the required adjustment in successive drives of 20 to 30 mm using a
jack.
Adjusting wedges must be inserted, in order to ensure that the opposing serrations are not off-set.
The horizontal level of the adjusted segments will be maintained thanks to a lever used at the
serration’s extremities

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10- INSTALLATION OF ANCHORAGES

The fully greased anchorages are manually installed and tightened..

M12 screw for Wd60 and Wd80

M16 rod for Wd110
Washer M22 rod for Wd160 and Wd230
(installed already greased)

Sleeve
Æext15 for Wd60 and Wd80
Æext20 for Wd110
Æext25 for Wd160 and Wd230

Bottom flange
Æ70 for Wd60 and Wd80
Æ88 for Wd110
Æ120 for Wd160 and Wd230

or
bottom cone socket:
Æ65/45 for Wd60 ; Wd80 and Wd110
Æ85/67 for Wd160 and Wd230
Plug or Wd110,Wd160 and
Wd230

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11-PREPARATORY WORKS BEFORE CONCRETING

Apply a protection on the segment’s upper (sealing tape for example).

Install longitudinal re-bars, 8 mm or 10 mm in diameter, each side of the anchorages.
Install pins, 8 mm or 10 mm in diameter with sizes according to the recess sizes
Blow the debris out of the recess.
Fill the bolt head casings with fine sand.
Copiously moisten the concrete faces.

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BREAK POINT
(in the presence of the consultant)
VERIFICATIONS ACTION TO BE TAKEN
1- Check the correct alignment of segments. 1- Rectify using the installation arms.

2- Check the correct level of the segments : 2- Rectify by inserting wedges under the
+0 -2 mm in relation to the road surface. installation arms.

3- Check the width of the joint 3- Adjust, if necessary, using a jack.

4- Check the solidity of the form and the 4- Place additional wedges.
stability of the installation arms.

5- Check the correct position of anchor bolts. 5- Rectify if necessary

6- Check the washers and nuts are fitted the 6- Rectify if necessary
right way up..

7- Check the reinforcement and cover along 7- Rectify if necessary

the form.

8- Check the position of the drain and the 8- Rectify if necessary

correct sealing of the waterproofing.

9- Check the cleanliness of the recess 9- Rectify if necessary by means of thorough

blowing

10- Check the protection of the surroundings 10- Rectify if necessary

before concreting.

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12- CONCRETING
If no special mix requested by the Client (High Performance concrete, admixtures, etc ...), use
5/15 to 5/25 grating B40 concrete (according to the size of the recess) batched with CPA45R or
CPA55R cement at a rate of 400 kg/m3 (see NT 93.013 J).
It is advisable to use concrete with a slump of +7 (better workability, correct shrinkage).
Except when otherwise stated, this concrete will be coloured by the addition of 320
BAYFERROX black tint, used at a rate of 1.25 % of the cement weight, i.e. 5 kg of black
admixture for one cubic metre of the concrete described above. The BAYFERROX must be
directly introduced directly into the mobile concrete mixer ; the batching should last against the
order.
At the request of the consultant or of the FREYSSINET site agent, informative samples will be
cast before concreting.
If there is any problem (poor concrete quality, non-conformity of concrete with regard to the
order, etc...), suspend the concreting and pour the concrete of the truck-mixer over steel-plates
spread on the road surface.
Pour the concrete as rapidly as possible, with a steady continuation each side of the form.
Carry out a vigorous vibration using 50 mm maximum diameter vibrators.
Do not pour concrete when the temperature falls below +5°C.
Pour concrete up to +3 mm over the road surface level.

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13- FINISHING

Before completing the concreting of the line, smooth the concrete using a float.
In accordance with the setting conditions of the concrete (about one hour after pouring), it is
imperative to loosen the installation arms : the movements of the deck due to temperature
variations effect the anchorages and cracks occur on the fresh concrete.
The concrete finish must be completed with a thorough smoothing, 1 to 2 mm above the level of
the metal components. As soon as the concrete has sufficiently hardened, dismantle the
installation arms.

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14- CONCRETE CURING

Curing is necessary on all surfaces submitted to atmospheric conditions likely to affect the
requested concrete quality.

As soon as the concrete surface finishing is completed, a watertight tarpaulin or thin PVC
membrane is positioned in contact with the concrete surface for 48 hours.
During hot weather, wet the concrete and protect it using straw mats or damp gunny bags, or
even by spraying a curing agent onto the fresh concrete surface.
During cold weather, cover the exposed surfaces with thick polystyrene sheets.

15- TENSIONING OF ANCHORAGES

If no informative concrete sample has been cast or in the absence of inspection equipment
regarding to standard NT 93.013 J must allow for a tensioning of anchorages at least 48 hours
after concreting ; beyond this period, the anchorages can be tightened.
Tensioning is carried out using either a jack (case of 22 mm diameter) or a torque spanner,
commencing with the anchorages located at the centre of the segments and finishing with the end
anchorages.

Type of joint Wd60 Wd80 Wd110 Wd160 Wd230

Type of anchorage Ø 12 Ø 12 Ø 16 Ø 22 Ø 22
Concrete strength 20 MPa 20 MPa 20 MPa 20 MPa 20 MPa
Tightening couple 12 [Link] 12 [Link] 24 [Link] 50 [Link] 50 [Link]
Type of jack RCH 302 RCH 302
Jack pressure 450 bars 450 bars
Force in anchorage 6500 kg 6500 kg 10000 kg 19000 kg 19000 kg

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15.1. TIGHTENING USING A TORQUE SPANNER

- Equipment :
The spanners to be used for tensioning the anchorages are the following :
S 203. FACOM spanner with S152 ratchet and S 19 H socket for anchorages 12 mm in
diameter.
S 203. FACOM spanner with SJ 214 extension-piece, S 152 ratchet and S 24 L socket for
anchorages 16 mm in diameter.
50/170 type SAM spanner for anchorages 22 mm in diameter.
-Methodology:
Screw the anchor in successive quarter turns using the spanner set for the selected couple.
As soon as the spanner is disengaged, stop tensioning : the requested force has been reached.
If, after six quarter turns, the spanner is not disengaged, stop tensioning : the requested force has
been reached.

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15.2. TENSIONING USING A JACK

- Equipment:
The jack used is the RCH 302 model from ENERPAC (it is possible to use a J30 jack calibrated
at 550 bars).
-Methodology :
Increase pressure to 450 bars then tighten the nut until it comes into contact with the joint ;
release the pressure then immediately increase it to 450 bars, tighten the nut again ; the force
requested in the anchorage has been reached.

Nut Æ22

Distribution plate

Jack Enerpac RCH 302

Stand

Tensile rod M22

Tightening socket

Sleeve for end to end

After tensioning, cut off the rods using a lapidary’s mill, without damaging the nuts.

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16- FINITION

Fill up the anchor head recesses and the temporary fixing holes with pure asphalt, then level
carefully.

Fill up the gap between joint segments with silicone mastic

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17- CUTTING AND INSTALLATION OF UPTURNS

The elements of ends will be cut out with length according to the width of roadway. The upturns
(elastomer section) are fixed using 2 screws M12 to the elements of ends on which the teeth were
sawn on 140 mm and 2 notches or 2 holes were practised for the passage of the M12 bolts.

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18-TREATMENT OF SIDEWALKS

Each Wd joint is associated with a sidewalk joint whose range of movement is at least as wide as
the roadway joint. Additionally, a kerb cover completes the whole set (expansion
joint/upturn/sidewalk joint).
The various sidewalk joints, as well as their respective block-outs, are specified as follows :

Type Block-out
Wd 60 TO 80 200 x 70
Wd 80 TO 80 200 x 70
Wd 110 TO 100 200 x 70
Wd 160 PL 160 250 x 120
Wd 230 PL 230 320 x 120

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