Expansion Joints

Modular Expansion Joints Type LR

www.mageba.ch
 2 Introduction

Contents Page
Introduction 2
Type designation 3
Movement capacities 4
Product characteristics 5
Design details 6
Support and control systems 7
Bridge connection 8
Special designs 9
Assembly and installation 10
Quotation and ordering 11
Products and references 12

Principle
Several lamella beams divide the movement range of a bridge gap in
individually moveable gaps, permitting easy passage of traffic. They are
connected water-tight with special sealing profiles.
mageba has been developing modular joints for decades. The results are well
proven, long lasting structures which are quiet, and almost tearand wear free.

Advantages
• Movements and rotations possible in all 3 dimensions at any time.
• All structural elements of mageba modular expansion joints are made from
high quality materials. The production follows the latest ISO 9001:2000
quality assurance guidelines.
• mageba modular expansion joints have been successfully tested for fatigue
and wear at independent institutes.
• Weld seams at high stressed connections are consistently avoided.
Therefore, mageba modular expansion joints have a continuously high
durability.
• Thought out design facilitates the easy exchange of individual parts where
necessary without any problems.
• mageba modular expansion joints have no loose or moving steel
components susceptible to high levels of load modification. Movement and
torsion are both transmitted between lubricated PTFE and high-grade
stainless steel, as well as through elastomeric components and plastics.
• The elasticity of the support system absorbs shocks and vibrations and also
allows larger movements in the transverse direction of the bridge. It also
allows for vertical movements and rotations.
• mageba modular expansion joints have an elastic self-regulating gap control
system. This system increases the durability of the whole structure, because
it helps to absorb the dynamic loads from the traffic passing over it. Any
potential damage to the structure caused by the “blocking“ of an individual
gap (e.g. by caught debris) is effectively averted due to the independent
elasticity of the steering system.
• Only a relatively small recess space is required for the installation of
mageba modular expansion joints on bridges and abutments. The
asymmetrical arrangement of the joist beam boxes means they adopt to a
wide range of situations on site.
 Type designation 3

Type designation, movements and dimensions

EPDM - seal Lamella beam Edge profil Sliding spring

Joist box Joist beam Sliding Sliding Sliding bearing

spring bearing

Max. Recess space Joint width

Type & range of Weight
b1 b2 h f0 f5 f65 f80
Size movement
mm mm mm mm mm mm mm mm kg/m
LR 2 160 400 300 400 140 150 270 300 150
LR 3 240 480 300 400 220 235 415 460 240
LR 4 320 560 300 400 300 320 560 620 330
LR 5 400 640 300 420 380 405 705 780 420
LR 6 480 720 300 420 460 490 850 940 510
LR 7 560 800 300 420 540 575 995 1'100 600
LR 8 640 880 300 440 620 660 1'140 1'260 690
LR 9 720 960 300 460 700 745 1'285 1'420 790
LR 10 800 1'040 300 480 780 830 1'430 1'580 900
LR 11 880 1'120 300 510 860 915 1'575 1'740 1'020
LR 12 960 1'200 300 510 940 1'000 1'720 1'900 1'140
LR 15 1'200 1'490 350 590 1'320 1'395 2'295 2'520 1'400
LR 20 1'600 1'860 350 655 1'770 1'870 3'070 3'370 2'050
LR 25 2'000 2'260 350 675 2'220 2'345 3'845 4'220 2'750
LR 30 2'400 2'660 350 735 2'670 2'820 4'620 5'070 3'500

Main characteristics
The type designation is calculated according to the number of sealing
profiles. It is built in a modular fashion and begins with Type LR2, which
involves two sealing profiles. In the figure above an Type LR6 m odular
expansion joint is shown with six sealing profiles.
Example LR6:
The range of movements is determined by the planned operational range of
the sealing profile. For instance, if the planned operational range of a sealing
profile is 80 mm, a LR12 Modular Joint will allow a movement range of 12 x 80
= 960mm.
The joint width f changes with movement of the joint.
For the minimum joint width f min the steel profiles are fully closed. For the
maximum joint width f max the gaps between the steel profiles open to 65, 70
or 80 mm, depending on the national specifications.
An example of this can be seen in the above table, where the joint width
f is displayed according to the corresponding gap widths (f0, f 5, f65, f80 ).
 4 Movement capacities

Movements
Modular expansion joints allow movement in all 3 directions (ux, uy, uz) and
rotations about all 3 axes (f x, f y, f z).
Large movements in the bridge’s transverse direction (uy) and vertical
direction (uz) of both the lamella beams and the cross beams are made
possible due to the consistent elasticity of the support system.

Principle of elasticity
A pre-requisite for ensuring a long lifetime of the modular expansion joint is
the avoidance of dynamic stress. Similar to the techniques used in the
automotive industry, the dynamic stress on mageba modular expansion joints
is drastically reduced by the use of a highly developed spring and damping
system. The joints and the adjacent structural elements are protected, and the
durability of the joint is significantly increased.
Detailed documents on these spring and damping systems, based on the
principle of elasticity, are readily available upon request.

Skewed movements
When the direction of the movement of the bridge is not perpendicular to the
joint axis, then the modular expansion joints can be designed insuch a way
that it can take the corresponding transverse movement.
A skewed positioning of the modular expansion joint itself to the bridge axis
can also be realised at any time.
Bridge axis
Fahrbahnachse B
Note: The direction of movement not necessarily has to be identical to the
direction of the bridge axis. ß
d
f x x a
Joint axis
Fugenachse
Movement capacity ux f z f y uy
Direction of skewed movement
Schrägverschiebungsrichtung
uz
The maximum movement capacity of the joint in all 3 directions (ux, uy, uz) as
well as the maximum possible skewed movement between the movement
direction and the joint axis, is presented in the table below.

Max. longit. Max. vertical Min. angle between movement

Max. transverse movement
movement movement direction and joint axis
Type
Number of max. uy [mm] α 1 ≤ α ≤ 90°
gaps max. ux [mm] where s = 0 mm max. uz [mm] where s = 0 mm
where s= 40 mm Standard Special Earthquake where s = 0 mm Standard Special
Design Design Design Design Design
LR2 2 ± 80 ± 12 ± 50 ± 80 ± 21 α 1 = 82° α 1 = 58°
LR3 3 ± 120 ± 12 ± 66 ± 120 ± 20 85 62
LR4 4 ± 160 ± 12 ± 82 ± 160 ± 20 86 63
LR5 5 ± 200 ± 12 ± 98 ± 200 ± 20 87 64
LR6 6 ± 240 ± 12 ± 114 ± 240 ± 20 88 65
LR7 7 ± 280 ± 12 ± 130 ± 280 ± 19 88 65
LR8 8 ± 320 ± 12 ± 147 ± 320 ± 19 88 66
LR9 9 ± 360 ± 12 ± 222 ± 360 ± 19 89 59
LR10 10 ± 400 ± 12 ± 244 ± 400 ± 19 89 59
LR11 11 ± 440 ± 12 ± 256 ± 440 ± 19 89 60
LR12 12 ± 480 ± 12 ± 277 ± 480 ± 19 89 60
LR13 13 ± 520 ± 12 ± 343 ± 520 ± 32 89 57
LR14 14 ± 560 ± 12 ± 367 ± 560 ± 32 89 57
LR15 15 ± 600 ± 12 ± 391 ± 600 ± 32 89 57
Standard Design: Standard joint with limited transverse movement capacity s: Gap width
Special Design: Joint with trumpet shaped joist box for larger transverse movement requirements ux,y,z: Possible movements in x, y, z direction
Earthquake Design: Joint with trumpet shaped joist box and all adjustments necessary to cope with earthquake
movements
 Product characteristics 5

Proof of quality
mageba modular expansion joints prove themselves every day thousands of
times under heavy traffic conditions. Durability is one of their main
characteristics. For more than 40 years they have been successfully used
worldwide.
Qualified staff, up-to-date manufacturing facilities, and consistent quality
control procedures are the fundamental elements which ensure the high
standards of quality of mageba products. mageba has been ISO 9001:2000
and EN 729-2 certified since 1991, and is holding the European Standard
Certificate for welding according to DIN 18800-7.

Materials and corrosion protection

Principal components of mageba modular expansion joints and their material
designation:
• S355 steel lamella and cross beams
• EPDM or CR sealing profile
• Rubber control and sliding springs from elastomeric material
• Sliding bearing from special elastomeric material and PTFE
• Special sliding material Robo®Slide used for joints in highly stressed
situations
The following standard corrosion protection is used for all exposed steel
components:
• SA 3 sandblasting
• 50µm zinc metal spray galvanizing
• two 40µm layers of top coat
Components located underneath the expansion joints can be galvanized with
a minimum thickness of 80µm. Alternative corrosion protection can be applied
upon request. The sliding plates are greased with a special lubricant, and
surfaces in contact with concrete remain in rough condition to have sufficient
friction.

Proven and tested

An independent test institute determined the dynamic performanceindicators
of the system as a whole, such as spring characteristic and damping effect by
conducting roll-over trials.
The figure opposite shows a trial structure, in which the joints were tested for
movement capability on all three axes.
All the components used in a modular expansion joint have been tested for
efficiency in durability tests.

Officially approved
mageba modular expansion joints are approved by numerous national
authorities, such as the German government approval TL/TP-FÜ 92, which
authorises up to type LR15 with 15 sealing profiles per expansion joint to be
used on motorways.
In Austria, mageba modular expansion joints are approved up to type LR12
according to RVS 15.45 standard.

Area of application
When the movement range of a bridge joint exceeds the operational
movement range of a single gap expansion joint (normally 80mm), mageba
modular expansion joints can be introduced. mageba modular expansion
joints can be constructed for large movement ranges (2’000mm and more).
The world’s largest joint at present is the one produced by mageba for the
Run Yang Bridge in China, compromising 27 sealing profiles, witha maximum
possible longitudinal movement capacity of 2’160mm.
 6 Design details

Recess space
The size of the recess space must be determined by the engineer in the early planning stage. The recess space values of the
structure must be checked by the site management before assembly begins, and should be corrected accordingly.

Cross section
Lamella beam

Control box
Joist box
Plan view

Anchor (footpath) Anchor (carriageway )

Joist box Joist beam

Kerb units and footpath

The outline of the kerb unit, which is formed either by welded on steel wedges or by cover plates, can be adopted to virtually any
bridge edge detail.

Standard with
Standard cover plates

Fascia plates
The fascia plates are made using frontally fixed steel sheets, which come in a edge profile
single or double sheet design (see Figure).
lamella
A water-tight edge groove which is running to the lower edge of the fascia is
also possible.
lamella beam

edge profile
 Support and control systems 7

Support system
The lamella beam is fixed to the joist beam with joist frames (see below) and move on elastic pre-stressed sliding components.
In the same manner, the joist box cover connects the joist beams to the joint edges. The entire system is elastic, force-locked
and at the same time remains free to move.

EPDM profile Lamella beam Edge profile Sliding spring

Joist box
Joist box Joist beam Sliding Sliding bearing Sliding bearing (Cross section A-A)
spring

Joist frame
(Cross section B-B)

Control system
Elastomeric control springs, in conjunction with the (EPDM) sealing profiles,
coordinate the individual lamella beams to work as a total kinematic system.
Thus the movement range is distributed across the individual gaps, and at the
same time braking and accelerating forces are elastically absorbed.
The forces are induced into the structural edge by the control boxes, and can
reach the following boundary values:
• Horizontally: maximum 10KN per control box
• Vertically: maximum 18KN per control box
In addition, the elasticity of the control system prevents damage to the joint by
the blocking of single gaps, e.g. caused by debris becoming jammed (through
stones, etc.) in between the individual lamella beams.
The result of the tests performed can be summarised as follows: lamella axis
• Faultless even after 9x105 load cycles (movement ±15 mm, 1 Hz, +20°C)
• Faultless even at extreme temperatures (minimum -50°C and maxi-
mum+70°C)
• Faultless even at high earthquake load (with 100 mm movement pergap)
 8 Bridge connection

Aussparung connection
Reinforcement
The reinforcement connections are arranged perpendicularly to the joint. They
are overlapped with the anchor loops of the modular expansion joint and
secured with longitudinal reinforcement.

Reinforcement arrangement
The reinforcement connection is designed according to the reinforced
concrete construction regulations. The anchor loops on the edge profile are
normally attached perpendicularly to the modular expansion joint. As a result,
the structure’s reinforcement is placed to the anchor loops. An additional
reinforcement should be added underneath the joist beam boxes to prevent
the formation of cracks in the adjacent concrete.
In order to guarantee a proper load transfer into the adjacent structural
components during the entire life of a joint, mageba recommendsthe following
minimum reinforcements:
• Bridge longitudinal reinforcement (Nr. 1):
minimum Ø16mm (a < 250mm)
• Bridge cross reinforcement (Nr. 2):
minimum Ø16mm (3 or 5 reinforcement bars per side, fitted before
installation of the expansion)
• Additional reinforcement (Nr. 3):
minimum Ø12mm (two pieces under each joist beam box)

Edge connections
Each individual bridge requires its own solution for the edge connection.
Preferred designs for concrete and steel bridges are shown in the figures
below .

Concrete bridge Steel bridge

 Special designs 9

Noise reducing top surface

Especially in urban areas, expansion joints should be as noise-free as
possible. mageba developed modular expansion joints with a noise reducing
top surface. The unique patented sinus plates with their teeth design prevent
continuous edges perpendicular to the road surface. This way, they ensure
the continual gripping of the vehicle to the expansion’s surface when driving
over it. Consequently, any unwanted noise from driving over the expansion
joint is greatly reduced.
In contrast to finger joints, there is no restriction as to what kind of traffic is
allowed on modular expansion joints with sinus plates. The special shape of
the sinus plates permits even cyclists to cross-over safely.
It is also possible to retrofit existing modular expansion joints with the noise
reducing sinus plates. This requires that the surface height of the asphalt is
increased by approximately 20mm around the joint edges.
Expansion joints with sinus plates are used on bridge structures in residential
areas and other areas sensitive to noise.

About tests and measurements

Difference in Amplitude (dB) of different joint types
At an independent test facility, fatigue testing was carried out on a piece 10.0

consisting of a lamella beam with bolted on sinus plates. By doing so, the
8.0
durability of the sinus plates and the bolted connections was proven.
(dB)
(dB)

6.0
Noise measurements carried out on different structures by an independent
levelLevel

facility have shown that modular expansion joints with sinus plates are
Noise Noise

4.0

significantly less noisy (up to 70%) than other types of expansion joints. 2.0

Detailed documents on fatigue testing and noise measurements areavailable 0.0

upon request. Roller shuter

Roller shuter
Modular
(450 mm movement range)
(450 mm movement range)
ModularExpansion Joint
Expansion Joint (400movement
(400 mm mm movement
range) range)
Mat
MatExpansion Joints
Expansion Joints (100movement
(100 mm mm movement
range) range)
Cantilever Finger
Cantilever Finger Expansion
ExpansionJoint
Joint (150 mm movement
(150 range) range)
mm movement
ModularExpansion
Modular Expansion Joint
Jointwith Sinusplates
with Sinusplates(400 mm
(400movement range) range)
mm movement

Fuse-Box: earthquake design

Principle of the Fuse Box
The patented Fuse-Box protects the joint and adjacent structure from damage
during an earthquake.
If the bridge gap in the structure closes more than a conventional expansion
joint can handle during an earthquake, this can lead to the damaging or failure
Normal condition of the structure. In order to avoid such damage, it is recommended to equip
the mageba modular expansion joints with the Fuse-Box.
Modular expansion joints equipped with the Fuse-Box are used in areas with
high risk of earthquakes. They not only reduce possible damage ot the
structure, but also ensure that, following an earthquake, emergency vehicles
Open to maximum (earthquake)
are able to cross over in the shortest possible time. mageba delivers other
earthquake safety systems upon request.

Closed to maximum (earthquake)

Situation after earthquake

 10 Assembly and installation

Assembly and transport

The modular expansion joint is assembled in the factory, ready for use. It can
be transported to the installation location as a single component up to a length
of 20 meters. It is lifted into the designated recess by a crane.

Postioning and setting

The joint width and pre-settings are checked first. Then, the height of the
modular expansion joint can be exactly measured on both edge profiles, and
secured with installation welding in such a way that it will work even before
concreting.
Generally, only trained expert staff should carry out the setting of the modular
expansion joints. Detailed assembly and installation instructions can be
provided upon request.

Retrospective installation possible

It is possible, to install the modular expansion joints as well after the road
surface has been laid.
Procedure: The recess for the joint is initially filled with lean concrete or
coarse gravel so that road asphalt can be easily and seamlessly laid. The
road asphalt and the lean concrete or coarse gravel is then removed from the
width of the recess and the modular expansion joint is installed.
The advantage of the retrospective installation lies above all n
i the fact that
the joints can be adjusted to level exactly to the height of the road surface.
This optimises driving comfort, reduces impacts, and increases the durability
of not just the joint but also the road surface.

Formwork and concreting

On the edge profiles, formwork plates are fitted and braced against the joint
edges. A high resistance concrete (C30/37 (B35) or equivalent) si carefully
added into a recess, which has been kept moist. It is then compressed and
the concrete joint is checked for shrinkage.
Attention: No concrete may penetrate the joist beam boxes!

Operation and maintenance

The modular expansion joint’s self -cleaning effect means maintenance is not
necessary under normal operating conditions. It is sufficient for checking to be
limited to general bridge inspections, where engineers shall check for leakage
and corrosion.
In order to identify and repair possible damage at an early stage, it is
recommended that an annual inspection of the joint is carried out. Detailed
instructions for inspections are available upon request. mageba also offers
inspection services as needed.
Any worn parts can be quickly and simply exchanged.
 Quotation and ordering 11

Inquiries
When making an inquiry, submit the relevant design criteria for the joint, thus
allowing us to give you the ideal choice of joints and the best quotation. It is
best, if you can also provide some drawings to indicate the joint geometry.
We process quotes immediately and make them available in a short time.

Quotation
To provide you with a quotation we will need the following documents :
• Detailed drawings of the area of the joint (bridge cross-section)
• Range of movement (requested movement capacity)
• Acceptable gap width (e.g. 80 mm per gap)
• Movement directions (for joints with skewed movements see Page 4)
• Asphalt or concrete connection details
Special considerations should be outlined in detail in your quote request.
Movements, edge connections for thicker surfaces or steel superstructures,
modular expansion joints with bridge gap widths, kinks or curvatures are
examples of special considerations.

Placing of orders
In addition to the information already supplied, the following documents are
also necessary when placing an order:
• Layout drawing of the structure
• Breakdown of all movement
• Pre-setting values
Work begins once the customer has approved and returned the documents
containing the pre-setting values.
Delivery time is kept to a minimum thanks to an efficient order processing
system and modern manufacturing methods.

The most important features of mageba LR Type modular expansionjoints

• mageba invented the modular expansion joint and has been producing them since 1963
• The modular expansion joints are approved by numerous national authorities such as the German TL/TP-FÜ92 standard
and the Austrian RVS 15.45 standard
• Quality assurance to ISO 9001:2000 and EN 729-2 certification
• European standard welding certificate DIN 18800-7
• External quality control conducted by independently approved institute
• Modular expansion joints come with noise reducing surfaces (sinus plates) as well as earthquake systems

Stoerebaelt West Bridge, Denmark

Equipped with 7 mageba Type LR modular expansion
joints (maximum possible longitudinal movement of
1’200mm)
 12 Products and references

Bridge Bearings
- Pot Bearings
- Elastomeric Bearings
- Spherical Bearings
- ILM - Bearings
- Special Bearings
- Rocker Bearings

Expansion Joints
- Single Gap Joints
- Modular Expansion Joints
- Sliding Finger Joints
- Cantilever Finger Joints
- Matt Joints
- Railway Joints
- Architectural Joints

Shock Absorbers
- Hydraulic Shock
Absorbers
- Spring Dampers

Services
- Inspections
- Tests
- Installations
- Refurbishments
- Cleaning
- Remote monitoring

More information on mageba and their products can be found onwww.mageba.ch

Worldwide references

®
mageba sa mageba sa mageba gmbh mageba gmbh
Solistrasse 68 Route de Montheron 8D Vogelsang 1 Seglerweg 1
www.mageba.ch 8180 Bülach 1053 Cugy VD 37170 Uslar 6972 Fussach
Switzerland Switzerland Germany Austria
Tel.: +41-44-872 40 50 Tel.: +41-21-731-0710 Tel.: +49-5571-9256-0 Tel.: +43-5578-75593
Fax: +41-44-872 40 59 Fax: +41-21-731-0711 Fax: +49-5571-9256-56 Fax: +43-5578-73348
info@mageba.ch cugy@mageba.ch mageba@t-online.de mageba@aon.at

bridges linking people - worldwide ®

Version 2004.11