vicroads

1999/002 Bridge Technical Note

DESIGN OF DECK JOINTS FOR ROAD BRIDGES

1. SCOPE

This document sets out VicRoads’ requirements for design and specification of deck joints for road bridges.

This document is supplementary to, and should be read in conjunction with the AS 5100 ‘Bridge Design’ -
2004 and Sections 660 of VicRoads’ Standard Specifications for Roadworks and Bridgeworks.

2. GENERAL

Deck joint systems are assessed for use by VicRoads based on the following criteria:-
• Compliance with AS 5100 requirements for loads, movements and material standards,
• Documented evidence of satisfactory performance for the particular in service conditions, and
• Experienced engineering judgement.

VicRoads Design’s practice is to provide on the bridge drawings a list of acceptable deck joint systems from
which the contractor may choose a supplier. If the contractor wishes to use an alternative joint system, the
contractor must submit design details in accordance with AS 5100 for the alternative. VicRoads makes the
final decision on the joint system to be used.

Appendix 1 of this Technical Note provides information on deck joint systems which have been
satisfactorily used by VicRoads. A list of suppliers of these deck joints is also provided.

3. DESIGN REQUIREMENTS
Deck joints and their associated anchorages shall be designed for the Ultimate Limit State traffic loads and
movements specified in AS 5100 with particular reference to Part 4 Clause 17.

Repair of deck joints is one of the most common, costly and potentially dangerous maintenance tasks.
Hence, it is essential to design and install these systems in a manner that minimises their maintenance
requirements.

3.1 Design Loads

Deck joints and their anchorages shall be designed in accordance with the requirements of AS 5100.4
Clause 17.3.2.

3.2 Fatigue
Deck joints shall be designed for fatigue in accordance with the requirements of AS 5100.4 Clause
17.3.3.

3.3 Movements
Deck joints shall be designed to accommodate Ultimate Limit State movements specified in AS 5100.4
Clause 17.3.4. Components of movement including temperature, creep, shrinkage, prestress, and any
additional construction or settlement movements likely to occur during the life of the bridge should be
considered. Ultimate load factors are given in AS 5100.2.

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Design of Deck Joints for Road Bridges

Deck joints do not normally accommodate full movement due to braking forces. The designer should
ensure that once the available travel of the deck joint has been exhausted, the additional force due to
braking can be resisted by passive earth pressure behind the abutment and the approach slab, if any.
The ultimate joint movement requirements and installation gap at a temperature of 20°C shall be
nominated on the drawings.

3.4 Gap Width

Requirements for gap widths and definition of open joints are specified in AS 5100.4 Clause 17.3.5.

3.5 Anchorage of Deck Joints

Anchorage requirements for deck joints shall be as specified in AS 5100.4 for two methods of
installation; that is, cast-in anchors or deck joints fixed by tensioning bolts or screws.
The use of masonry anchors is not permitted.

3.6 Drainage

Deck joints are rarely completely watertight, and sealing is recommended to prevent the entry of water
and dirt which not only requires a drainage system, but causes staining and deterioration of the bridge
superstructure and substructure.
When deck joint drainage is provided, it should be designed to facilitate inspection and maintenance.

3.7 Installation
Deck joints should be designed and detailed to follow the bridge deck geometry including kerbs and
parapets when used. Specification Section 660 provides installation tolerances, and AS 5100.4
Clause 17.7 specifies a method of determining the bridge temperature at installation.
The most common maintenance requirements of deck joints are anchorage failure which can be
attributed to under-design or poor installation. For this reason Specification Section 660 requires all
deck joints to be installed by the supplier.

3.8 Maintenance
To ensure that deck joints are supplied and installed in accordance with the manufacturer’s
specifications, the supplier shall install the joint and provide a warranty on the serviceability of the joint
for a minimum period of 10 years after installation.

3.9 Joint Sealants

Flexible continuous joint sealants and fillers, and pourable sealants may be used on short span bridges
with movement range less than 20 mm. Movement range is limited to + or – 25% of the installation
width. The advantage of this type of deck joint is the seal is repairable without replacement of the full
length of seal.
Cellular neoprene compression seals are often used to replace the types of sealants referred to above.
Compression seals may be used with concrete, or steel plate ‘nosing’ – refer to 4.1 below. Compression
seals should be continuous for the full length of the deck joint

3.10 Detailing
To simplify detailing and fabrication, alignment of skew deck joints should be ‘square’ at crossings of
kerbs and parapets.

4. JOINT SYSTEMS

4.1 Compression Seal Joints

Compression seal joints consist of a cellular neoprene seal held in position by a combination of
precompression and adhesive. The vertical faces may be formed or saw-cut concrete for light traffic use
(less than 150 v p d) or steel plates. The seal should be supported so that it is 5mm below the deck level
to prevent damage by traffic.

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Design of Deck Joints for Road Bridges

Compression seal joints are not suitable for skew joints as the cellular seal will be subject to racking
movements which breaks adhesion on the nosings. The most common failure of compression seals is
caused by loss of adhesion and ‘walking’ of the seal out of the recess. All compression seals shall be
installed in accordance with the supplier’s recommendations using a lubricant/adhesive which is
compatible with the seal material.
Cellular compression seals come in many sizes and shapes, but are designed to work within a movement
range. Seals must resist loading from stones and road debris and the walls are subjected to fatigue from
temperature movement and may eventually fail due to tearing or splitting. Joint suppliers shall provide a
test certificate showing that the seal is made from elastomer passing specified material test criteria.

4.2 Strip Seal Joints

Strip seal joints consist of a continuous elastomeric membrane held in place by recesses in steel or
aluminium alloy edge protection strips. The edge protection strips are bolted down using fully tensioned
high tensile bolts. This type of joint is relatively easy to install and maintain and the edge strips can be
raised or replaced if required.
The movement range of this type of joint is limited by AS 5100 maximum allowable open gap width of
85mm. The minimum gap may be 0 or 15mm depending on the shape of the membrane. Joint suppliers
shall provide a test certificate showing that the seal is made from elastomer passing specified material
test criteria.

4.3 Finger Plate Joints

Finger plate joints consist of overlapping steel or aluminium fingers which allow longitudinal
movements of up to 300mm. Water passes freely through the joint and is collected in a trough or the
joint may be fitted with a neoprene seal.
Design of the fingers and anchor bolts should be in accordance with AS 5100.4, and the joint geometry
should provide maximum gap widths of 35mm where bicycle access is allowed.
Wide finger plate joints and joints located at turning lanes are not recommended unless a suitable
permanent surface treatment is employed to prevent vehicles skidding on the exposed steel.

4.4 Asphaltic Plug Joints

These joints may be suitable for replacement of existing deck joints or for short span bridges having
expansion movements of less than 20mm. The joint consists of a mixture of flexible binders and
aggregate constructed in place to form a flexible layer across the expansion gap. A flashing layer
prevents the joint material from entering the gap and these joints are usually cured using hot air.
Serviceability of these joints is dependent on quality control of materials and workmanship. Asphaltic
plug joints are not suitable for stopping/turning movements or where there are low or very high/heavy
traffic volumes.

4.5 Modular Joints

Provisions for modular deck joints are specified in AS 5100 4 Clauses 17.3.2 and 17.6.
Modular or multi-seal joints are used on bridges having expansion movements in excess of the range of
finger plate joints. These joints have internal bridging members which support the joint modules which
carry the wheel loads. Modular joints contain sliding surfaces which are subject to wear and can become
noisy if not correctly maintained.
In addition to the requirements of Clause 3.8 of this BTN, maintenance of modular joints shall be carried
out by the supplier in accordance with a service agreement to be established as part of the Contract.
Bridges with modular joints shall provide access for maintenance of the joint from below deck level if
possible.

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Design of Deck Joints for Road Bridges

5. CALCULATION OF JOINT MOVEMENT

The following steps are typical of the design process required to determine the movement requirements of
deck joints for a particular bridge.

STEP 1 : From the bridge geometry, support conditions and construction sequence, calculate
horizontal stiffness of all supports, including substructure and any stiffness of the deck joints being
considered.

STEP 2 : Determine the ‘null’ or point of fixity of the bridge.

STEP 3 : Determine the average age of the superstructure concrete at the time of installation of the
deck joints.

STEP 4 : Calculate longitudinal and lateral movements due to temperature using the temperature
range from 20°C and the Code coefficient of thermal expansion in AS 5100.5 Clause 6.1.6.

STEP 5 : Calculate movement due to shrinkage using AS 5100.5 Clause 6.1.7 to determine values
of k1 for the appropriate environment and the average age of the concrete and 30 years. Calculate the
movement due to shrinkage using the net value of k1.

STEP 6 : Calculate movement due to creep using AS 5100.5 Clause 6.1.8 to determine values of k2
and k3 for the appropriate environment and the average age of the concrete and 30 years.

STEP 7 : Calculate movement due to braking forces using the longitudinal force obtained from
AS 5100.2 Clause 6.8.2 divided by the stiffness found in STEP 1.

STEP 8 : Tabulate all joint movement components and ultimate load factors from AS 5100.2, and
hence calculate the worst combinations of ULS movements. Braking force movements do not need
to be included in the total movement, provided that designers ensure that once the available travel of
the deck joint has been exhausted, the additional force due to braking can be resisted by passive
earth pressure behind the abutment.

STEP 9 : Choose, and show on the drawings suitable alternative deck joints having sufficient
movement capacity. Show also initial (20°) and maximum gap, and dimensions of deck joint profile
including kerbs and parapet, if any.

6. REFERENCES

AS 5100 – ‘Bridge Design’ 2004

VicRoads Specification Section 660 – Deck Expansion Joints

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Design of Deck Joints for Road Bridges

Approved June 2005

MIKE VEREY
PRINCIPAL BRIDGE ENGINEER

For further information please contact:

Principal Bridge Engineer
3 Prospect Hill Road Camberwell Vic 3124
Telephone: (03) 9811 8307
Facsimile: (03) 9811 8329
Email: mike.verey@roads.vic.gov.au
Bridge Tech Notes are subject to periodic review and may be superseded.

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Design of Deck Joints for Road Bridges

APPENDIX 1
Table 1 below shows deck joint system types and suppliers. VicRoads’ information is taken from suppliers’
catalogues – further information may be obtained from the suppliers listed below.

TYPICAL MOVEMENT PRODUCT

JOINT SYSTEM SUPPLIER
RANGE (MIN-MAX) mm NAME

Evazote Austress-Freyssinet
COMPRESSION Firmsec FMS-C Firmsec
20 – 40, 50 – 80
SEAL Miska NH Miska Pty Ltd
Wabo Granor Rubber & Eng

Ausflex AC-AR Granor Rubber & Eng

Cipec WOSd or WR Austress-Freyssinet
STRIP SEAL 15 – 85
Firmsec FMS-HD Firmsec
Miska BJ6 Miska Pty Ltd

Cipec Wd Austress-Freyssinet
FINGER PLATE 0 – 250
Firmsec FMS Firmsec

ICL FC44 ??? Miska Pty Ltd

ASPHALTIC PLUG 20 – 40 Wabo Expandex Granor Rubber & Eng
Thormajoint Prismo Pty Ltd

Maurer Firmsec
MODULAR Up to 500
SHW Austress-Freyssinet
D.S Brown Steelflex Miska Pty Ltd

Table 2 Deck Joint Suppliers

Contact Phone
Company Address
Number

37 Prime Drive
SEVEN HILLS NSW 2147 (02) 9674 4044
Austress-Freyssinet Pty Ltd Or Or
Level 3 313 Burwood Road 9810 4527
HAWTHORN VIC 3122

Firmsec 36 Phoenix Street

9387 3806
BRUNSWICK VIC 3056

Granor Rubber & Engineering Pty Ltd 2 Turbo Drive

9720 6606
BAYSWATER NORTH VIC 3153

Miska Pty Ltd PO. Box 4203

9725 5711
CROYDON HILLS VIC 3136

Prismo Pty Ltd 18-20 Pelmet Crescent 1300 309 577

THOMASTOWN VIC 3074

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