mageba repair and replacement services for modular expansion joints

Product catalog summary

Overview: The document outlines the 'Box in Box' method developed by mageba for the repair and replacement of modular expansion joints in bridges. This method focuses on minimal encroachment, quick installation, and reduced costs by retaining the existing substructure.

Concept and Planning: The method allows for the replacement of damaged expansion joints without impacting the bridge's structure. The new joint is placed on the old substructure, which is repaired as needed. This approach can reduce costs by allowing for a joint with lower movement capacity, as deck shrinkage and creep have already occurred.

Methodology: The replacement process is not governed by specific norms, so mageba bases its design on existing standards and national approvals. The construction methodology is adapted to the old joint type, with new support bar boxes concreted into the old ones.

Preparatory Works: Necessary road closures and traffic management are arranged. The asphalt and waterproofing membrane are removed to treat the substructure with corrosion protection. Scaffolding may be erected for better access.

Joint Replacement Procedure: The procedure involves several steps: removing old components, cleaning and priming retained parts, positioning and welding new components, filling voids with grout, and applying corrosion protection. The process can be phased to minimize traffic disruption.

Final Works and Acceptance: The waterproofing membrane and road surface are reinstated, and the works are inspected and handed over to the bridge owner.

Structural Monitoring: Suggested text for tender requests includes details on the renewal process, surface treatment, and optional features like noise-reducing plates.

Project References: Examples of completed projects include bridges in Germany such as the Inn Bridge Simbach and Rhine Bridge Frankenthal.

Catalog excerpts

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Monitoring & Services mageba repair and replacement services for modular expansion joints minimal encroachment, quick installation, reduced cost

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Monitoring & Services Concept and planning Repair and replacement of old or damaged modular expansion joints mageba - an innovative partner for renovation works In the course of routine structural inspections, damage to expansion joints and deterioration due to age is often observed, which may require a joint to be replaced. Because such a replacement method is not governed by any norm or standard, mageba ensures that the design is based as closely as possible on existing expansion joint design standards and national approvals. If the bridge structure is otherwise in good condition, it is desirable...

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Monitoring & Services Joint replacement Procedure To optimise the work for all concerned, it is carried out in steps as described below. After removal of shuttering, the existing steel edge profiles (including waterproofing membrane connection flanges) are reinstated where removed, and equipped with new connection steel for the elastomeric sealing profiles of the joint. Step 1: Removal of the old elastomeric sealing profiles and lamella beams (centerbeams), and the steel edge profiles at each support bar location. The top of each support bar box is then cut away, enabling the old support bars...

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Monitoring & Services Suggested text for tender requests Renewal of an existing modular expansion joint. Removal of all load-bearing and moving parts of the existing joint, and replacement with a new watertight modular expansion joint of proven quality and durability. Retention of the existing substructure (concreted-in parts) to support the new expansion joint. All necessary surface treatment and corrosion protection works are to be included in the pricing. Target thickness of corrosion protection to be 390 µm. All voids between existing and new support bar boxes to be filled with non-shrinking...

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