USL PRODUCT RANGE C1/SfB

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Transflex Expansion Joint System (BD33/94: Type 5 Elastomeric)

The Transflex System is a heavy duty flush surface joint for situations exposed to a range of traffic conditions such as multi-storey car parks,
shopping centres, overpasses and highway bridge decks. The Transflex system differs to that of the Britflex ‘BEJ’ system in that it comprises
of steel angles and a steel bridging plate encased in a flexible elastomer which is bolted to the structural deck on either side of the
expansion joint.
A range of models is available to accommodate movement up to 330mm, and skew angles, providing a substantially waterproof joint with a
smooth, wear resistant surface.

UCP Expansion Joint System

The ‘UCP’ Expansion Joint System has been carefully developed to provide a safe, efficient and economical method of sealing low to
medium movement expansion joints in pedestrian footbridge and car park structures. The system meets all medium expansion joint
requirements and is capable of accommodating movements up to + 35mm.
The system utilises the proven design technology successfully used in the Department of Transport approved Britflex ‘BEJ’ range of
expansion joints. The ‘UCP’ system is particularly suitable for applications where watertightness, low noise and smooth riding
characteristics are paramount.

Febajoint (BD 33/94 Type 2 Asphaltic Plug Joint)

A Department of Transport approved asphaltic plug joint for use in low to medium movement expansion joints on highway structures.

‘NJ’ Expansion Joint System (BD 33/94 Type 4 Nosing and Preformed Compression Seal)
The ‘NJ’ Joint is ideally suited for maintenance schemes and has been developed to provide a whole life economic solution for applications
where previously asphaltic plug joints have always been considered and can be installed to the full depth of the surfacing.

‘LJ’ Expansion Joint System

The ‘LJ’ System has been specifically developed to provide an effective method of sealing soffit and longitudinal expansion gaps. It is
available in a range of sizes to suit individual requirements.

Uniflex Buried Joint System (BD 33/94: Joint Type 1)

The Uniflex Expansion Joint System consists of a continuous Butyl rubber membrane bonded to the substrate with Uniflex Epoxy Adhesive,
providing a tough, flexible, waterproof and permanent joint that is easily installed. The Uniflex membrane is capable of withstanding up to
300% elongation and is ideally suited to a variety of conditions from those on an asphalt-covered car parks and bridge decks with sheet
membrane, spray on coating or asphalt waterproofing. It can also be used with two layer mastic asphalt or brick paving systems.

Dri-Deck Bridgedeck Drainage

Dri-Deck Bridgedeck Drainage is a patented system designed to collect water from the upper surfaces of bridge deck waterproofing
membranes and protective layers to alleviate damage to bridge deck surfacing during freeze thaw cycles.
 Universal Sealants (U.K.) Ltd

BridgeCare Offering the complete service for bridge

A division of Universal Sealants (UK) Limited
deck protection.
l expansion joints
l spray membranes
l concrete repairs

StructureCare Supply and installation of expansion joints,

A division of Universal Sealants (UK) Limited
protective coatings, concrete repairs and
joint sealants to car parks, elevated
structures and the construction industry.

International Supply and installation of bridge expansion

A division of Universal Sealants (UK) Limited
joints and specialist construction products
worldwide.

Nufins Manufacturers and suppliers of formulated

A division of Universal Sealants (UK) Limited
products for civil engineering, construction,
repair and refurbishment.

Head Office
Universal Sealants (U.K.) Ltd. Kingston House, 3 Walton Road, Pattinson North, Washington,Tyne & Wear, NE38 8QA, United Kingdom.
T: +44 (0)191 416 1530 F: +44 (0)191 415 4377 W: www.usluk.com E: [email protected]

Sales and Marketing

Universal Sealants (U.K.) Ltd. Blenheim Court, Newbold Road, Chesterfield, Derbyshire, S41 7PG, United Kingdom.
T: +44 (0)1246 207 000 F: +44 (0)1246 209 100 W: www.usluk.com E: [email protected]

North America China Malaysia Singapore

USL North America Panyu Chengzhu USL Asia Pacific (M) SDN BHD USL Asia Pacific PTE Ltd.
Strategic partner of the Britflex Expansion Joints Ltd. No.1, Jalan TPP 5/16, 50 Tuas Crescent,
Geocel Corporation, 99 Wu Yang Nan Lu, Taman Perindustrian Puchong, Singapore,
53280 Marina Drive, Wu Jin Town, Seksyen 5, 638730
Elkhart, Xin Jin County, 47100 Puchong, T: +65 6863 6363
IN 46514 Chengdu, Selangor Darul Ehsan, F: +65 6861 9566
Sichuan Province, Malaysia.
T: +1 800 348 7615 W: www.usluk.com
611430
F: +1 800 348 7009 T: +60 3 8061 4223 E: [email protected]
P.R.C.
W: www.usluk.com F: +60 3 8061 5223
E: [email protected] T: +86 28 8251 1338 W: www.usluk.com
F: +86 28 8251 1498 E: [email protected]
W: www.usluk.com
E: [email protected]
APRIL/2004

FM 11022
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BRITFLEX ‘BEJ’
EXPANSION
JOINTS

BRIDGING THE GAP

WORLDWIDE
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Figure 1
The Product In Brief
Carrier rail
The ‘BEJ’ Expansion Joint is a surface Standard 48 x 25
mounted mechanical system, with an low profile 43 x 25
elastomeric insert between two metal
runners or carrier rails. It is unique in that Elastomeric
the rails which house the insert are set insert
into a patented, rapid curing elastomeric
Sinusoidal
resin compound known as Britflex Resin anchorage
Mortar. (See Figure 1).
Anchorage to the deck is achieved
through the remarkable bonding qualities
of the polyureide resin, without the need Through deck
drainage
for any mechanical fixings. This type of Britflex “Dri-Deck unit”
system has an unrivalled worldwide track resin mortar
record of in-service performance over the Plinth cast monolithic
past 25 years. with bridge deck

The ‘BEJ’ system is registered with the Structural

Concrete Structural
UK Highways Agency for use on highway Abutment Concrete Deck
bridge decks on all classes of roads and
motorways. (Department of Transport BD which are load bearing enabling a range failed joint systems. The benefits of
33/94: Joint Type 6 refers). The Britflex of movement to be accommodated up rapid on site assembly allow phased
‘BEJ’ system is included in the Highways to 150mm. working outside peak traffic hours
Agency list of approved products SAI/98. resulting in minimum traffic disruption
Britflex Resin Mortar is also included in The Britflex ‘BEJ’ For which results in a significant saving of
SAI/98 as an approved material for associated traffic management costs.
transition strips to all types of expansion
Maintenance
The track record of the system shows
joint. ‘BEJ’ Expansion Joints incorporate The Britflex ‘BEJ’ is ideally suited for that future maintenance costs are
cellular elastomeric inserts maintenance schemes to replace other also minimised.

A total of 1290 linear metres of ‘BEJ’ Expansion Joint have been successfully installed throughout the
Channel Tunnel U.K. Terminal Network.
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Design Detail
Table 1
4
Minimum Nominal 1 Minimum Maximum Cover to 2 Kerb Upstand 5 Optional 3
Movement Capacity Nosing Sizes Kerb Plate
Nosing Gap Nosing Gap Nosing Gap Services Clearance
Detail

BEJ Horizontal Vertical C D B B. Min. B. Max. E X W

3 35 +12 100 60 45 25 60 70 125 + 125 tan a 225

5 50 +15 120 60 55 30 80 70 125 + 135 tan a 270

8 80 +15 140 70 70 30 110 85 125 + 145 tan a 310

10 100 +15 160 70 90 40 140 105 125 + 160 tan a 365

13 130 +15 180 70 115 45 175 165 125 + 170 tan a 405

15 150 +20 200 70 125 50 200 180 125 + 180 tan a 445

NOTE: Elastomeric insert changes according to joint size. All dimensions in mm

Notes
1. Nominal nosing gap is that selected at average design effective bridge deck temperatures and does not take movement into account
other than temperature movements.
2. This is the standard condition. Please refer to USL Technical and Advisory Service if a ‘special’ is required.
3. Based on minimum nosing widths – see Figure 10 and specification Paragraph (xi).
4. For skew movement, greater than + 15mm, please refer to USL Technical & Advisory Service.
5. See Figure 2 and 4.

C B C

D E

Verge Carriageway

a
Nosing to
match kerb
profile

Cha
ng
of u e in slo
psta pe
nd

Face of kerb
X

Plan
Figure 2 Plan on Skewed Joint Figure 3 Kerb Detail
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Section
Design Guidelines to depth, if in our doubt please contact Nosing to
our Technical and Advisory Service. Rails suit kerb
The ‘BEJ’ Expansion Joint is not only D
simple to install but easy to detail at the When placing Britflex resin mortar around
design stage. The USL Technical and services, the designer should give 25° D
Advisory Service is however able to assist consideration to the spacing around them.
X
and advise on all detailing matters, from A minimum clearance of 25mm is
the most simple to the most complex of required beneath services/sleeves and the
problems. Figure 4 Kerb Detail
top clearance is given in Table 1. This is to
accommodate the insert which dips NOTE: Upstand plinth reinforced
Simplicity – between the nosings at maximum and formed as part of
compression. Bridge Deck.
Based on essentially three component
materials, the ‘BEJ’ system is flexible and A spacing of 125mm between each duct
may be adapted in numerous different is required to enable proper construction
configurations. of the joint. It is normally sufficient to
The standard method of installation for provide a debonding/sleeving
new works is to cast the resin nosings arrangement on the abutment side.
directly on to structural concrete of the
abutment & plinth cast monolithically with Drainage –
the deck. See figure 1. A drainage channel is normally used to
At the kerbline, the plinth and ballast wall relieve hydrostatic pressure in the
should be ramped to deal with the change surfacing when the expansion joint is at
in level. Details are indicated in Figure 4. the low end of the bridge deck.

Alternatively the nosings may be extended The channel is terminated with a flexible
to match the depth of the bridge deck tube, either down the expansion gap or
surfacing, both in the carriageway and the into pipework, cast into the deck within
verges. However in so doing, attention the area of the joint.
must be paid to the aspect ratio of the The channel is not usually required when
nosing, the passage of any service ducts the expansion joint is at the high end of
through the resin mortar and the drainage the bridge deck. Figure 5 Alternative at Kerbline or
of the surfacing upstream of the joint. into Parapet Recess
(See Figure 7). It is recommended that the use of a more
positive and larger capacity ‘Dri-Deck’
Flexibility – drainage system is considered, either in
conjunction with or in place of the in-
Britflex resin mortar exhibits excellent joint drainage.
bond strength to steel as well as concrete.
Therefore the ‘BEJ’ system may also be If this is adopted and the expansion joint
set onto metal deck plates or into a is built onto a structural concrete upstand
recess provided by metal shelf angle as per figure, in-joint drainage may be
supports. (See Figures 8 and 9). considered to be redundant.

In maintenance particularly, the top plate In order to provide a satisfactory

of certain types of mechanical joint or junction to the bridge deck waterproofing
vertical upstand joint may be removed system, the membrane should be brought
and the ‘BEJ’ Expansion Joint bonded to 50mm into the joint area on both sides
the lower plate provided of course it is of the joint.
securely anchored. This is subsequently removed during the
Alternatively the steel carrier rails of the installation of the ‘BEJ’ Expansion Joint
‘BEJ’ system may actually be welded and the free edge of the
directly to the lower plate, but advice waterproofing sealed with resin at the
should be taken prior to undertaking this priming stage.
application. Figure 6 Alternative at change on
Movement – plan
Steelwork should be clean and free of
rust. Table 1 indicates the basic movement
capacity of each joint in the system.
Standard Nosings for new works have an
aspect ratio of nominally 2:1 in width to
depth. When using nosings of the same
depth as surfacing, the appropriate width
will depend on the joint type, class of
road and extent of trafficking but never
less than an aspect ratio of 1.25:1 width
 BEJ EXPANSION JOINTS C1/SfB
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Design Details provided that advice has been taken

from the relevant Statutory
(a) Carriageway Authority regarding the effect of
In new works or when re-surfacing heat at 80°C (max).
in maintenance schemes, it is (d) Kerbs
necessary to temporarily cover the
expansion gap to prevent ingress of Kerbs should be laid starting flush
materials into the deck expansion with and working away from the
gap. Any such coverings should be expansion gap. The kerbs are saw
easily removed when the trench is cut to the appropriate trench width
excavated for the joint. and removed during the joint
installation.
Temporary saw-cuts into the newly
laid surfacing above the deck Proprietary continuous kerbline side
expansion gap may be considered entry gully systems may be used in
necessary to prevent unacceptable conjunction with the ‘BEJ’
cracking of the surfacing before the Expansion Joint. Expansion Units
joint is installed. This may not be are available which are compatible
required when the joint is installed with the ‘BEJ’ system. Advice should
shortly after the surfacing has been be sought from USL or the BEJ Expansion Joints have been
laid. manufacturers of the side entry installed in the Moscowretski Bridge,
gullies at the design stage. Moscow, Russia.
However if appreciable deck
movement is predicted after (e) Footway Areas
surfacing and before joint Kerb cover plates or footway cover
installation, the saw cutting should plates can be provided as an
be carried out by the main optional addition. The USL
contractor after the surfacing has Technical and Advisory Service
cooled sufficiently. should be consulted regarding their
(b) Verges inclusion.

Granular verge and central reserve Other Applications

construction immediately adjacent
to the joint is not recommended. (i) As an improvement over
asphaltic plug joints for low
A concrete verge infill is movement joints in heavily trafficked
recommended adjacent to the joint areas subjected to standing traffic,
and a trench should be formed to on heavily skewed joints or steeply
accommodate the required joint graded carriageways. However the
width. NJ system may prove to be more
If flexible surfacing is required over suitable
any verge concrete the prepared
trench may be temporarily (ii) As a longitudinal joint between
backfilled and the position of the two deck halves. However the ‘LJ’
trench referenced on the kerb and system may be more suitable.
parapet by the main contractor.
(iii) On building structures, car parks
Any newly placed concrete should and elevated ramps with the need
be nominally seven days old and for a heavy duty expansion joint
cured in accordance with the system.
contract. Concrete of at least grade
30 is recommended. (iv) On marine quayside structures.
(c) Service Ducts
(v) On footbridges, however the
Any service ducts passing through ‘UCP’ system may be more suitable.
the joint should be properly sleeved
to revent leakage and articulated to (vi) Britflex Resin Mortar may be Section of carriageway installed with
the Engineers details. used for new and replacement the ‘BEJ’ Expansion Joint System.
transition strips to elastomeric
Ducts and sleeves may be in uPVC The ‘BEJ’ Expansion Joint System has
expansion joints and general
or other similar materials provided been extensively used throughout the
carriageway ironmongery. It may
they do not appreciably soften A74(M)/M6 upgrade. Universal
also be used as a transition to the
below 80°C. Cables should not be Sealants successfully installed 1486
metalwork of existing proprietary
drawn until after the joint is expansion joints where the adjacent linear metres of expansion joints on
installed, if at all possible. surfacing is distressed. all nine sections of the project, to 38
individual structures.
Cables may be retained in existing
ducts during joint installation
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Specification For (vii) Discharge Tube

The ‘BEJ’ Expansion Joint When an in-joint drainage channel is
specified, this is terminated with a
Materials braided PVC flexible tube with a
25mm internal diameter (32mm
(i) Polyureide Resin
external diameter), discharging to a
The patented Britflex Polyureide suitable collection point.
Resin is a two part liquid system
comprising one clear component (viii) Polystyrene
(Base) and one black (Hardener).
25mm and 50mm sheets of
Packed in colour coded drums.
expanded polystyrene are cut to Structural
size to form a temporary shutter in Concrete
(ii) Aggregate
the expansion gap between the
The aggregate is a graded mix nosings and also in the kerb area.
supplied in 20kg sealed plastic bags. Figure 9
(ix) Spacer Plates
(iii) Carrier Rails
The spacer plates set the rails at the
Nosing recessed and
The extruded metal rails are appropriate gap setting during

B
to match kerb face
supplied in either mild steel to installation.
Grade 070M20 (BS 970 Pt.1:1983)
with factory applied corrosion
They are available in 5mm B
increments.
protection or at additional cost in
Grade 304 stainless steel. The
(x) Strongbacks/Hangers

W
extrusion is nominally 25mm wide
x 48mm deep with welded The spacer plates are connected to
sinusoids to provide anchorage into the hangers which suspend the rails
the Britflex Resin Mortar. The rails over the expansion gap at Plan
are generally delivered in 7500mm carriageway level.
lengths and cut to length on site.
Figure 10
For special applications a
(xi) Kerb/Footway Cover Plates Aluminium five bar tread
25mm wide x 43mm deep pattern kerb cover plate
(Optional Additions)
carrier rail is available.
These may be supplied fabricated D
(iv) Kerb Units from 4.5mm thick aluminium plate
D
with five bar tread pattern.
The metal carrier rails are cut, Resin nosing
mitred and welded on site, to suit
the kerb upstand detail. Figure 7
Technical & Advisory Service
(v) Elastomeric Insert Further technical information may be
The extruded EPDM insert is obtained on request and consultation is
available in various sizes, each encouraged to ensure choice of materials
capable of accommodating a selected and detailing are optimised to suit
different range of movement. in-service performance requirements and
The inserts are supplied in coils economic solutions.
of a maximum length of 25/60m.
Health & Safety
(vi) Drainage Channel (optional) Universal Sealants U.K. Ltd. operate a
Structural
Standard drainage channel is 20 Concrete strict policy on health and safety and
x 20mm square aluminium tubing, in details are available on request.
5 metre lengths. The channel has Figure 8
11mm diameter holes drilled on Note:
one face at 90mm nominal centres. The colours used in the illustrations may not be
indicative of the finished product.
If specified, the channel is installed Universal Sealants U.K. Ltd. reserve the right to
along the carriageway length of update and improve the ‘BEJ’ Expansion Joint and its
the joint. specification without notice and Engineers and
Contractors should satisfy themselves that they have
full and up to date information.
Stitch welding Steel Britflex is a registered trade mark of Universal Sealants
(Intermittent) Deck Plate
U.K. Ltd.

7.99
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Installation (x) The rails are positioned on spacer

plates of the selected size, attached
(a) General steps in the installation to the hangers/strongbacks,
of the ‘BEJ’ Expansion Joint positioned over the expansion gap
and set for line and level.
(i) The two resin components are
warmed in oil jacketed gas fired
heaters and maintained at 65°-85°C.

(ii) The joint width is marked out on

the asphalt surfacing and saw cut to
provide a trench in the carriageway.
The trench width will depend on the
selected nosing width, type of joint
and the required gap setting.
(vii) If drainage is specified, prime
beneath the position of the drainage
channel with a mix of the two resin
components. (See section (xi)).The
drainage is fixed with masonry nails (xi) The polyureide resin is batched
into the surfacing and protected from calibrated jugs of the two
from resin ingress with masking components and mixed with a
tape. The flexible discharge tube is powered paddle until homogeneous
then fitted at the low end of the and streak free.
channel and terminated.
(xii) The resin mortar is batched by first
(viii) The polystyrene shutter is cut to pre-heating one 20kg bag of
size and placed in the expansion gap, aggregate to approximately 70°C in
ensuring it is firmly in the gap. The a powered mixer. One batch of the
complete trench is then primed with resin compound (See (xi)) is then
the resin mix. (See section (xi)). added and mixed until
(iii) The surfacing or the existing failed homogeneous.
joint is broken out and removed.
(xiii) If required a measure of ‘Aerosil’
may be added towards the end of
the mixing cycle to stiffen up the
mix for placing in steeply graded
areas.

(xiv) The resin mortar is placed into the

prepared trench in the carriageway
and trowelled flush with the rails
and surfacing.

(ix) The carrier rails are cut and welded

to suit any general changes in level
or direction.
(iv) The concrete deck and any
previously formed recess in the
verge/central reserve is lightly
scabbled and/or wire brushed and
substandard asphalt/concrete
removed.

(v) All loose arisings and any standing

water are removed with (xv) Once a suitable length of joint has
compressed air. been poured curing hoods may be
erected over the joint and hot air
(vi) All exposed surfaces should be dried applied.
before priming, by using
compressed air and/or hot air
depending upon the weather
conditions.
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Installation (b) Weather and Temperature

Criteria
(xvi) The resin mortar will cure after
two to three hours at approximately The polyureide resin may be
70°C. It is then allowed to cool installed in temperatures of up to
before the spacer plates, hangers 50°C. It is not affected by freezing,
and polystyrene shuttering are but care must be taken to ensure
removed. the substrate is frost free and
sufficiently dry before the priming
(xvii) The sections of joints in the verges/ stage.
central reserve are installed in a Once the exposed surfaces have
similar manner. been primed, the joint is effectively
sealed. At temperatures below 5°C
the resin will be dormant until heat
is applied. At temperatures, the
resin will cure unaided.
Britflex Polyureide Resin does not
emulsify in water. Consequently the
resin mortar may be placed with The BEJ system used extensively in
care in periods of rain, provided the Tower Bridge.
resin is placed in such a way as to
prevent water from being trapped
in the trench.
The preliminary operations of saw
cutting and breaking out can be
undertaken during inclement
weather.
(xviii) The elastomeric insert is installed
using compression tongs and
(c) Time lag after completion and
compressed into the carrier rails.
before opening to traffic

Once the resin mortar has cured

the elastomeric element can be
inserted and the joint opened to Marina Bay Bridge, Singapore.
traffic. During phased working the
joint can be opened to traffic after
curing with or without the The Britflex ‘BEJ’ System is also
elastomeric element in place to suit approved in the following countries:
the sequence of installation and
minimise traffic disruption.
• Hong Kong • Indonesia
(d) Other Notes • Singapore • Kuwait
• China • Denmark
When the ‘BEJ’ system is bonded to
steel, this should be prepared by • Brunei • Greece
gritblasting or mechanically • Philippines • Switzerland
abraiding just prior to the priming
operation. • Malaysia • Russia

The ‘BEJ’ insert should be protected

from white-lining materials,
e.g. with sand.

(xix) If specified, any kerb cover, footway

or parapet plates are fitted.