Infrastructure | Buildings | Industrial structures

Expansion joints

mageba modular expansion joints –

the benchmark for large movements

TENSA®MODULAR Types LR and LR-LS

proven, versatile, low-noise
Expansion joints

Product characteristics
Principle Characteristics Parts and components
TENSA®MODULAR expansion joints are Expansion joints are subjected to consider- The joint’s individual lamella beams ①
based on the following concept: The able demands and must satisfy these over rest on and slide along support bars ②,
movement gap at the end of a bridge deck a service life of many years. The design of and are connected to these by stirrups ③
is divided into smaller individual gaps by the watertight TENSA®MODULAR expan- through which the support bars pass. The
horizontal lamella beams. This enables sion joint, which was invented by mageba, support bars span between support bar
deck movements of well over 2’000 mm to has been continually developed in recent boxes ④ in the deck structures at each
be accommodated. Rotations about every decades. The current 4th generation of side of the movement gap. Both support
axis can also be facilitated. the system fully accommodates these high bars and lamella beams are supported by
The individual gaps are sealed watertight demands. high-quality polymer elements and pre-
by elastomeric profiles, enabling the joint The TENSA®MODULAR expansion joint stressed by elastomeric components. The
to be completely drained at the deck was developed, as the name suggests, as movements of the lamella beams relative
surface. The movements of the lamella a modular system, with joints for specific to each other and along the support bars
beams relative to each other are regu- needs built up from proven components. are regulated by control springs. Sealing
lated, elastically and constraint-free, by a The principle variable in this process is the profiles ⑤, which connect the lamella
control system. movement range which must be accom- beams to each other and to the joint’s
modated. edge profiles ⑥, make the system endur-
mageba TENSA®MODULAR expansion
ingly watertight.
joints are typically used in bridges with Each individual gap of the joint, and its
movements of over 80 mm. sealing profile, allows maximum gap open-
The fitting of so-called “sinus plates” to the ings of between 60 and 80 mm, depending
joint’s surface enables noise from over- on the relevant norm. However, if noise-
rolling traffic to be reduced by up to 80 %. reducing sinus plates are bolted to the up-
per surface of the lamella beams and edge
profiles, the movement accommodated by
each gap increases to 100 mm. For special
load cases such as earthquakes, yet larger
movements can be facilitated. The maxi-
mum joint movement is used to determine
the number of gaps and lamella beams
that the joint will require.

⑥ ①
⑥

③
④
②

Schematic illustration of the TENSA®MODULAR

expansion joint
④

2
 Expansion joints

Client benefits
Design Functionality
Highlights
• Welding is avoided in all highly stressed • All parts of the joint are elastically pre-
• Allows free movements in all direc- connections, increasing durability. stressed, making them highly resistant
tions and rotations about every axis to fatigue.
• All of the joint’s well-proven wear parts
• Completely watertight system with are bolted in place, and can be replaced • The elastic gap control system increases
drainage at the bridge surface if necessary with little effort and with- the service life of the entire joint by
• Versatile and freely adaptable to suit out disrupting traffic. damping the impact loading from over-
client‘s wishes • For the installation of the joint, only rolling traffic.
• Can be used on all types of bridges relatively small recesses are required • The joint’s prestressed connections
• Based on well-proven and thorough- in the bridge structure at each side. damp impacts and vibrations, while fa-
ly tested components and parts Thanks to its asymmetric design, it can cilitating large transverse movements,
be easily adapted to suit specific cir- vertical displacements and rotations.
• Low-noise when fitted with sinus
cumstances. • Sinus plates, which can optionally be fit-
plates
• The orientation of the support bars, in ted to the surface of the joint, reduce
the direction of the deck’s span, simpli- noise from over-rolling traffic by up to
fies the placing of the connecting deck 80 %, making the joint suitable for use
reinforcement. in noise-sensitive areas.

1 2

1 Installation works on the Run Yang Bridge

2 TENSA®MODULAR joint featuring sinus plates
– in service
3 Installed 24-gap joint allowing 1‘920 mm of
movement and weighing 41‘000 kg
4 Control system with control springs and
connection plates
5 Recesses prior to concreting

3 4 5

3
Expansion joints

Movement capacity
Movements of the joint Skewed orientation and movements
1
mageba TENSA®MODULAR expansion Expansion joints are typically installed
joints allow movements in every direction perpendicular to the bridge’s axis, with
and, at the same time, rotations about their longitudinal movements parallel to
every axis. Their elastic control system can the same axis. But it is also possible to de-
accommodate large transverse and verti- sign modular joints for installation with a
cal movements without developing con- different orientation (i.e. not perpendicu-
straint forces. lar to the bridge axis), or for longitudinal
If necessary, the joint’s support bar boxes movements which are not parallel to the
can be designed with a trapezoidal shape bridge axis. In such cases, the support bar
to increase the joint’s transverse move- boxes can be orientated either parallel to
ment capacity to match its longitudinal the bridge axis or perpendicular to the
movement capacity. joint’s axis.
In this case, the support bars of the joint 2
can rotate until they are orientated at 45
degrees to the bridge axis. This simple ge-
ometric adaptation represents one signifi-
cant advantage of the TENSA®MODULAR
joint: the functionality and construction
of the overall system remains the same for
small or large transverse movements.
The table below presents the maximum
movement capacities of various sizes of
TENSA®MODULAR expansion joint, in the
longitudinal and transverse directions.
Transverse movements are considered
with all gaps fully closed. 1 Vertical movement capacity of the joint
2 Transverse movement capacity of the joint

Type LR (without sinus plates) Type LR-LS (with sinus plates)

Number of
Type Max. longitudinal Max. transverse Max. longitudinal Max. transverse
gaps
movement movement movement movement*
[-] [-] [mm] [mm] [mm] [mm]
LR 2 2 160 ± 80 200 ±0
LR 3 3 240 ± 120 300 ±0
LR 4 4 320 ± 160 400 ±0
LR 5 5 400 ±200 500 ±4
LR 6 6 480 ± 240 600 ±9
LR 7 7 560 ± 280 700 ± 13
LR 8 8 640 ± 320 800 ± 17
LR 9 9 720 ± 360 900 ± 22
LR 10 10 800 ± 400 1‘000 ± 26
LR 11 11 880 ± 440 1‘100 ± 30
LR 12 12 960 ± 480 1‘200 ± 34
LR 13 13 1‘040 ± 520 1‘300 ± 39
LR 14 14 1‘120 ± 560 1‘400 ± 43
LR 15 15 1‘200 ± 600 1‘500 ± 47
LR 20 20 1‘600 ± 800 2‘000 ± 67
LR 25 25 2‘000 ± 1‘000 2‘500 ± 87
LR 30 30 2‘400 ±1‘200 3‘000 ± 107
Dimensions for larger and intermediate movements on request *) Values significantly increased at reduced longitudinal movements

4
 Expansion joints

Design details
Support and connection system provided in the table below. The values for control sets, which are rigidly connected to
The joint’s lamella beams are connected B1 and B2 are valid for an expansion joint that beam by steel and to the neighbouring
to the support bars beneath by stirrups with both a moving side and a fixed side as beams by control springs. At each edge of
through which the support bars pass. In the shown in the cross section. Alternatively, the joint, the control set is connected to the
same way, the support bars are enclosed by expansion joints can be designed to allow bridge structure by so-called control boxes.
support bar boxes at the edges of the joint. movement at both sides. In such cases, the The entire movement range of the joint is
In this way, the whole system is supported total longitudinal movement can be split as thus distributed among the individual gaps,
and connected elastically and securely, desired between the two sides, with B1 re- and braking and acceleration forces from
while still allowing movements as desired. duced and B2 increased accordingly. Exact traffic are elastically damped and resisted.
values can be provided on request. The elasticity of the control system prevents
ROBO®SLIDE sliding material damage to the joint should individual gaps
Control system become blocked by stones or debris. The
Where sliding components are subjected
to demanding loading or movements, ma- Elastomeric springs control the movements system is designed to ensure that the con-
geba uses ROBO®SLIDE, a highly developed of the individual lamella beams and make trol springs are not stressed in the trans-
modern alternative to the traditionally used them work as a single kinematic system. verse direction when the joint is in its cen-
PTFE. This material consists of modified The movements of each lamella beam tral position. This minimises fatigue and
ultra-high molecular weight polyethylene, relative to its neighbours are regulated by thus increases service life.
and offers very high bearing strength, low
friction and exceptional resistance to wear.
The increased service life of components
which feature this material considerably re-
C C
duces maintenance effort.

Recess dimensions
The main dimensions of the recesses (block-
outs) required in the bridge structure for
the installation of various sizes of expansion
joint, and the weight of joint per meter, are B1 A B2
Section through a modular joint of type LR6

Type LR (without sinus plates) Type LR-LS (with sinus plates)

Type
Amin Amax B1 B2 C* Weight Amin Amax B1 B2 C* Weight
[-] [mm] [mm] [mm] [mm] [mm] [kg/m] [mm] [mm] [mm] [mm] [mm] [kg/m]
LR 2 150 310 400 300 420 150 150 350 450 350 440 190
LR 3 240 480 480 300 420 240 240 540 550 350 440 310
LR 4 330 650 560 300 420 330 330 730 650 350 460 430
LR 5 420 820 640 300 440 420 420 920 750 350 460 560
LR 6 510 990 720 300 440 510 510 1‘110 850 350 460 670
LR 7 600 1‘160 800 300 440 600 600 1‘300 950 350 480 790
LR 8 690 1‘330 880 300 460 690 690 1‘490 1‘050 350 510 910
LR 9 780 1‘500 960 300 480 790 780 1‘680 1‘150 350 530 1‘040
LR 10 870 1‘670 1‘040 300 500 900 870 1‘870 1‘250 400 550 1‘190
LR 11 960 1‘840 1‘120 300 530 1‘020 960 2‘060 1‘350 400 550 1‘350
LR 12 1050 2‘010 1‘200 300 530 1‘140 1‘050 2‘250 1‘450 400 570 1‘500
LR 13 1‘020 2‘200 1‘330 350 560 1‘230 1‘020 2‘320 1‘550 400 610 1‘660
LR 14 1‘200 2‘360 1‘410 350 560 1‘320 1‘200 2‘600 1‘650 400 640 1‘810
LR 15 1‘320 2‘520 1‘490 350 590 1‘400 1‘320 2‘820 1‘750 400 640 1‘970
LR 20 1‘580 3‘370 1‘890 350 650 2‘250 1‘870 3‘870 2‘290 400 650 2‘650
LR 25 1‘980 4‘220 2‘290 350 690 2‘900 2‘345 4‘845 2‘790 400 740 3‘350
LR 30 2‘380 5‘070 2‘690 350 720 3‘500 2‘820 5‘820 3‘290 400 830 4‘050
Dimensions for larger and intermediate movements on request *) The minimum value of the recess refers to an asphalt thickness of 70 mm

5
Expansion joints

Testing & optional features

Laboratory testing FUSE-BOX
2
1
The TENSA®MODULAR expansion joint has The optional FUSE-BOX feature protects
proven its worth in testing by independent the modular expansion joint and adjacent
institutions on many occasions. For exam- bridge structure from seismic damage. If a
ple, the durability of the joint was verified standard joint (without FUSE-BOX) closes
in testing with 6 × 106 load changes, after more than geometrically allowed dur-
which no signs of fatigue could be estab- ing an earthquake, the joint and bridge
lished. structure will be damaged or could even
All critical components and their materials, fail. The FUSE-BOX prevents such damage
such as elastomers and sliding surfaces, by enabling the joint’s connection to the
were also subjected to individual testing. structure at one side to fail in a controlled,
designed manner. Due to the inclination of
In an Opening Movement & Vibration
its failure plane, the joint can slip back into
(OMV) test as defined by American stand-
its original position after an earthquake,
ards, the joint proved its suitability in a 2
enabling emergency vehicles to cross the
programme which simulated a 100-year
bridge in the earthquake’s aftermath.
service life – and specifically, the thermal
opening and closing movements, and the The use of FUSE-BOX enables the design
vibrations from traffic, to which a joint of of a particular joint for exceptional load
this type would be subjected during that cases to be optimised, resulting in more
period. economical solutions.
Furthermore, an LR7 joint was subjected
Sinus plates
to intensive seismic testing, which ex-
ceeded the requirements of American The use of “sinus plates” reduces the noise
standards and additionally simulated from over-rolling traffic by up to 80 % by
an actual earthquake – the Northridge covering the straight transverse gaps in
earthquake which, with its magnitude of the carriageway. The wheels of over-roll-
6.7 and ground movements of 1.2 m/s, ing vehicles thus maintain constant con-
tact with the expansion joint’s surface, 3
destroyed infrastructure across parts of
California in 1994. The joint withstood this eliminating the noise caused by impacts
testing without any damage, demonstrat- with the gap edges. The special shape of
ing in impressive fashion its ability to ac- the sinus plates also enables motorcy-
commodate multidimensional movements cles and bicycles to cross the joint safely.
and rotations. TENSA®MODULAR expansion joints featur-
ing sinus plates are ideal for use on bridges
Videos of the testing can be viewed at
near residential areas or in other noise-
mageba-group.com.
sensitive zones.
National approvals The bolting (rather than welding) of the
sinus plates to surface of the joint enables
TENSA®MODULAR expansion joints have
the sealing profiles beneath to be easily
been subjected to scrutiny, and awarded
and quickly replaced if necessary.
national approvals, in many countries
4
around the world – for example, in ac-
cordance with the German standard
TL/TP-FÜ or the latest version of the Aus-
trian standard RVS.

1 Fatigue testing of an LR joint

2 Seismic testing of an LR joint
3 FUSE-BOX during an earthquake
4 Comparison of noise levels generated by traffic
crossing joints of different types (yellow: a
modular joint featuring sinus plates)

6
 Expansion joints

Materials & installation

Materials Installation
1
The following high-quality materials in In particular, the installation of very large
particular are used as standard for the TENSA®MODULAR expansion joints should
manufacturing of TENSA®MODULAR ex- be supervised by a mageba specialist.
pansion joints: Before installation, the bridge gap width
• Lamella beams and support bars of and temperature are checked by the con-
S355 steel; hybrid lamella beams in- tractor, and the joint’s presetting value is
cluding stainless steel can be provided adjusted as appropriate. The joint is then
on request levelled against both edge profiles.
• Sinus plates of S355 steel
Footway and edge area
• Sealing profiles of EPDM or CR
At the edge of the bridge, where a footway
• Control springs, sliding springs and slid- or similar may exist, the TENSA®MODULAR
ing bearings of elastomer, PTFE and joint can be detailed to precisely suit the 2
polyamide structure’s profile with a kerb block, or fit-
• Special high-grade sliding material ted with cover plates for the comfort and
ROBO®SLIDE for sliding bearings and safety of pedestrians and cyclists.
sliding springs in particularly demand-
ing circumstances Connection reinforcement
The connection reinforcement in the
Corrosion protection bridge structure adjacent to the joint is to
The steel profiles are treated with cor- be designed and implemented in accord-
rosion protection systems based on ISO ance with the relevant reinforced concrete
12944 as standard, or on applicable na- norm. The anchor loops on the edge pro-
tional standards (e. g. ZTV-ING, ASTRA, files are normally perpendicular to the
RVS, ­ACQPA) as required. joint, but can, on request, be welded at
any other angle. Beneath the support bar
boxes, additional local reinforcement is 3
Watertightness
The TENSA®MODULAR expansion joint is needed to prevent tensile cracking.
100 % waterproof, thanks to the well-prov-
en mageba sealing profile. The profile has Operation and maintenance
provided reliable service in many bridges TENSA®MODULAR expansion joints are,
over a period of several decades. It has a under normal operating conditions, virtu-
number of special sealing points, which ally maintenance-free. The opening and
prevents the passage of water through the closing movements of the joint, combined
joint. Should the sealing profile ever be- with the continual passage of traffic across
come damaged due to external mechani- the surface, results in a self-cleaning ef-
cal influences, it can be quickly and inex- fect.
pensively replaced. Inspections may therefore simply entail
checking for corrosion and confirming wa-
Assembly and transport tertightness during regular bridge inspec- 4
mageba TENSA®MODULAR expansion tions. To ensure early detection of any
joints are assembled in the factory, and wear or damage that may arise, however,
prepared for transport to site. They can it is recommended that full inspections be
generally be transported in the lengths carried out about every five years, on the
with which they will be installed, but can basis of mageba’s relevant Inspection &
if necessary be jointed on site. A crane is Maintenance Manual. These inspections
required on site for unloading and instal- can be carried out by mageba if desired, as
lation. an additional service.
All wear parts are standard components
and can be quickly replaced when re-
quired using simple tools, from beneath
the joint if access allows and thus without 1 Transport of a modular expansion joint
2 Installation of a modular expansion joint
any impact on traffic.
3 Footway in joint with kerb block
4 Footway in joint with cover plate

7
Expansion joints

Quality & support

Related products Quality
1
The following mageba products can be used The 100 % watertight modular expan-
in combination with TENSA®MODULAR ex- sion joint was invented by mageba in
pansion joints: the 1960s. For five decades, mageba
• ROBO®DUR: Strengthening ribs of spe- TENSA®MODULAR expansion joints have
cial mortar, which reinforce the asphalt proven their worth in thousands of struc-
adjacent to the joint. These reduce rut- tures under the most demanding condi-
ting, increasing driver comfort and the tions. In addition to the product prop-
durability of the joint erties, the extensive experience of our
well-qualified manufacturing and installa-
• ROBO®MUTE: Noise-protection system,
tion staff also contributes to the product’s
consisting of mats placed beneath and
high quality and durability.
at the ends of the joint to reduce noise
emissions mageba has a process-orientated qual-
ity system that is certified in accordance
• ROBO®GRIP: Anti-skid coating with 2
with ISO 9001. Quality is also regularly
high coefficient of friction, preventing
inspected by independent institutes,
skidding of over-rolling vehicles in wet
such as the University of Stuttgart’s ma-
conditions
terials testing body (MPA) and the Uni-
• ROBO®STATIFLEX: Strengthening strip versity of Innsbruck. mageba factories are
of quick-hardening polymer concrete certified for welding in accordance with
along the side of an expansion joint, ISO ­3834-2, and according to the current
which reduces rutting, increasing driver steel construction standard EN 1090.
comfort and joint durability
• ROBO®CONTROL: Sensor-based elec- Customer support
tronic monitoring system which can Our product specialists will be pleased to
serve many purposes – e.g. continuous advise you in the selection of the optimal
measurement and transmission of data solution for your project, and to provide 1 Tsing Ma Bridge, Hong Kong
relating to an expansion joint’s move- you with a quotation. Equipped with TENSA®MODULAR
ments and the conditions to which it is expansion joints of type LR25
On our website, mageba-group.com, you
subjected Providing reliable service since 1996
will find further product information, in- 2 Storebaelt West Bridge, Denmark
cluding reference lists and tender docu- Equipped with TENSA®MODULAR
mentation. expansion joints of type LR15
Providing reliable service since 1994

Reference projects TENSA®MODULAR Type LR expansion joints

Golden Ears Bridge (CA) Incheon Bridge (KR) Ba Lin He Bridge (CN) Talübergang Lavant (AT) Pont de Normandie (FR) Ganter Bridge (CH)

mageba expansion joint types

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