Strictly confidential

TERAJOINT AND
TERADOWELS
INSTALLATION
GUIDELINES
Date July 3, 2020
SUB-BASE
PREPARATION
• Subbase must be prepared according to
project specifications.
• Soil must be well compacted and as flat as
possible.
• Flatness tolerance +/- 10mm
• Slab thickness for Carmona Warehouse
Project is 200mm, Terajoint height is
185mm, allowing 15mm gap underneath the
joint. To compensate uneven slab flatness.

2
 Having no gap between Terajoint and Subbase may lead to
locking of the slab (restrain movement of concrete during
shrinkage or problems with leveling).

WRONG CORRECT
For this project, there will be 15mm gap underneath the joint to the
subbase
3
• Plastic film shall be placed on top of the subbase in order to
separate it from concrete and allow movement as shown below:

4
• Columns, walls and corners/protruding parts from foundation
shall be separated with flexible foam according to drawing
specifications.
• Reinforcement around columns/corners/protruding parts (if any) shall
be placed according to drawing specifications.
• Floor casting must be done under the roof with walls
constructed.
• If some walls are not finished or there are windows or doors, it is
recommended to cover them with plastic sheet. This will keep
more or less similar temperature inside the building (important for
concrete drying) and helps to protect from accidents, such as rains,
when rainwater will go inside the building and onto wet concrete or so
on.
• It is recommended to cover columns, walls and other protruding
parts (if any) with plastic film approximately 1.5 meter high. This
will protect it from concrete splashes during floor casting. After floor is
finished – just remove the plastic film. This is much easier than clean
columns/walls.
5
INSTALLATION OF
TERAJOINT
• The required layout, position and height of
the joints will be specified on the floor slab
drawing which must be followed closely.
String lines are placed to identify the position
of joints according to the slab layout
dimensioned drawings.
• It is recommended to install Terajoint with
sleeves (green plastics) to be poured with
concrete first.
• Always install Terajoint same side (plastics
with plastics; dowels with dowels). Don’t mix
sides.

6
• Joints are placed sequentially away from columns/walls or vertical
separation lines, dividing construction zones.
• If TJX/TJT pieces are used the first joint is connected to the junction
piece at the overlap section using a dowel bush, plastic bolt and steel
nut.
• If junction pieces are not used the first joint is placed adjacent to column
or wall allowing for isolation material. If Terajoint is placed to column or
wall; vertical line of Terajoint or Teradowels; isolation joints or to
continuing line of Teradowels its overlap part must be cut out:

7
• Overlap part is cut flat for installation to
a wall or a column or separation
material or to other joints (NO TJX/TJT
used) = OK
• When installing to vertical lines of joints
(separation lines of Zones
construction) put 3-5mm flexible foam
between Terajoint profiles in junction.
• If vertical line is Terajoint it is a must to
cut through top strip of vertical line of
Terajoint at a place of junction.
Minimum depth of cut is 45mm – cut
top strip fully than it is ok.

If there will be an intersection using

Terajoint and Teradowels,
CUTS MUST BE DONE.
• The joints are placed in the correct position
according to the string or laser line, and the
height is adjusted to correct level.
8
INSTALLATION
WITH TFX
• TFX comprises of two
main components, the
adjustment device itself
and a removable ‘TIP’
which engages with the
TFX itself and also with
the joint.

9
TFX Features
• TFX provides a stable
frame to support the
joints at the top and
bottom.
• The rear of the device
has a round hole to
allow the insertion of a
pin into the sub-base
which can then be
locked in place by
tightening the bolt, as
seen in the picture.

10
TFX Features
• The front of the device
is complete with tapered
‘feet’ which gives stability
but then also allow easy
removal from any solidified
concrete which can flow
under the joints. There is
also a vertical support
block to support C-profile
of the joint.
• The front face of the TFX
has a slotted aperture to
both receive and lock in
place the support tip, The
tips are provided with a
wing-bolt to allow both
locking in place and also
the possibility to adjust
later by virtue of a slot.

11
TFX Features
• The support tips
have a machined pin
and threaded portion
to allow engagement
with the joints and then
fixing with a wing-nut

12
 1
TFX Features 3

Vertical adjustment
is facilitated by
rotating the hex
nut at the top of the
device
INSTALLATION
PROCEDURE
➢ 1. Prepare TFX and
Terajoint, put them in
the place of installation.
The TFX’s required for
a project should be set
to approximately the
correct height for the
slab under construction
bearing in mind the joint
height being used.
 TFX Set-up
➢ 2. It is recommended to
use 4pcs of TFX per 1
Terajoint profile (3meter
long). Alternatively 2pcs
of TFX can be used per 1
Terajoint profile (one
piece on each end of
Terajoint) and use 2 sets
of pins to support
Terajoint in the middle.
➢ 3. Support tips should
be fitted to the TFX’s and
locked in place using the
wing-nut.
➢ 4. The joints should be
fitted to the TFX’s by
inserting the tips through
the spare holes in the top
strip and fixing with a
wing-nut.
 TFX Set-up
➢ 5. Joints should
normally be placed
with the NON-SLEEVE
side facing the TFX.
Since there is a
straightening rebar at
the dowel side of the
joints small piece of it
shall be cut off in order
to allow TFX to be
installed.
➢ It is always
recommended to cast
the concrete on the
SLEEVE SIDE
(GREEN PLASTIC) of
the joint first.

16
 TFX Set-up
➢ 6. TFX’s required per joint should
normally be placed as follows:
➢ At both ends of the joint. They
shall be placed first. Those
TFX’s are very important as
vertical alignment of Terajoint will
be done with their help.
➢ Another 2pcs in the middle of
the joint on approximate
distances from each other.
➢ 7. Once in position the vertical
level of the joints can be adjusted
precisely using the adjustment nut at
the top of the device.
➢ 8. Fine adjustment in the
horizontal direction is possible using
the wing bolt and slot. If the joint is
adjusted forward, then packing
wedges may also be required
between the bottom of the joint and
the vertical support.
 TFX Set-up
➢ 9. Round bar or rebar shall
be installed through the hole
in the bottom flange of TFX
for fixation it to the ground.
Hammer it deep enough into
foundation to enable firm
connection. Pneumatic
hammers or manual ones
with big head are
recommended. Use
horizontal hex bolt of TFX to
tighten the installed bar,
preventing its side to side
movement.
➢ Bars used for fixation of
TFX are re-usable. Take
them out and use again for
next installations.
Terajoint pallet packaging materials can
be used for this purpose.
➢ 10. Gaps between vertical support
block of TFX feet and C-profile (if any)
shall be filled be wedges or pieces of
wood material. This is needed to
provide solid support of Terajoint C-
profile. Vertical support block of TFX
shall push C-profile firmly either by
direct contact or through wedge/wood
which covers gap between it and C-
profile
➢ 11. After the concrete is poured the
vertical level can again be checked and
corrected for any movements while still
wet. This function is applicable if only
TFX used for Terajoint installation. This
will not work if pins were used together
with TFX to install Terajoint.
 2
TFX Features 0

• Using of
wedges
between TFX
and Terajoint or
between
Terajoint and
subbase can be
done for even
better fixation.

Make wedges from rectangular

shape of wood, not square!
 REMOVAL OF TFX
✓ After the concrete is sufficiently
hardened the TFX’s can be
removed by:
✓ Remove fixation bar from the
bottom of the TFX.
✓ Untighten nut on the TFX pin.
✓ Remove TFX.
✓ Use wrench to turn TFX pin
counterclockwise and remove pin
from concrete.
✓ Nut of TFX pin will remain in
concrete forever. For next usage
use new M8 nut/wing nut.
✓ Clean TFX/pin from
dust/concrete, oil thread surface.
Keep in good condition for next
use. This will prolong lifetime of
device and allow to use multiple
times. Protect the devise and use
it with care.
 Wing nut from below picture will stay in the slab
Note: Wing nut used permanently. New nut shall be used for next
installations
to connect TFX pin
to Terajoint (see
picture below) will
stay in concrete
permanently. For
next applications
new M8 nut shall
be used. We
delivered plenty
with Terajoint as ✓ Once removed the TFX’s can then be re-used for another
part of the project. Always clean TFX and especially its
spare parts. In bolted part and parts with thread from concrete. It will help
case if not enough to keep TFX undamaged and increase its lifetime.
more M8 nuts shall ✓ Once the project is complete the TFX’s should be
be purchased from cleaned thoroughly and the threaded portion sprayed with
an appropriate lubricant to ensure perfect operation in
hardware shop. future. When cleaning/lubrication is done TFX shall be
packed and kept in dry condition under the roof. Use it
again for other projects.
22
 2
3

INSTALLATION
WITH
TFX and PINS
✓ If pins are used together with
TFX (combined installation) it’s
recommended to use TFX on
the both ends of Terajoint and
use pins in the middle. This will
allow easier vertical levelling of
Terajoint with help of TFX,
where pins will be used for
fixation only.
 ✓ Use TFX at each side of Terajoint profile (2pcs of TFX
INSTALLATION needed). Align profile vertically and to correct position with
WITH TFX and PINS TFX. Use 2 sets of pins in the middle of Terajoint profile on
similar distance from each other and TFX.
✓ Simply hammer straight pin to foundation (put straight
pin in the corner between straight rebar and welding stud
of Terajoint). Make spot welds to welding studs and/or
straight rebar to fix pin to joint.
✓ Alternatively, can bundle pin firmly with wire. Use
wedges between pin and divider plate of Terajoint or weld
additional bars (as shown on above picture) to protect joint
from movement under concrete pressure.
1. Note: Pins MUST be cut off before casting of
next strip!

BEFORE

AFTER

25
 CONNECTING OF 2
TERAJOINT PROFILES
TOGETHER
✓ Terajoint profiles can be
connected together by
overlapping.
✓ Put bush through oval
hole of both overlap parts
and fix with help of plastic
bolt and nut delivered with
Terajoint.
✓ When connecting 2
overlap part leave very
small gap around 1mm
allowing longitudinal
movement:

26
 WELDING TO WELDING TO TOP
TERAJOINT STRIPS
✓ It is not allowed to make welds
✓ It is not allowed to weld to on top strips from plastic
plastic sleeves (green color), sleeves side (green color).
neither to dowels. If welding
✓ If welding is needed i.e. for butt
is required, weld to studs, connection of cut joints, weld
straight rebar or divider plate from top strip side without
of armour joint. plastic sleeves. Welding shall
be light, non structural, just
allowing for armour joint profile
to stick together.
✓ Weld from one side of top strips
only! Side without plastic
sleeves.
27
ADDING WELDING STUDS TO
TERAJOINT
✓ There are welding studs welded to top strips of Terajoint from both
sides. Average spacing is 230mm between studs.
✓ According to project requirements it was requested to have
Terajoint and Teradowels lines in the project. In some areas there
will be Terajoint and Teradowel lines one after each other. Terajoint
must be cut flat before touching Teradowel line. It might happen
that Terajoint will be cut right after the studs, leaving quite big piece
of profile without studs. If it happens, and distance from the edge of
joint profile till next studs is more than 15cm, it’s recommended to
weld 2 studs one from each side of Terajoint top strip on
similar position and angle as other studs. Also studs from cut off
left-overs of Terajoint can be re-used (removed from left-over parts
and used where is needed).
28
 Welding studs
Welding studs might be
at Terajoint needed to
Profile weld in below
areas
29
In such cases where zones are separated by Terajoint or Teradowel
vertical lines:
✓ Horizontal lines of Terajoint touches vertical lines of Terajoint
✓ Horizontal lines of Teradowels touches vertical line of Terajoint

➢ Cuts through Terajoint top strips at the place

of junction must be done!

✓ Cut must be done completely through the both top strips and
straightening rebar. Minimum depth of cut is 45mm,
recommended is 50-60mm.
✓ It is recommended to remove 20-30mm of straightening rebar
completely at the area of junction and cut on Terajoint top strips is
done.
30
Such cuts must be done at every
junction described
31
EXAMPLES OF AREAS WHERE
CUTS SHALL BE DONE
✓ Note: Horizontal lines of joints
shall not touch vertical line. If
junction is Terajoint to Terajoint
(green lines), put flexible foam (3-
5mm thk) in junction area. Width of
foam shall be 20mm, height
according to slab height. After floor
is ready foam can be taken away
partially and filled with sealant.
✓ Saw Cut Joints
✓ Saw cut joints shall be done
according to project drawings and
specifications. Saw cut joints must
be cut through Terajoint or
Teradowels lines. In case of cutting
through Terajoint top strips must be
cut completely (minimum depth is
45mm, advised depth is same
32
depth as saw cuts: i.e. 50-60mm)
TERADOWELS INSTALLATION

OPTION 1: INSTALLATION TO TIMBER

FORMWORKS

OPTION 2: INSTALLATION TO STEEL

FORMWORKS

33
 ➢ Step 1. Sleeves Installation
• Prepare timber according to slab height and bay or
strip dimensions. It is recommended to use 40mm
timber, if not available use a bit slimmer (but not less
than 20mm) one with proper fixation from other side,
not allowing timber to move and bend (similar to
banana shape ) during concrete pour. Surface of
timber must be smooth and straight allowing good
leveling and sleeves installation.
OPTION 1:
• Mark a horizontal line on the formwork at the level of
INSTALLATION half slab thickness (h/2) and mark the required center
TO TIMBER to center spacing of the sleeves along this line.
FORMWORKS
• Before installation check that sleeves are not
damaged and longitudinal hole in the bottom is
properly sealed with tape.
• If sleeve is damaged – do not use it.
• If tape is damaged – replace it with other tape. Seal
properly.
• Nail the sleeves firmly through the nail holes at the
marked locations on the formwork.
34
➢ Center spacing c/c between
sleeves shall be 500mm.
• First sleeve shall be installed with c/c 250mm,
allowing c/c 500mm total spacing. Another
250mm coming from next strip (250mm +
250mm).
• If dowel/sleeve was removed at Terajoint
profile at the place where Terajoint borders
with Teradowels formwork – install sleeve
(green plastic) right in the beginning of the
formwork. This will allow more or less similar
dowels spacing and will compensate removed
dowel at Terajoint.
• Nail sleeves to timber firmly with 2 nails each
side of the sleeve.
• Install timber according to level and strip
dimensions. Fix properly.

35
 ➢ Step 2. Pouring Concrete
• Pour concrete as normal around dowel sleeves
paying particular attention to the fill around the
sleeves. All plate type dowels require adequate
compaction with a vibration poker around them, to
eliminate the possibility of air entrapment below the
sleeve.
• It is recommended to make marks on opposite side
of timber to show location of sleeves inside. When
OPTION 1: using vibrating poker use it carefully in areas
INSTALLATION TO around sleeves, but not on sleeves. This will help
to avoid damaging/mispositioning of sleeves due to
TIMBER
hit of vibrating poker.
FORMWORKS

36
 ➢ Step 3. Dowels Installation to
Sleeves
• After concrete has hardened adequately and the
formwork removed, the nails should be flattened
and the dowels inserted into the sleeve pockets.
The dowels should be inserted fully into the
sleeves. The second slab can be then poured
against the face of the first and the exposed
portion of the steel dowels.

OPTION 1:
INSTALLATION TO
TIMBER
FORMWORKS

37
 ➢ Step 1. Installation of Sleeves to Steel
Formwork
Sleeves can be installed with steel formwork in two
ways:

FIRST WAY
• Use self-tapping screws to attach sleeve to steel
formwork.
• Go to hardware shop with Tera sleeve (green plastic).
Check for size of self-tapping screw which will fit to nail
holes of sleeves good and tight, but same time don’t
OPTION 1: burst/break the sleeve. Screws must be same length or
a bit smaller than slots for nails at sleeve + thickness of
INSTALLATION TO metal formwork. Don’t use screws which are longer than
STEEL it, otherwise it will be difficult to remove screws from
FORMWORKS concrete – disassemble the formwork.
• Dimensions of nail slot at sleeve are shown on picture
below. Add thickness of formwork to it to calculate screw
length.

38
 Step 1. Installation of Sleeves to Steel
Formwork

• Drill holes in steel formwork according to sleeve

position. Holes in formwork shall match with nail
holes at sleeves.
OPTION 2: • Take sleeves, remove nails.
INSTALLATION TO
STEEL
FORMWORKS

BEFORE AFTER

39
 Step 1. Installation of Sleeves to Steel
Formwork

• Screw self tapping screws through formwork into the

sleeve. Make sure they did not burst or break the sleeve
and connect it to formwork properly. In case sleeve was
damaged – replace the sleeve. Below pictures shows
simulation by using carton.

OPTION 2:
INSTALLATION TO
STEEL
FORMWORKS

• After concrete is poured and hardened untighten the

screws and remove the formwork. 40
 Step 1. Installation of Sleeves to Steel
Formwork
Sleeves can be installed with steel
formwork in two ways:

SECOND WAY
OPTION 2:
• Use small bolts and nuts (ideally you need small
INSTALLATION TO wing-nuts). Bolt sleeve to formwork with them.
STEEL Bolt them from opposite side, nuts or wing nuts
FORMWORKS shall be from steel formwork side (opposite side
of casting).
• Then do steps 2 and 3 as described in Option 1

41
 POURING CONCRETE

• Concrete should be poured to the

level of the top strips with
particular attention to
consolidation around the dowels
and sleeves. All plate type
dowels require close attention to
filling around the dowels to
eliminate the possibility of air
entrapment. This should be done
with a suitable vibrating poker.
• Put special attention to concrete
work around joints. Floor
concrete shall be casted
accurately on the same level as
top strips. Don’t make concrete
level over the top strips of joints
or below it! Use trowels or other
flooring equipment to level
concrete around joints, remove
extra concrete where it is
needed.
42
 OK.
NOT OK.
CONCRETE IS ON THE LEVEL
CONCRETE IS OVER THE
WITH TOP STRIPS OF
JOINT TOP STRIP LEVEL
TERAJOINT

43
LEVELING OF CONCRETE AROUND THE JOINTS

44
 REMOVAL OF
CONCRETE FLOW

After casting of bay there will be

concrete flow to opposite side
through the gap between
Terajoint and subbase. Such
concrete flow shall be removed
when concrete is still wet. Use
trowel to remove it.

45
Wet concrete was not removed during previous bay casting. Now it
is hardened and will require hammering, thus, more difficult to
remove. Clean dowels from soil, concrete and remove all the
construction garbage from the subbase of next bay/strip.

46
End of
Presentation

47