EXPANSION JOINTS LTD.

BRIDGE EXPANSION JOINT SYSTEMS

Suitable for movements between 12 mm and 80 mm

A bridge is a slab-shaped construction - or a

series of slabs - designed to cross an
obstacle (a river, a valley, roads). The
intersection between two such “decks" -
adjacent elements of the superstructure of
a bridge - is called EXPANSION JOINT.
Camelot devices ensure the
seamless crossing of vehicles over these
joints, even in conditions where the bridge
decks slowly change their dimensions, due
to the contraction or thermal expansion of
the superstructure elements. Our devices
successfully cope with these complex
movements, ensuring traffic flow and
safety in all conditions through resistance
and flexibility.

Camelot Regular
In all applications in which they are
already installed, CAMELOT joint devices
work perfectly under heavy traffic, being
characterized by ingenious, economical and
safe technical solutions. For the most part,
our products incorporate original technical
solutions.

Area of applicability: renovations and newly built bridges, concreted on the beam layer
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
mains

The smooth crossing of vehicles over bridge

joints is ensured by specially designed devices or
systems.
The dimensions of the expansion gaps
change slowly in time, mainly from summer to
winter, but also from day to night, due to the
contraction or expansion of the superstructure
elements, caused by thermal differences.
In addition to these slow movements, there
are also faster, short-term ones, due to traffic and
variations in its values, as well as more violent
movements, caused by strong winds or
earthquakes.

The Camelot Regular device, designed to equip the expansion

joints of road bridges, solves the technical problem of unhindered traffic
over the joint area, in the conditions of an improved construction variant
compared to other products on the market.
The device consists of a prismatic rubber profile, mounted in
the slot between the sides of two metal profiles of a special shape, with
sections that give them resistance to bending mainly in the vertical
direction, being provided with a thickened and flattened area at the side
upper, in the area of the road plan; the whole assembly being anchored
by embedding in concrete some reinforcements in the shape of loops,
welded directly on the metal profiles.
The chamfered shape of the edges, as well as the resulting
robust section, give the assembly a high resistance to traffic wear. Their
massive structure avoids the appearance of the resonance phenomenon
from the traffic that takes place in the joint area.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
mains

The toughness of the mounting in the console

and the balance of forces allow the system to take
over in good conditions the traffic efforts, in normal or
exceptional situations, while ensuring the
waterproofing of the gap between metal profiles by
elastic rubber profile between them in compressed
position, additionally sealed with a special adhesive .
Subsequent layers of subsequently poured
waterproofing and asphalt complete the firmly
mechanical fixing of the device and ensure the
assembly against vibration or leakings. The elastic
sealing profile, mounted after pouring and finishing the
last layer of asphalt, is mechanically fixed and adheres
to the special relief of the sides of the metal profiles by
means of a waterproofing adhesive mastic (mono or
bicomponent silicone compounds).
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
mains

Table with the prices and

dimensions of the section
by Type

Type Movement A, mm B, mm C, mm D, mm Price

Camelot Regular D12 12 mm 20 30 96 266 £92
Camelot Regular D20 20 mm 25 35 101 271 £99
Camelot Regular D22 22 mm 30 40 106 276 £112
Camelot Regular D30 30 mm 40 50 116 286 £128
Camelot Regular D35 35 mm 45 60 126 296 £161
Camelot Regular D50 50 mm 50 80 146 316 £186
Camelot Regular D65 65 mm 80 90 156 326 £218
Camelot Regular D80 80 mm 100 110 176 346 £265
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing
Installation instructions
"Camelot Regular" is the product conceived, designed,
patented and manufactured by us, perfectly suitable for equipping
the joints of medium-sized road bridges, subject to heavy traffic.
The method of installing it is by partial embedding in freshly
poured concrete. The best method of installing the Camelot Regular
device is the one carried out on the bridge deck before concreting
and asphalting, which consists in fixing and consolidating the metal
elements by welding the reinforcement bars of the deck.
The subsequent embedding in concrete of the whole
assembly, thus ensures the resistance of the joint areas made in this
way.

The installation operations begin by checking the dimensions

and geometric shape of the bridge under construction, in the phase
immediately following the application of the deck steel
reinforcement, over the beam bedding of the sub-structure.
Check and mark the level elevations of the future over-
concreting surface, marking the important elevation points and then
deducting the level of the final asphalt elevation (and pavement
finish, where applicable), at each important point. The establishment
of these dimensions correlates with the level of the upper bars in the
layers of the reinforcing nets.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

In the worksite, for mostly bridges builded with a composite deck

by pouring a reinforced over-concreting on a bedding of prefabricated
beams, the thickness of the concrete slab is between 12 cm (on the long
sides of the bridge, parallel to the longitudinal axis "x") and 18 cm ( on
the middle, longitudinal axis); and the upper level of the reinforcement
bars is 5 cm below the level of the concrete surface.
The perimeter formwork of the deck is made only on
its long sides. On the short sides (transverse, parallel to the
"y" axis) the formwork is provided by the metal elements of
the Camelot Regular device.
When establishing the level and the exact position of
each metal element that makes up the whole joint device,
the calculated level dimensions - previously noted – must
be carefully observed, especially the final level of the
asphalt to be poured at the end.
The upper edges of the side profiles of the Camelot
Regular device must be in the future plane of the asphalt
surface, thus delimiting its surface. Moreover, the entire
sequence of subsequent operations: concreting, application
of waterproofing in the field of the concrete surface, the
protective mortar of the insulation and then the two layers
of asphalt, must be carried out so that, in the end, the
asphalt surface should be exactly at the same level of the
edges of the joint device.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

The first elements to be mounted are the side members

corresponding to the road surface, on half of the total width of
the road, joined in the middle to form a dihedral angle,
corresponding to the projected shape of the cross section of
the bridge extrados, which will ensure precipitation. If the
bridge is provided with sidewalks, the elements intended to
equip the joint in their area shall be laid and fixed accordingly.

Usually, the difference in height of the sidewalks

from the road in the curb area is 15 cm.
Therefore, the short side members,
corresponding to the sidewalks, are mounted 15 cm
higher than the long ones, which correspond to the
roadway.
First fix the ends of the short side members in the
area of contact with the long ones; then align in the
plane and adjust the horizontal position using a level.
Then, all the welds are strengthened and
longitudinal reinforcement bars and bar ends,
transversely and diagonally, are added to achieve a firm
anchorage.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

The installation of the metallic elements that will

finally compose the Camelot Regular joint devices is made
by electric welding, with powerful devices, able to execute a
quality joint; and staff must be qualified for such
operations.
Both the final success of the connection to the
surfaces of the successive finishing layers of the bridge, and
the durability of the joint area depend on the precision and
resistance of the installation operations.
It is therefore essential in the construction site the
presence of a stable voltage source - or an electric
generator with a power of at least 5kW (recommended, 6.5
kW or more); plus cutting tools with abrasive disc (angle
grinder), additional long and short reinforcement bars.

For the eventuality in which the installation continues during the

night, the electric generator must allow the simultaneous supply of some
site lamps. Adjusting the position of the side members, as well as
correcting their placement, is done using long and short crowbars - so the
"arsenal" of tools, devices and hand tools must be as complete as possible
to reduce any unscheduled breaks during operations.
If the bad weather is expected, the presence of a construction site
tent can be particularly useful.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

After laying, checking and consolidating the first metal elements of

the Camelot Regular device, which form a "lost formwork", the elements
are mounted - pair of them, at predetermined distances according to
each type of construction, corresponding to the projected movement
deviation of the joint .
Thus, the place where the rubber gasket will be mounted (after
asphalting) is composed, with the role of sealing the joint.
Particular attention must be paid to achieving the perfect
equidistance between the pairs of side members facing each other, so
that the resulting joint has a uniform opening.

Not only the equidistance between the pairs of side members is

important, but also the most accurate vertical alignment of their section
- so, achieving the best possible parallelism of the planes between
which, after asphalting, the elastic gasket will be mounted.

Of particular importance is the laying of the side members as

accurately as possible at the same height, exceptions being allowed only
for bridges with a steep slope, in which case the upper edges of the side
members are located on the inclined plane that will be formed by the
surface. the final layer of road asphalt - and, of course, the final finish of
the sidewalks.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

To ensure the parallelism and the predetermined distance between the

inner planes of the side members - pairs, between them are mounted wooden
spacers, rectangular in shape and appropriate dimensions (see table, page 4).
The spacers must be mounted so that, after their removal, the side
members do not visibly change their position.
The contact pressure between the spacers and the side members must
be minimal so that their removal does not cause displacement of more than 1
mm in the elevation between the parallel planes of the side members. The
distance between any two consecutive spacers must not exceed 1 meter. By
their nature, the steel side members that make up the Camelot Regular joint
devices are massive and hard, and their bending is unlikely.
However, as an additional precaution against the effects of thermal
expansion and contraction in welding, their position and dimensions must be
checked at all times, especially in the case of long side members, which
correspond to the purpose in the roadway. If the joint crosses a large-width
deck, the requirements are even more demanding.

If the checks show that deviations from the predetermined position or

dimensions, deviations of parallelism or positioning from the vertical or level have
occurred, these deviations shall be corrected immediately by moving the element
with the help of levers (crowbars) simultaneously with the consolidation of the
installation by application and welding of bars. If the deflection found cannot be
remedied in this way, the welds shall be cut off and the deflector shall be
repositioned and then re-welded to the correct position.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

Particular attention must be paid to the correspondence,

vertically of the joint section, of the median plane equidistant
between the inner faces of the side members of the device,
compared to the vertical median plane of the joint between the base
of the abutment and the ends of the deck beams. and
superstructure.
If rainwater drains are provided, they shall be installed near
the junction of the ends of the long and short side members in the
area of the road bounded by the future curb.

Finally, a general check is made of the

correctness of the arrangement of each part and of
the rigidity of all the welded joints, intervening
where necessary to achieve the strongest possible
assembly.
The elements that make up the Camelot
Regular device are considered to be properly
anchored, if they have sufficient rigidity so as not
to allow their movement with the free hand, even
if energetic efforts are applied - or if you step on
them.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

The ends of the side members that meet on the

road axis are joined by a compact welding bead, except
for the parallel inner planes that will contain the elastic
rubber insert.
The finishing of this central joint is performed by
grinding with an abrasive disc the possible weld
protrusions on the upper chamfered
edges of the side members.
In fact, these areas will eventually
be part of the road surface of
vehicles.

Finally, the apparent areas of the joints of the side

members, located on the axis of the road, must present a
constant and uniform relief; and the welded joint - viewed
from above - must be almost invisible.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

The next step in installing the Camelot Regular device is to complete the
formwork with expanded polystyrene boards. By this measure, the formwork
consisted by the elements of the device is completed, in order to form an enclosure
from which the poured concrete should not leak, and the shape of the joint and its
continuity to be ensured, vertically and horizontally.

The thickness of the plates must be chosen carefully, being calculated

according to the distance between the inner faces of the side members. If the slabs
are too thick, their insertion will be difficult or impossible, and the forced opening
of the gap between the side members, in order to facilitate the insertion of the
polystyrene boards, can permanently disturb the predetermined value of the joint
between the side members. If the slabs are too thin, there is a danger of the
concrete entering the joint.
Usually, the insertion of the polystyrene plates in the slot formed by
the side members starts from one end. The first slab is inserted vertically,
until the lower end ensures the separation of the volumes of concrete
that will be poured into the over-concreting of the deck or abutment. Of
course, one of the vertical edges of the plate will have to be in contact
with the adjacent vertical formwork, already installed on the longitudinal
side of the bridge. The following slabs are inserted one by one in the
same way, taking care that their vertical sides are in firm contact, in order
to avoid concrete leakage.
Placing the plates is not possible without removing the spacers
mounted earlier between the side members - so before inserting the
polystyrene plates, the spacers must be removed.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

Continue placing the polystyrene boards along the entire length of the
joint, until the entire gap between the side members is completely filled in this
way. The last plate is cut vertically if necessary, in order to fit as well as possible
in completing the closing of the gap.
After the polystyrene plates have been applied to complete the formwork, at
both ends of the bridge, along the entire length of the joints, the ends of the
plates that protrude vertically above the edges of the Camelot Regular device
are cut, so as not to affect the smooth running of the following operations.
concreting, waterproofing and asphalting.

Concreting is carried out up to the prescribed height for each reference point of
the deck plane, usually 100 mm below the height of the upper edges of the side
members. After the concrete solidification period has elapsed (at least two weeks),
crossing thresholds are prepared, which will serve to cross the vehicles and asphalting
equipment over the joint devices, in order to avoid their dislocation. Before
waterproofing and asphalting, both on the concrete surface and especially in the joint
area, cleaning and dusting measures are applied, in order to avoid the accumulation of
impurities harmful to the best possible contact between the outer flank of the side
member and bitumen.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

After applying and cooling the last layer of asphalt, you

can move on to the final phase of installation - mounting the
gasket (elastic rubber insert) in place.
For this purpose, remove the polystyrene plates from the
housing with a pickaxe, by deep scratching, until a deep housing
is created below the level of the support shoulders of the elastic
insert. Then, the polystyrene residues are removed by sweeping
or compressed air jet. Carefully observe both the inner surfaces
between the side members and the edges of the rods that
constitute the support shoulders for the elastic profile. The
condition of these surfaces must be clean, free of impurities or
adherent residues of asphalt or traces of concrete. Unless
otherwise noted, these areas are carefully cleaned by scraping,
alternating with repeated and insistent dusting, until the entire
area is clean.
The rubber profile that will seal the joint is compressed
laterally and forcibly inserted between the flat and parallel
faces of the metal side members, starting from one end. Shortly
before, an adhesive based on rubber solution is applied by
brushing in the place, with a double role: of lubricant to
facilitate the assembly; and adhesive, intended to ensure the
firm fixing of the elastic profile in the seat. A good quality acetic
silicone sealant can be used instead of the adhesive, inserted
with a "silicone-salami" gun. In this case, the application will be
performed not by brushing, but with a spatula, in a thin layer.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

So, let's recap:

For the construction of a new bridge, the concrete plinths
(piles and abutment) that will support the support devices are
being prepared. In turn, they will support a bed of prefabricated
beams.

In the next phase, the reinforcement, nets and steel bars are
laid and anchored over the beams, then the formwork is prepared
on the long sides of the future bridge (parallel to the X Axis).

Then, place and secure the appropriate Camelot Regular

joint device (usually parallel to the Y Axis).
The installation is completed by stiffening the semi-profiles
of the device on either side, for each section of the structure,
respecting the mechanical separation of the subsequent horizontal
movement on the X Axis and the default values of the average joint
opening, in accordance with the thermal average of the works.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
installing

Pour the concrete related to the over-concreting of the

deck, including all the reinforcements and anchors of the joint
device. In this stage, the level, the slopes and the rough shape
that will support the road layer are formed. The perimeter
formworks on the short sides (parallel to the Y Axis) are formed
right by the side members of the Camelot Regular device.

After stripping the concrete, bituminous primer and

waterproofing membrane are applied on the entire surface,
paying special attention to sealing the joint area. A layer of
protective mortar is applied over the membrane, then two layers
of asphalt, until the upper level of the edges of the joint device is
reached.

Finally, the polystyrene plates are removed mechanically or

with a flame from the joint, the area is cleaned and the rubber
sealing profile is mounted between the metal side members of
the device.
In the areas connecting the sidewalks, the profile is cut and
adapted accordingly.
For a secure fixation, silicone sealants or rubber-based
sealants are optionally used.
EXPANSION JOINTS LTD. BRIDGE EXPANSION JOINT SYSTEMS
Suitable for movements between 12 mm and 80 mm
Camelot Regular
conclusions

Thus, by the natural staging of the works, a succession

of layers similar to the one in the figure is made.
Of course, in practice, situations may arise that differ
from case to case compared to the standard scheme; but the
Camelot Regular device has a high degree of adaptability, for
a wide variety of designed variants or existing conditions.
Aware that your time is precious, we are at your
disposal for the analysis and detailing of each feature of the
projects in which our product has applicability, for new
bridges or bridge renovations.
For any additional details, we are waiting for your questions or suggestions at the e-mail address:
info@the-expansion-joints.co.uk