Bearings and Seismic Isolators - Installation Manual

AW 8850
Installation manual for

Created: COSU Revision: 10
mageba structural bearings
Reviewed: MDEL Date: 18 Jan 2017
and seismic isolators
Approved: NMEN Page: 1
Installation Manual
for
structural bearings
Copyright © 2016 mageba Group, Bülach, Switzerland. All rights reserved.

AW 8850
Contents
1 Introduction ........................................................................................................................... 4
2 Applicability ........................................................................................................................... 4
3 Importance of proper installation......................................................................................... 4
4 Purpose of this Installation Manual ..................................................................................... 5
5 Introduction to structural bearings ...................................................................................... 5
6 Planning and preparation of installation work .................................................................... 5

6.1 Availability and use of relevant information ............................................................................... 5
6.2 Materials, tools and equipment .................................................................................................. 6
7 Competence of installation personnel ................................................................................. 6
8 Supervision of installation work .......................................................................................... 6
9 Health and Safety issues during installation....................................................................... 7

9.1 Risk of falling from a height......................................................................................................... 7
9.2 Risk of being hit by a large, heavy object during lifting .............................................................. 7
9.3 Risk of damage to health through contact with fresh concrete / mortar / grout etc. ................ 7
9.4 Risk during welding (if applicable)............................................................................................... 7
9.5 Risk from general construction hazards – use of appropriate PPE ............................................. 7
10 Care of bearings during and after installation .................................................................... 7
11 Recording of work carried out.............................................................................................. 8
12 Key bearing features ............................................................................................................. 8

12.1 Type plate .................................................................................................................................... 8
12.2 Movement Scale .......................................................................................................................... 8
12.3 Pre-setting ................................................................................................................................... 9
12.4 Transportation fittings................................................................................................................. 9
12.5 Markings on top of bearing .......................................................................................................10
12.6 Levelling surfaces ......................................................................................................................10
12.7 Dust protection .........................................................................................................................11
12.8 Anchor plates.............................................................................................................................11
13 Transport, checking and storage of bearings ................................................................... 12

13.1 Transport and handling .............................................................................................................12
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13.2 Checking of bearings .................................................................................................................12

13.3 Storage ......................................................................................................................................12
14 Design of connecting structures........................................................................................ 13
15 Positioning of bearings ...................................................................................................... 13

15.1 Location (which bearing goes where) and orientation on the structure ..................................13
15.2 Adjustment of presetting ..........................................................................................................13
15.3 Precise positioning of bearings .................................................................................................14
15.4 Possible method for adjusting elevation or inclination ............................................................15
16 General installation requirements ...................................................................................... 15
17 Support of bearings and connection to substructure ...................................................... 16

17.1 Concrete substructure...............................................................................................................16
17.2 Steel substructure .....................................................................................................................18
18 Connection of bearings to superstructure ........................................................................ 19

18.1 Concrete superstructure ...........................................................................................................19
18.2 Steel superstructure ..................................................................................................................19
19 Cutting / removal of transport fittings ............................................................................... 20
20 Installation beneath an existing superstructure ............................................................... 20

20.1 Lifting of the superstructure as required ..................................................................................21
20.2 Removal of the existing bearing, and connecting structure as appropriate .............................22
20.3 Preparation of the structure to receive the new bearing .........................................................22
20.4 Insertion of a new bearing into position beneath an existing superstructure..........................22
20.5 Precise positioning and adjustment of pre-setting if necessary ...............................................24
20.6 Connection of the bearing to the structure ..............................................................................24
20.7 Lowering of raised superstructure to rest on new bearings .....................................................26
21 Installation of elastomeric bearings .................................................................................. 26
22 Final checking and cleaning of fully installed bearings ................................................... 28

22.1 Checking and repair of corrosion protection (if applicable) .....................................................28
22.2 Cleaning of bearing and confirmation that it is free of obstructions ........................................28
22.3 Confirmation of complete and proper installation ...................................................................28
Appendix 1: Tools etc. to be provided by the contractor ......................................................... 29
Appendix 2: Installation Report ................................................................................................. 30

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1 Introduction
Structural bearings are carefully engineered components which are typically subjected to intense fatigue
loading during their lifetime despite generally being considerably less robust than the main structure. Proper
installation, and care at all times, is therefore essential to ensure that the bearing will perform safely and
well for its intended service life. Supervision of installation, which also serves to train the contractor’s staff
for future installation work (unless they have already been appropriately trained and certified in bearing
installation by a competent body), can be provided by mageba on request, and is strongly recommended
unless the contractor has sufficient experience and expertise.
The installation of elastomeric bearings that do not have steel plates at their connection surfaces (e.g.
LASTO®BLOCK Type B) is generally easier than other bearing types, and is described in Section 21.
2 Applicability
This manual can be used in connection with the installation of all types of mageba bridge-type structural
bearing, including RESTON®POT, RESTON®SPHERICAL, RESTON®DISC, RESTON®FORCE, RESTON®LINEAR and
LASTO®BLOCK. It also applies to the installation of all types of mageba seismic isolator, including LASTO®LRB,
LASTO®HDRB and RESTON®PENDULUM, since these can be considered a particular type of bearing. The term
“bearing”, where it appears in this manual, can thus be understood to apply also to such seismic isolators.
The bearings and seismic isolators to which this manual applies have generally been developed for use in
bridge structures, but the manual can also be used, as appropriate, where such bearings or isolators are
installed in buildings and other non-bridge structures. Where the word “bridge” appears in this manual, the
word “structure” or “structural” can be understood to apply, as appropriate. Where the word “deck” appears,
the word “superstructure” can be understood to apply.
The extent to which the general guidelines in this manual should be applied to any particular bearing type
and situation requires engineering judgement, and mageba should be contacted in case of any doubt or lack
of adequate competence in the installation team or its management or supervision. In particular, reference
must be made to all relevant national or international requirements and guidelines.
This manual primarily applies to the installation of bearings during the initial construction of a structure,
before the superstructure has been constructed or lifted into place. Installation of replacement bearings in
an existing structure requires project-specific planning, and mageba should be consulted in such cases for
appropriate guidance, but general guidance is provided in Section 20 for use as appropriate.
3 Importance of proper installation

Proper installation is critically important in ensuring the good long-term performance of any bearing. If not
properly installed, a bearing can suffer in many ways, including, for example, from
- mechanical damage from impacts during transport and installation or improper handling
- damaging constraint forces during structure movements
- inadequate ability to facilitate all structure movements and rotations
- contamination of sliding interfaces and other surfaces
- excessive loading
- reduced ability to withstand static and dynamic loading
Appropriate attention must therefore be paid to ensuring that bearings are properly installed, considering in
particular all relevant guidelines in this document.
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4 Purpose of this Installation Manual

This installation manual provides guidance on how mageba bridge-type structural bearings should be
installed under typical and normal circumstances, by suitably trained and competent personnel, to help
ensure proper functioning and a long life. However, the installation should not rely entirely on the guidance
given in this document – the engineering judgement of the responsible installation supervisor and team are
also important.
This manual does not seek to fully address non-technical aspects of bearing installation, such as safe access,
traffic management and Health, Safety & Environment (HSE) considerations. While some advice relating to
health and safety aspects is provided in Section 9, all such issues are outside the scope of this document.
5 Introduction to structural bearings

Structural bearings are used to form the connections between a structure’s superstructure and its
substructures (in the case of a bridge, between its deck and the deck’s support abutments or piers). They
typically transmit vertical loading (including weight of superstructure and live loading from traffic etc., and
possibly uplift forces), and allow the superstructure to move as required by the structure’s design.
Movements of the superstructure may arise due to expansion and contraction of the superstructure due to
temperature changes, shrinkage/creep of concrete, wind, traffic forces, settlement of substructures, seismic
effects and/or other sources. These movements may take the form of translations in any direction (insofar
as these are permitted by the structure’s design), and rotations about any axis. Conversely, bearings may be
designed, as required, to resist horizontal (transverse or longitudinal) forces.
There are various types of bearing, such as the pot bearing, spherical bearing, rocker bearing, roller bearing,
disc bearing and elastomeric bearing, each of which offers its own advantages in certain situations. Each
bearing type typically has three main sub-types, which differ depending on the freedom for horizontal
movement they allow the connected bridge deck, as follows:
 Free sliding/deforming - can accommodate horizontal movements in any direction.
 Guided sliding/deforming - can accommodate horizontal movements in either the longitudinal or
transverse direction, while resisting movement (and force) in the other direction.
 Fixed - cannot accommodate any horizontal movements – but rather resists the forces which would
tend to cause any such movements.
An introduction to various bearing types and sub-types is contained in the appendices of mageba’s Inspection
& Maintenance Manual for mageba bridge bearings and seismic isolators (AW 8880).
6 Planning and preparation of installation work

6.1 Availability and use of relevant information
All information that can help the responsible installation personnel to understand the design, functioning,
etc. of the bearings they are about to install must be made available to them by the responsible supervising
engineer and reviewed appropriately. In the absence of adequate relevant information about the bearing
type or its structure-specific design, mageba should be consulted for assistance. The relevant information
should include up-to-date versions of the following, where applicable and available.
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6.1.1 Structure-specific drawings, etc.

Reference must be made to all relevant structure-specific drawings and documents. Most importantly, these
must include mageba’s bearing design drawings. The most up-to-date drawings of the bearings and the
connecting structures must be at hand and referenced so that special features and the functioning of the
bearings can be fully understood by the installation team. Records from the installation are to be kept as
detailed below, for use by inspectors who will carry out subsequent inspections.
6.1.2 Further instruction documents relating to installation

Should any other instruction documents be provided or referenced by mageba, these must be consulted and
complied with.
6.1.3 General product information

Where necessary to provide an adequate understanding of the design and functioning of a specific bearing
type, reference should be made to relevant product information (e.g. brochures).
6.2 Materials, tools and equipment

Unless otherwise expressly stated, all materials, tools and equipment are to be provided by the Contractor.
Refer to Appendix 1 for a list of tools and equipment typically needed. In case of any doubt about the
materials, tools or equipment required, mageba should be contacted for guidance.
7 Competence of installation personnel

Installation of bearings must be planned and carried out by competent and properly informed/inducted
personnel. These should have good general knowledge of mechanical structures in general and of the
relevant type of bearing in particular, and should have been appropriately trained and certified in bearing
installation by a competent body.
The installation personnel should be provided with the appropriate information and drawings to enable them
to undertake the work properly.
Should unforeseen complications arise, or significant work be required that is not covered by this document
(in particular, anything which could impact on the correct long-term functioning of the bearings), mageba
should be consulted in advance.
All work should be planned and carried out under the supervision of a suitably qualified and competent
professional bridge engineer, who should ensure the competence of the involved staff and the correct
completion and recording of the work.
8 Supervision of installation work

A mageba Installation Supervisor should be in attendance during installation of the bearings, to ensure the
proper installation of these complex constructions, unless the contractor has the necessary knowledge,
capabilities and experience. A suitably qualified professional bridge engineer must oversee and be
responsible for all works for which a mageba installation supervisor is not expressly responsible. If bearings
are installed without mageba installation supervision, mageba shall not be responsible for any possible
damages or consequences of faulty installation.
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9 Health and Safety issues during installation

The following risks may arise during installation of bearings. This list is not exhaustive, and every worker and
every superviser must carefully consider the conditions and circumstances on site and all local/national laws,
standards and guidelines before commencing work, and ensure that all risks are identified and appropriate
measures taken to ensure the safety of all.
9.1 Risk of falling from a height

It must be ensured that the measures taken to prevent falling from a height (including falling from the bridge)
are adequate to ensure the safety of all. If necessary, additional safety fencing etc. should be erected, and/or
other suitable safety measures (e.g. use of a safety harness) implemented.
9.2 Risk of being hit by a large, heavy object during lifting

All persons must stand well back during lifting and moving of any large objects, in particular during lifting
bearings into position. If controlling the lifting operation, the worker must ensure that all others on site are
also sufficiently far back to ensure they will not be hit by the object.
9.3 Risk of damage to health through contact with fresh concrete / mortar / grout etc.
The health of all workers must not be jeopardised through contact with fresh concrete/mortar/grout or other
construction materials, by wearing suitable clothing, and safety gloves and safety goggles as appropriate to
protect their skin and eyes from splashes.
9.4 Risk during welding (if applicable)

Suitable equipment must be used during any welding carried out on site, including safety shield and gloves.
9.5 Risk from general construction hazards – use of appropriate PPE

PPE (Personal Protective Equipment) must be worn as appropriate depending on the circumstances on site.
This should include: safety boots where a risk of injury to feet exists; a safety helmet where a risk of being hit
on the head by swinging or falling objects exists; safety glasses where a risk of eye injury exist; and high-
visibility vest or jacket where high visibility of the worker is appropriate.
10 Care of bearings during and after installation

Care must be taken at all times to protect bearings from damage. Damage can result, for example, from
construction activities such as sandblasting of superstructure steel or application of corrosion protection.
Bearings must be kept clean and free of any dust or contamination, especially at sliding surfaces. Dust, dirt,
grit, mortar and all foreign matter must not be allowed to enter the moving parts of bearings. For this reason,
bearings should not be dismantled after leaving the factory. If it is necessary, this may only be done under
mageba’s supervision. Splashing with fresh concrete/mortar etc. must be avoided, and any such splashes
must be cleaned immediately. Paint must not be applied to sliding surfaces (including any stainless steel).
Bearings must not be used for any unforeseen purpose, and must not be exposed to loading or conditions
other than those for which they have been designed. All impacts must be avoided, and damage to corrosion
protection must be prevented, with any such damage repaired immediately. Any damage to the bearing must
be immediately reported to mageba. The responsibility to prevent damage to the bearing is the contractor’s,
but mageba will be glad to offer advice for any particular circumstances.
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11 Recording of work carried out

The installation work must be properly recorded – as a minimum using the Installation Report included in
Appendix 2. Certain types of bearing (pot, spherical and disc) require recording of key dimensions (sliding
and tilting gaps) immediately following installation, for reference during future inspections. This is noted and
illustrated with sketches in the same appendix.
Additional blank pages should be used if required, and the use and number of such pages noted on the main
report sheet.
A photographic record should be created.
After completion of all works and all necessary measures have been taken and confirmed, all reports and
records must be carefully filed for future reference – in particular, during inspection and maintenance work.
12 Key bearing features

The following features and aspects apply to many bearing types, and their purpose and functioning must be
understood as appropriate.
12.1 Type plate

The type plate, if provided, contains key data relating to the bearing and its design.
P-No. = mageba project number
Location = Bearing location on the structure

vx / vy = Movement range in x and y directions
ex / ey = Pre-setting values
NEd,max / VEd, max = Max. normal and transverse design level (ULS) forces, respectively
12.2 Movement Scale

Movement scales are typically provided for sliding bearings with a movement range of over 100mm. These
enable current values of bearing displacements to be easily read at any time.
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12.3 Pre-setting
Pre-setting of bearings, if required, is done in the factory before delivery. Pre-setting may be required, for
example, if the movements of the superstructure following bearing installation will be more in one direction
than in the opposite direction (e.g. due to creep and shrinkage of a concrete structure, or because the
bearings are installed at a particularly cold or particularly warm time of year). It is necessary to account for
this by pre-setting the bearings accordingly, to ensure that the remaining sliding capacity of the bearing in
each direction is adequate to accommodate any future movements that can arise.
In the example shown above, the bearing is to be installed with a pre-setting value of approximately 8 cm to
one side. Although the bearing has a total movement capability of 30 cm (+/- 15 cm if the bearing was
installed at its central position, with the pointer indicating “0” on the movement scale), it has been
determined by the structure’s designer that superstructure movements following installation will be
predominantly towards the left as viewed, relative to the base of the bearing. If the bearing was installed
without any pre-setting, the largest design movements to the left (of approximately 22 cm) could not be
accommodated by the bearing.
Pre-setting of bearings is done at mageba’s workshop according to values advised by the structure designer
(who has the knowledge of the structure’s design and behaviour that is required to determine these values).
Should pre-setting need to be adjusted following delivery of the bearings, mageba must be consulted, as this
is specialised work which must generally be done by approved bearing experts. It should be noted, however,
that such a need rarely arises because a significant tolerance is generally allowed for in the bearing’s design
(consult with the bridge designer and/or mageba in case of any doubt).
12.4 Transportation fittings

Bearings (except for simple elastomeric bearings) are generally fitted with temporary transportation fittings
(such as metal or plastic threaded rods) which hold the bearing together until it has been installed and may
set the bearing (if a sliding type) at a specified pre-setting value.
These temporary fittings must not be cut or removed until the bearing has been installed, as to do so would
allow the bearing to rotate or fall apart and become damaged and internally contaminated. Plastic rods will
generally self-shear when the bearing is in service and the superstructure starts to move. Metal rods
generally have to be cut immediately after fixing of the bearing to both the substructure and superstructure,
when they are no longer required to serve their purpose and before superstructure movements would be
resisted by the fittings (which could result in damage to the bearing). If it is necessary to adjust the pre-setting
value of the bearing before it has been finally connected to the structures above and below, this requires
expert supervision and guidance from the manufacturer.
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12.5 Markings on top of bearing

Markings on the top plate of a bearing may provide
information such as the type of bearing, bearing number (as
noted on the drawings), x- and y-axes (x-axis indicating the
structure’s longitudinal axis in the case of a bridge), bearing
weight and project number. The markings must be read in
the pre-setting direction. The arrows on sliding bearings
indicate the directions of horizontal movement, with
double-arrows indicating the pre-setting direction (see
example on right). All markings must be checked against the
relevant drawings prior to installation.
12.6 Levelling surfaces

To assist with proper levelling of bearings during installation (to ensure horizontal), a device containing two
spirit levels (at right angles to each other) is often used, as shown below. Some bearings have specially
prepared surfaces (machined to be perfectly parallel to the bearing’s sliding interface, if any, or otherwise to
the bearing’s bottom surface) where this device should be used – either on top of the bearing or on a steel
plate welded to its side. If this surface is on top of the bearing, and the bearing is supplied with a separate
anchor plate for the upper connection, the anchor plate may feature a set of three holes which allows the
legs of the levelling device to reach the specially prepared surface, through the anchor plate. Alternatively,
where circumstances allow, common spirit levels with sufficient accuracy may be used.
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12.7 Dust protection

Bearings that accommodate sliding movements are typically provided with some form of dust protection to
prevent contamination of the sliding surface. Such contamination can result in scratching or other damage
to sliding surfaces such as stainless steel and PTFE/ROBO®SLIDE, and loss of performance of lubricating grease
that may be applied to the surfaces.
This dust protection is typically in the form of a rubber skirt which hangs around the bearing, or a multiple
leaf skirt (a folding sheet similar to that used in a bellows or an accordion) which is placed horizontally across
the sliding surface at each end of the bearing.
 Rubber skirt protection: This type of protection is attached to the bearing by Velcro tape and is
therefore easy to remove and re-attach, to allow the bearing to be cleaned and inspected.
 Multiple leaf skirt (bellows) protection: Dismantling of this type of protection requires more effort so
the extent to which it must be temporarily removed for any inspection should be considered based on
the circumstances. However, multiple leaf skirts protect the sliding surface more completely. In the
case of bearings that are designed to be installed “upside down”, with the sliding plate at the bottom,
this kind of protection is generally preferred.
The dust protection should only be removed if necessary (e.g. if required during inspections), and must then
be quickly replaced after ensuring that no contamination of the sliding surfaces etc. has occurred. Any
contamination must be properly cleaned, without damaging surfaces. The proper condition and functioning
of the dust protection must be ensured at all times.
12.8 Anchor plates

Bearings are often supplied with anchor plates, where specified, for easier connection to a concrete structure
– and in particular for easier replacement of an existing bearing without the need for concreting work. In the
case of a precast superstructure, the appropriate anchor plate may be concreted into the superstructure
during its construction.
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13 Transport, checking and storage of bearings

The proper condition of bearings must be ensured at all stages prior to installation.
13.1 Transport and handling

Bearings are precision components which must be handled carefully to ensure their proper functioning.
Any temporary transportation fixings (such as metal or plastic rods, see Section 12.4 above) must not be cut
or removed until the bearing has been fixed to both the substructure and superstructure, as to do so would
enable the bearing to rotate or fall apart and become damaged and internally contaminated.
Bearings must be lifted with care to ensure they will not be allowed to fall or suffer any impacts or damage.
Corrosion protection can be easily damaged by even light impacts. Ring nuts, which can be screwed into the
top surface of the bearing, are typically supplied with the first batch of bearings of each kind. These ring nuts
must be used for lifting all bearings (first to last delivery).
Bearings must not be lifted by their anchorage fittings (head bolts, dowels etc.), or any other elements that
are not designed for use in lifting and indicated as such.
In case of any doubt, mageba should be contacted to ensure correct and safe lifting and handling of bearings.
13.2 Checking of bearings

Bearings must be checked as follows immediately following delivery:
 Check that bearings are free of external visible damage
 Check that bearings are clean
 Check that corrosion protection has not been damaged
 Check that temporary transportation fixings are tight and in order
 Check that type plate and markings are as expected (see Section 12)
 Check movement scale, and value and direction of pre-setting against structure drawings
If any damage is detected, or if a bearing is found to not comply with specifications or fulfil requirements in
any way, this must be marked on the delivery note and mageba must be notified in writing within 3 days of
delivery. In the absence of any such notification, the bearings are deemed to be accepted as delivered.
13.3 Storage
If bearings are not installed immediately upon delivery, they must be stored on wooden pallets (flat, level) in
an appropriate, safe location. During storage, bearings must be kept clean and protected from mechanical
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damage, moisture, excessive heat, sunlight, oils, fuels and other deleterious effects. In order to prevent
condensation of water, air circulation must be ensured.
It should be noted that steel parts which will be concreted in are not generally provided with corrosion
protection, except at edges, because suitable concrete will provide the required protection. Any excessive
corrosion of these unprotected surfaces that may develop during storage must be cleaned in advance of
installation.
14 Design of connecting structures

The design of connecting structures (substructure beneath bearing and superstructure above) is not the
responsibility of the bearing supplier (generally, it is the responsibility of the main structure’s designer). In
general, the design and construction of connecting structures must ensure the following points, among
others.
- All loads that can arise in any design case (including SLS and ULS) must be properly and safely carried
and transferred, without damage to bearings or connecting structures. In the case of concrete
connecting structures, this requires, in particular, suitably designed and placed reinforcement and
suitably designed, placed and compacted concrete.
- All bearing movements and rotations that can arise in any design case (including SLS and ULS) must
be accommodated by the connecting structures, without unintended contacts or impacts.
- Adequate access (for bearing inspection or maintenance, etc.) must be possible in any state or
condition.
- Bearing replacement must be possible when the time for replacement comes. As appropriate, this
should include consideration of all aspects of the bearing replacement process, including lifting of
the superstructure (e.g. positioning of hydraulic jacks) and access.
Where uplift forces must be resisted, or where otherwise required to resist large horizontal forces etc.,
appropriately designed tension anchors are required. The design and supply of such anchors is not the
responsibility of the bearing supplier.
15 Positioning of bearings
15.1 Location (which bearing goes where) and orientation on the structure
The correct location in the structure of each bearing, and its orientation, must first be established with
reference to all relevant structure and bearing drawings, including any bearing location drawings that may
exist. The locations of individual bearings are generally indicated on mageba’s bearing drawings, by means
of a sketch and/or a table. Reference must also be made to the bearing’s type plate (if any) and any markings
that may have been made on the top surface of the bearing (see Section 12). In case of any discrepancy or
doubt, or should the location and orientation of any bearing not be clearly identifiable, clarification must be
sought from the structure’s designer and/or mageba as appropriate.
15.2 Adjustment of presetting

If it is necessary to adjust the pre-setting value (refer to Section 12.3) of a sliding bearing before it has been
finally connected to the structure above and below, to ensure that it will be able to accommodate all future
sliding movements in all directions (considering the superstructure’s current position), this requires mageba
supervision.
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15.3 Precise positioning of bearings

The required location (two axes) and elevation of the bearing (with reference to mageba’s design drawing)
must be defined in advance by the structure’s designer, and marked on the substructure. If the bearing is to
be installed with an inclination (i.e. not horizontal), this must also be indicated and understood.
The correct location, elevation and inclination of the bearing must be achieved as follows:
15.3.1 Location
The bearing axes (x and y) are generally indicated on the bearing with punch marks and highlighted with
yellow paint. The bearings must be carefully and precisely positioned such that the punch marks coincide
with the axes marked on the substructure.
15.3.2 Elevation
The reference point for elevation is the centre of the bearing’s top plate or sliding plate (not including any
additional anchor plates etc.). The installation level can be adjusted as required using shim plates/adjusting
screws, e.g. as described below. Light bearings should be secured to prevent displacement during grouting.
15.3.3 Inclination
Parallelness of the upper and lower parts of the bearing is generally ensured by the temporary transportation
fittings (typically threaded rods) which hold the bearing together during transportation and installation. The
reference plane for checking horizontalness (or for setting inclination, where inclination is allowed) is as
follows:
o If the bearing contains a specially created levelling surface as described in Section 12.6 above, this
must be used.
o In the case of sliding bearings which do not have such a specially created levelling surface and where
access allows, the reference plane is the stainless steel sliding surface.
o In all other cases – assuming the bearing has been delivered with transportation fittings (e.g.
threaded rods) that ensure the parallelness of the top and bottom parts of the bearing - the reference
plane is the top surface of the bearing (excluding any separate anchor plates etc.), but noting as
follows:
- If the bearing is connected to (hung from) the superstructure first before connecting to the
substructure, the bottom surface of the bearing may be used as the reference plane.
- The external surface of any tapered plate (which does not have parallel sides) is not suitable for
use as a reference plane; in such cases, the internal surface should be used.
o In case of any doubt, mageba should be consulted.
Inclinations are generally not allowed for seismic isolators unless explicitly designed for this and confirmed
by the design engineer.
In many cases, inclination can be adjusted using adjusting screws as described below.
The inclination error (from horizontal or approved inclination) should not exceed 0.3% (3 mm/m) unless
confirmed acceptable by calculations - or any lower value that may be specified by the design engineer.
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15.4 Possible method for adjusting elevation or inclination

Elevation / inclination of a bearing can often be adjusted during installation as follows, to ensure correct:
- Place three adjusting screws, vertically oriented, in the top surface of the substructure, to form a
triangle of roughly equal sides.
- Adjust the levels of the tops of the screws so that the plane they define has the elevation and
inclination that are appropriate for the underside of the bearing.
- Place the bearing on top of the adjusting screws, and after the elevation and inclination of the bearing
are confirmed once more, the space beneath the bearing can be grouted using suitable non-shrinking
mortar, properly placed and compacted (where appropriate, refer to Section 17 below).
Top of substructure
16 General installation requirements

The construction company / contractor is required to provide all required tools (see Appendix 1), lifting
equipment and, if necessary, scaffolding for the bearing installation.
After positioning, any lifting rings must be removed and replaced by plastic hole covers to prevent ingress of
mortar etc.
It is essential to ensure that bearing loads are evenly transferred to/from both the substructure and the
superstructure, over the entire area of each connection surface, via flat connecting surfaces of adequate
strength and stability. High pressure at any location due to uneven support and load distribution may lead to
deformation and failure of the bearing or of the supporting surface.
Particular care is required in the case of disc bearings, which tend to distribute loading to the connecting
structures above and below less evenly than other bearing types, with higher pressure at the centre of the
bearing. Therefore, it is particularly important in the case of disc bearings to ensure that the grout/mortar
bed (if any) is properly designed and executed without voids.
Connecting surfaces must be clean and free of dirt and debris, and in particular, of shuttering/formwork oil
etc., in order to ensure appropriate bonding / friction between bearing and connecting surface.
The functionality and proper long-term performance of bearings must not be negatively affected in any way.
In particular, a bearing’s ability to accommodate movements and rotations must not be inhibited, e.g. by
debris. Any splashing of the bearing by concrete or mortar must be immediately cleaned off, and any damage
to a steel bearing’s corrosion protection must repaired as instructed (refer to mageba’s Instruction AW 8801).
Any damage which cannot be fully repaired and which could impact on the bearing’s functionality and proper
long-term performance must be immediately notified to mageba and addressed in accordance with any
resulting guidance.
AW 8850
17 Support of bearings and connection to substructure

Bearings are typically (in the case of a concrete substructure) supported on a mortar/grout bed to ensure
flatness of surface and even distribution of loading. In some cases, however, bearings can be placed directly
on a steel substructure. Each of these connection types is described in the following sections.
17.1 Concrete substructure

In the case of a concrete substructure, bearings must be supported on a non-shrink, non-deforming
mortar/grout bed to ensure flatness of surface and even distribution of loading. The thickness of the bed
should be determined with reference to the construction drawings (typically between 20mm and 50mm,
unless noted otherwise), and in particular to ensure that the level of the installed bearing will be correct.
The choice of bedding material is influenced by the size of the gap to be filled and whether below or above
the bearing, the size of the bearing, the strength required, access around the bearing and the required setting
time. The bedding must ensure that all horizontal and vertical forces that may arise in service (refer to
applicable design calculations) will be safely transferred without damage, throughout the bedding’s service
life. In some cases it may be necessary to carry out trials to ascertain the most suitable material, particularly
if flowable mortar/grout is used. Selection of bedding type and mix, and placing, are the responsibility of the
contractor. Often, grout of type BETEC 140 by Grace Construction Materials is appropriate.
All applicable instructions of the mortar/grout supplier must be complied with, unless otherwise agreed.
Immediately prior to placing of cement-based mortar or grout, the connecting concrete surface must be
made wet by applying water and kept wet for a suitable period, to ensure that water will not be lost to the
existing structure from the fresh material while it cures. Any excess water must be removed before placing
of the new material. In the case of a reaction resin mortar (polymer concrete), which is not cement-based
(and which should not be used in connection with elastomeric bearing surfaces, to avoid unintended sliding),
the connecting surface must generally be dry prior to its placing.
For bearings with sockets or shear connectors, it is often practical to temporarily support the bearing in its
final position, and pour flowable mortar/grout into the space beneath the bearing, including the recesses in
which the sockets or shear connectors are located. If desired, bearings can be rested on levelling aids while
the material is placed, as long as these aids are adequately compressible or can be removed afterwards.
 The fluid material can be poured through a flexible see-through plastic hose (with the help of a
funnel), as illustrated below by VHFL, the Germany-based association of manufacturers of structural
expansion joints and bearings. To prevent any voids, the grout should be poured from one side only,
slowly retracting the pipe as the bed fills. The amount by which the mortar bed extends out from the
bearing’s base plate should generally comply with the mortar material’s data sheet / instructions,
but mageba will be glad to assist in case of any doubt.
 Alternatively, a half-pipe can be used, but this requires more care to ensure that the space beneath
the bearing is completely filled and to avoid spilling grout/mortar onto the bearing.
AW 8850
Recesses for the sockets or shear connectors should be filled and allowed to set before placing the main bed,
in order to avoid local shrinkage deformation at these locations. It is essential to immediately and thoroughly
de-aerate the freshly placed material, e.g. using metal chains pulled back and forth through the material. The
spacing between chains should typically be approx. 15 to 20 cm. The grout/mortar must be poured until the
space beneath the bearing is completely filled, leaving no voids. Assuming the bearing’s bottom plate (e.g.
an anchor plate if present) does not have to be readily removable, the material should be further placed until
it extends about 1 cm above the lower surface of the bottom plate.
For bearings without sockets or shear connectors, flowable mortar/grout can be poured into the space
beneath the bearing as described above, or non-flowing mortar can be packed into the space from the side,
leaving no voids. Alternatively, and especially in the case of very large bearings (due to the increased difficulty
of properly introducing grout or mortar from the side), it may be most practical to prepare a flat, smooth
mortar bed and place the bearing on top. Regardless of which method is chosen, the structure designer must
ensure that bearing displacements during service will be prevented (e.g. by adequate friction forces). If the
bearing, or its bottom plate, does not have to be removable in the future, and if approved, resistance to
displacements can be increased by placing mortar/grout around the edge of the steel plate (e.g. by pressing
it into the fresh mortar, where the mortar bed is placed before the bearing).
In the case of very large bearings, a trial grouting is recommended to ensure that the desired result will be
achieved with the actual bearings, with the material spreading properly and fully filling the space beneath
the bearing. The use of a transparent plastic sheet to simulate the bearing can be considered, as this enables
the material’s spreading behaviour to be observed during placing (see pictures below).
Bearings must be prevented from moving or vibrating until the mortar/grout has properly set. If necessary,
bearings should be securely fixed in position in advance, e.g. by welding of anchor studs to reinforcement.
If mortar/grout gets on the bearing at any time, it must immediately be properly cleaned off.
AW 8850
17.2 Steel substructure

If the bearing is placed directly on a steel substructure, the connecting surface must be machined, with a
tolerance of 0.0003 x [diameter or diagonal]. If this flatness is confirmed, and the inclination of the connecting
surface is suitable, then the bearing’s bottom plate may be bolted directly to the substructure, or welded to
it by means of a fillet weld. Otherwise, a thin layer of special mortar/grout should be placed to achieve the
required conditions, as described below.
17.2.1 Creation of a suitable bearing surface if required

If necessary, the correct bearing conditions (in terms of flatness and inclination) for the bearing can be
achieved using shim plates as illustrated below (not to scale). To ensure that contact pressure is distributed
evenly, the gap between the bearing and the substructure must be filled with a suitable special heat-resistant,
super-fluid mortar of sufficient strength. It must be ensured that no voids remain between the bearing and
the substructure, e.g. by placing as described above for the case of a concrete substructure. The material
must also be placed in such a way as to not interfere with the welding that follows.
17.2.2 Connection by bolting

Supply of the bolts is the responsibility of the contractor, unless otherwise arranged.
17.2.3 Connection by welding

The length, size and quality of the weld seam are as indicated on the applicable design drawings.
The surfaces being welded together must be clean and free of any dirt or grease.
Special care must be taken during welding to avoid damage to the bearing or the main structure. Any part of
a bearing that is not made of pure steel can be easily damaged by welding, if suitable measures are not taken
to prevent this. PTFE/ROBO®SlLIDE sliding materials, elastomers (as are used, for example, inside the pots of
pot bearings and in elastomeric bearings), and features such as dust protection should not be subjected to
temperatures of over 150°C. The temperature development of the steel between the welding and all
temperature-sensitive parts of the bearing must be monitored, e.g. using temperature-sensitive chalk (see
below).
After completion of welding, corrosion protection must be applied to the welded areas and any damaged
corrosion protection must be repaired (refer to mageba’s Instruction AW 8801).
AW 8850
18 Connection of bearings to superstructure

Similarly to the substructure connection, the superstructure connection can be concreted or grouted (if the
superstructure is of concrete), or can alternatively be bolted/welded directly to a steel superstructure. Each
of these connection types is described in the following sections.
18.1 Concrete superstructure

Generally, a concrete superstructure can be poured directly onto the bearing, after placing of formwork all
around the bearing. The formwork must be placed as tight as possible to the bearing plate, and the remaining
gap must be carefully sealed using appropriate material (e.g. Hilti shuttering foam CF-FW 500 (D)) to ensure
that no concrete/grout leaks through onto the vertical face of the bearing. Sliding plates must be fully
supported, to prevent distortion or rotation of the bearing under the weight of the fresh concrete.
If concrete leaks through the formwork to the bearing, it should be cleaned off immediately. This is especially
important in the case of elastomeric bearings, whose ability to compress and rotate could be diminished.
After removal of the formwork, the bearings must be cleaned and any damage to corrosion protection must
be repaired (refer to mageba’s Instruction AW 8801).
18.2 Steel superstructure

The connecting surface of a steel superstructure should be machined, with a tolerance of 0.0003 x [diameter
or diagonal]. Otherwise, flatness must be achieved with a thin layer of special mortar (refer Section 17.2.1 as
appropriate).
Bearings are generally connected to a steel superstructure by bolting or by welding (see below).
18.2.1 Connection sequence

In the case of a steel superstructure, the bearing must generally be connected to the superstructure first,
and then to the substructure, to ensure that the steel surfaces of the bearing and the superstructure come
perfectly together without any voids in between.
18.2.2 Connection by bolting

Supply of bolts is the responsibility of the contractor, unless otherwise arranged.
AW 8850
18.2.3 Connection by welding

The length, size and quality of the weld seam are as indicated on the applicable design drawings.
The surfaces being welded together must be clean and free of any dirt or grease.
Special care must be taken during welding to avoid damage to the bearing or the structure. Any part of a
bearing that is not made of pure steel can be easily damaged by welding, if suitable measures are not taken
to prevent this. PTFE/ROBO®SLIDE sliding materials, elastomers (as are used, for example, inside the pots of
pot bearings and in elastomeric bearings), discs of disc bearings, and features such as dust protection should
not be subjected to temperatures of over 150°C. The temperature development of the steel between the
welding and all temperature-sensitive parts of the bearing must be monitored, e.g. using temperature-
sensitive chalk.
19 Cutting / removal of transport fittings

As soon as the bearings are fully installed and properly supported (with any concrete or mortar hardened
enough – typically after about 8 hours, depending on mix, temperature, etc.), and prior to any pre-stressing,
any temporary steel transport fittings (see above and refer to bearing drawing) must be removed to avoid
constraint forces and damage as the superstructure starts to move. (If the transport fixing rods are of plastic,
these will self-shear when the superstructure starts to move, so they do not necessarily have to be cut and
removed.) It should be ensured, when placing any scaffolding / formwork etc., that access to any steel
transportation fittings will be possible. Steel rods can be cut using a cutting disc, taking care to protect the
bearing. If such steel rods serve a double purpose, and will be used to connect the bearing to the main
structure, then the ends must not to be removed. Otherwise, the ends of the rods must be removed and the
holes filled with silicone or epoxy resin.
20 Installation beneath an existing superstructure

As noted in the introduction, the preceding sections primarily apply to the installation of bearings during the
initial construction of a structure, before the superstructure has been constructed or lifted into place.
Installation of replacement bearings in an existing structure requires project-specific planning, and mageba
should be consulted in such cases for appropriate guidance. This section contains general guidance for such
cases, which may be applicable and helpful in some cases and should be used as appropriate. The general
bearing installation principles and guidance provided throughout this document should also be applied
wherever appropriate, and are not repeated here.
Specific challenges and general considerations may include:
- The available working space may be very limited, heightening the need for careful planning.
- It must be ensured that the superstructure remains secured against undesired movements at all
times. While a bearing which provides a certain fixity is being replaced, that fixity must be temporarily
provided by another bearing or by alternative means. For instance, if a superstructure is supported
at one bridge pier by a guided sliding bearing and a free sliding bearing, temporary restraint against
transverse movements must be provided during replacement of the guided sliding bearing.
- It must be ensured that constraint forces don’t build up between bearings at any time. For instance,
in the example given above, if a free sliding bearing on a bridge pier is made to temporarily function
as a guided sliding bearing during replacement of the adjacent guided sliding bearing, this temporary
function must be terminated as soon as the bearing replacement has been completed and transverse
deck movements are resisted by the new guided sliding bearing.
AW 8850
The challenges associated with installation beneath an existing superstructure typically also include:
 Lifting of the superstructure as required.
 Removal of the existing bearing and connecting structure (concrete, dowels, etc.) as appropriate.
 Insertion of a new bearing into position beneath an existing superstructure (insertion from the side,
with the superstructure preventing use of a chain or sling to lift it into place)
 Predefined clear height and angular rotation (possible deviation from parallelness) between upper
and lower connecting surfaces, and perhaps predefined hole locations for bolted connections.
 Possible appropriateness of connecting bearing to superstructure before substructure.
If the connecting surfaces of an existing bearing are to be re-used when the bearing is replaced, e.g.:
 If both surfaces are of steel
o where both substructure and superstructure are of steelwork, or
o due to the presence of re-usable separate steel anchor plates in concrete structures); or
 If the bearing has not been and will not be fixed in place or bolted/anchored to the connecting
surfaces, e.g.:
o In the case of elastomeric bearings that are kept in place by friction or by external means
then the bearing replacement process typically comprises the following main steps:
 Lift the superstructure by the small amount required to remove and insert the bearings.
 Remove the existing bearing.
 Repair or improve connecting structures/surfaces as required (e.g. treatment of corrosion,
application of corrosion protection, etc.)
 Insert the new bearing, of suitable design and dimensions, considering compressibility (in relation to
height) and details and positions of any connecting holes.
 Connect the new bearing to the connecting surfaces if/as required.
In doing so, the new bearing’s ability to accommodate all future displacements and rotations must be
ensured – for example, by installing the bearing with a suitable pre-set. Any deviation from parallel between
the bearing’s upper and lower surfaces must be considered in the context of the bearing’s total rotational
capacity (which may be reduced by such a deviation). Whether or not the new bearing should first be
connected to (hung from) the superstructure, before connecting to the substructure, should also be carefully
considered.
If, however, the connecting surfaces are not both to be re-used (e.g. where an existing concrete structure or
the bearing’s anchorage in it must be modified or reconstructed), the process becomes more complex and
requires detailed project-specific planning. In such cases, mageba should always be contacted for guidance
as appropriate.
General guidance for typical situations is provided below.
20.1 Lifting of the superstructure as required

The degree to which a superstructure must be lifted to enable an existing bearing to be removed depends
on the type of bearing and how it is connected (if at all) to the structures above and below. It also depends
on the extent to which the existing bearing and its connections (e.g. dowels) require to be removed, and
whether or not the existing bearing was equipped with anchor plates to facilitate relatively easy replacement
of the actual bearing.
The consequences of lifting the superstructure must be considered in advance, and in particular when
deciding how much it is to be lifted. Damage to surfacing etc. should be minimised, and the safety of traffic
must be ensured at all times. If the structure is not closed to traffic while the superstructure is raised, any
step introduced in the driving surface must be acceptable for the traffic using the structure at this time. This
is particularly important for railway structures, which generally require perfectly flat rails for the passage of
any rail vehicle.
AW 8850
Hydraulic jacks (e.g. Eberspaecher, Type ZERK) are often used to lift a superstructure. Lifting devices must be
of adequate number and lifting capacity, and suitably located where the strength of the structures and access
is adequate. Jacks should generally be equipped with a spherical bearing plate and locking rings, which should
be used wherever appropriate to avoid unnecessarily depending on the jack’s hydraulic pressure. Where
multiple jacks are used to lift the same element, it should be possible to control each jack independently. All
details, including precise positioning of jacks, must be as defined by the engineer.
Before lifting the superstructure, the bearing must be disconnected from the main structure (e.g. by
removing bolts) as required to prevent the bearing from tying the structures together.
20.2 Removal of the existing bearing, and connecting structure as appropriate

The extent to which the existing bearing, its connections and the connecting structures are to be removed
must be determined by the responsible engineer, considering the design of the new replacement bearing
and its support and connections, the condition and suitability of any retained elements, and the space
requirements of any equipment (e.g. drills) that may be required to install the new bearing. Further removal
or destruction of structure must be avoided, except to the extent approved by the engineer.
If either or both of the existing bearing’s support surfaces (e.g. concrete or mortar plinths or anchor plates,
if present), or any existing connection possibilities (bolt holes, dowels, etc.) are to be used by the new bearing,
damage to these must be prevented.
20.3 Preparation of the structure to receive the new bearing

Any damage to retained elements (e.g. support surfaces or connection possibilities such as dowels) must be
made good to the satisfaction of the responsible engineer. Reconstruction of removed sections of structural
elements must be in accordance with an approved design. Corrosion protection must be appropriate and
adequate.
The condition and suitability of all relevant structures, including both retained and reconstructed elements,
must be approved by the responsible engineer prior to installation of the new bearing.
20.4 Insertion of a new bearing into position beneath an existing superstructure

Where bearings are heavy and/or access is difficult, it can be a significant challenge to insert a new bearing
into position beneath an existing superstructure (inserting from the side, with the superstructure preventing
use of a chain or sling to lift it into place). Depending on the structure’s geometry and the challenge presented,
it may, for example, be helpful to erect a temporary steel structure at the top of the substructure, creating a
cantilevering platform at the appropriate level to allow the bearing, when lifted onto the outer end of the
platform, to be slid along the platform (on a PTFE surface) into position. An example of how such a temporary
platform might be constructed (in the case of an isolated bridge pier) is illustrated in the following sketches.
These sketches merely indicate the principle; a proper design by a qualified engineer is required. Such
platform structures can typically be re-used for subsequent bearing replacements, if required.
AW 8850
Tem porary Bloc k Final Plac e

(For UP-Lift Forc es)
Crane
Steel Construc tion

for support
Example of temporary platform at top of a bridge pier: Elevation (view from adjacent pier)
Final Place
Hydraulic jack Tem porary place
Example of temporary platform at top of a bridge pier: Plan view
Example of temporary platform at top of a bridge pier: Section (parallel to bridge axis)
AW 8850
20.5 Precise positioning and adjustment of pre-setting if necessary

If the exact positioning of the new bearing (with reference to plan position, elevation and/or inclination) is
not precisely defined and automatically achieved by the bearing’s connection to the superstructure or
substructure, the exact positioning must be otherwise defined and achieved in accordance with the design
and the responsible engineer’s instructions. Refer to Section 15 as appropriate.
Refer to Section 15.2 in particular in relation to the verification, or adjustment if necessary, of pre-setting
(the ability of the bearing to accommodate all future movements/rotations, starting from its current
condition).
20.6 Connection of the bearing to the structure

Following preparation of the structure to receive the new bearing, as described above, and insertion of the
new bearing into position (in stages if required, e.g. with anchor plates or similar inserted first if appropriate),
the bearing may be connected to the main structure in accordance with the relevant design and the
responsible engineer’s instructions. Depending on the design, such connections may take the form of positive,
anchoring connections (e.g. bolted), or simple friction-based connections (which prevent bearing
displacement by friction, where adequate and permissible).
The design and execution of the connections must also consider the predefined (existing) clear height
between the substructure and superstructure, and any angular rotation (possible deviation from
parallelness) between the connecting surfaces. In the case of bolted connections, any existing hole locations
must also be considered.
Refer to the sections of this manual which relate to bearing installation and connection in general (e.g.
Sections 16, 17, 18 and 19 in particular), and apply these guidelines as appropriate.
Care must be taken to ensure that all loads will be properly and safely transmitted between the bearing and
each connecting structure. For example:
- Where a mortar bed (e.g. thickness approx. 30mm) is required beneath a bearing, the use of a
free-flowing mortar such as BETEC 140 by Grace Construction Materials might be considered.
Refer to Section 17 as appropriate.
- Where a thin levelling course is required (e.g. between bearing connection plate and
superstructure), the use of two-part Sikadur®30 adhesive grout might be considered. Refer to
Section 18.2 as appropriate and applicable for the case of a steel superstructure.
In particular, it must be considered in advance by the responsible engineer whether it is appropriate to first
connect the bearing to the superstructure (hanging from it) before connecting it to the substructure. This is
very often the case, since it is generally easier to design and execute a modified connection to a substructure
than to a superstructure. In particular it is generally the case, for example, where a steel bearing is to be
connected to a superstructure without the use of grout/mortar in between, and where it must be ensured
that the opposing surfaces come together perfectly, with no gap or rotation between them.
Where it is deemed appropriate to first hang a bearing from the superstructure before connecting it to the
substructure beneath, care must be taken to ensure that the bearing will not fall apart under its own weight
when hanging from above – in particular, if the pre-setting of a sliding bearing must be adjusted, requiring
the transportation fittings that hold the bearing together to be disconnected or removed at this stage.
AW 8850
20.6.1 Example: Positioning and connection to superstructure first, with levelling course between
The following sketches and photographs illustrate how a bearing (e.g. a free sliding bearing) may, in certain
circumstances, be placed in position and connected first to the superstructure using adhesive grout. In the
photographs, shuttering has been placed to retain and shape the grout (note the uneven surface of the fresh
grout), which has a significant thickness in order to overcome substantial lack of evenness (due to a retained
steel connection plate) in the superstructure’s lower surface.
AW 8850
20.7 Lowering of raised superstructure to rest on new bearings

Before lowering the superstructure to rest on the newly installed bearings, care must be taken to ensure that
the supporting/connecting structures and all connections are strong enough (e.g. concrete or grout has
strengthened sufficiently), and that no potentially damaging constraint forces will arise.
21 Installation of elastomeric bearings

Elastomeric bearings such as LASTO®BLOCK Type B, that do not have steel plates at their upper/lower
connection surfaces, are generally far less complicated to install than other bearing types. However, their
compressibility must be considered in their design and installation, especially in the context of a group of
bearings supporting a single structural element, to avoid differential settlement.
AW 8850
LASTO®BLOCK Type B bearings are normally laid, where permitted, without anchoring on a smooth and level
mortar bed (cement mortar or epoxy resin of suitably high compressive strength) – except in the case of a
suitable steel substructure. When placing the bearing, it must be ensured that it is absolutely horizontal
(unless otherwise noted or advised). Adjacent bearing support surfaces should normally be arranged parallel
and level with each other to ensure even distribution of loads and avoid shear deformation.
The flatness of connecting surfaces should be within a tolerance of +/- 1 mm over the full contact area.
Any deviation from parallel between the bearing’s upper and lower surfaces must be considered in the
context of the bearing’s total rotational capacity (which may be reduced by such a deviation).
Where displacement of the bearing from its correct location is to be prevent by friction between the bearing
and a connecting surface, an adequate level (coefficient) of friction must be ensured. If the minimum load
required to prevent displacement is not ensured, the bearing must be secured against shifting, e.g. by
external means.
Bearings should in general be arranged and installed in such a way that they can be replaced in the future
without difficulty.
Where elastomeric bearings are placed in a line for use as linear bearings (e.g. beneath a wall of a building),
only bearings of the same dimensions should be used if possible.
The mortar bed (cement mortar or synthetic resin mortar) should typically be 20 – 30mm (generally not less
than 10 mm) thick. If more than 30 mm thick, the use of reinforcement may be appropriate. The bed should
extend a few centimetres beyond the edge of the bearing at all sides.
The formwork for the construction of any levelling course placed above the bearing (to the superstructure)
should fit the bearing very closely so that no concrete can leak down the sides of the bearing and
subsequently influence its freedom to deform. The formwork must also be easy to remove. Polystyrene
sheeting has been found to be suitable for this in some circumstances.
AW 8850
22 Final checking and cleaning of fully installed bearings

Before a newly installed bearing is permitted to be exposed to traffic loading, its suitability and readiness for
this must be declared by the responsible engineer. In particular:
- Its corrosion protection (if any) should be in good condition, with any damage caused during
transport or installation repaired.
- It must be clean, and free of any obstructions or debris that could inhibit free movements.
- Its complete and proper installation must be confirmed.
See below for further details.
22.1 Checking and repair of corrosion protection (if applicable)

The condition of the bearing’s corrosion protection (if any) should be checked to ensure it is complete (not
including sliding surfaces unless expressly indicated) and has not been damaged during transport or
installation. Immediate detection and repair of any damage helps avoid more extensive, costlier repairs at a
later date.
The corrosion protection applied to a bearing must be compatible with the bearing and its condition, and
also with the existing corrosion protection system and its condition. It must also be suitable for the bearing’s
environment, for durability, effectiveness, etc. Consult with mageba for guidance, with particular reference
to mageba’s Instruction AW 8801 which provides guidance on repairs to corrosion protection.
22.2 Cleaning of bearing and confirmation that it is free of obstructions

The bearing must be clean and free of any obstructions or debris that could inhibit free movements (where
the bearing is designed to allow movements). Any sliding surfaces must be clean and free of paint, dust and
other contamination.
22.3 Confirmation of complete and proper installation

The complete and proper installation of a newly installed bearing, and its readiness to be placed in full service,
must be declared by the responsible engineer before it is exposed to traffic loading.
If any repairs are required, e.g. due to damage during transport or installation, these must be carried out
promptly. For guidance in relation to repair work, reference should be made to the appropriate mageba
Inspection and Maintenance Manual.
In determining whether a bearing has been properly installed, it may be useful to carry out an inspection in
accordance with the appropriate mageba Inspection and Maintenance Manual. This manual states that a first
inspection must be carried out “shortly after the structure has been put into service (at the latest 1 year after
the installation of the bearing)”. The timing of such a first inspection should be determined to ensure that
any concerns remaining after installation are investigated and addressed at the earliest opportunity.
AW 8850
Appendix 1: Tools etc. to be provided by the contractor
 Lifting equipment (crane/forklift) to unload goods and lift bearings into place
 Surveyor for precise levelling and positioning of bearings
 Two spirit levels for horizontal positioning of the bearings
 Hand tools such as hammers and wrenches
 Welding equipment
 Gas cutter (e.g. Oxy-Acetylene)
 Cutting disc / angle grinder
 Shim plates to place beneath bearings
 Wood for temporary support of bearings
 Compressor set (for adjusting recesses in concrete if necessary)
 Pick-up truck for transportation
For grouting:
 Plastic half pipe (  100mm), or

flexible plastic hose (  30mm) and a funnel
 Formwork
 Metal chains, number depending on bearing size and number
 Tools for mixing grout / mortar
AW 8850
Appendix 2: Installation Report

Name of Project
Project Information
Structure Type (Steel/Concrete etc.)

Client
Contractor
Bearing Location Drawing (No.)
Responsible Person for Bearing Installation
Brand Name and Type of Mortar Product
Construction Method of the Mortar Bed
Bearing Location (according to Installation Drawing)
Bearing Type and No.
Applied Load V [kN]
Pre-setting [mm]
Before Installation
Movement range [mm]

Date of Delivery
Unloading and Storing according to Manual
Marking of the Bearings (Top Plate)
Type Plate (right notations)
Working Scale (in order)
Cleanliness and Corrosion Protection
Tapped Rods (typically Pos. 16, correctly fixed)
Cleanliness of Contact Surface to Mortar Bed
Lifting of Superstructure (Date, Time)
Pouring of Mortar Bed (Date, Time), Bottom
Pouring of Mortar Bed (Date, Time), Top
Installation
Thickness of Mortar Bed [mm], Top/Bottom / / / /

Air Temperature [°C]
Horizontal Inclination Error x/y [mm/m] / / / /
Pre-Setting and Direction [mm]
Lowering of Superstructure (Date, Time)
Beginning of service
Removal of Temporary Transport Rods (Date, Time)

Air Temperature [°C]
Check of horiz. inclination error x/y [mm/m] (Sect. 6) / / / /
Displacement x/y [mm] (sliding/deforming bearings) / / / /
Sliding, Guidebar and Tilting Gaps Record initial values following installation in the table on the
(for specific types of bearing as detailed) following page, as appropriate
Comments
Date and Signature: Client

Date and Signature: Main Contractor
Date and Signature: Engineer
AW 8850
Measurement of Sliding gaps, Tilting gaps and Guidebar gaps
The following extract from the Inspection Report of the mageba Inspection & Maintenance Manual for
mageba bearings must be completed immediately following installation of each bearing, also to provide
reference data for future inspections.
Element of Inspection Results / Remarks
(8.1) Sliding gap h (4 locations) A: B: C: D:

- sliding bearings only Conclusion: Minimum value =
(8.2) Tilting gap s1 (4 locations) A: B: C: D:

- tilting bearings only Conclusion: Average = (A+B+C+D)/4 =
(8.3) Guidebar clearance s3 (4 sectors) A: B: C: D:

- guided sliding bearings only Conclusion: A + B = Conclusion: C + D =
The sliding gap, h, is the thickness of sliding material (PTFE/ROBO®SLIDE)

which can be seen from the side, i.e. which extends from the steel plate in
which it is recessed. It is illustrated below for specific types of bearing, but
must be measured for all sliding bearings. The sliding gap should be
measured at the four locations A, B, C and D as shown on horizontal
section X-X.
The tilting gap, s1, at any side of a bearing is the vertical distance that the
bearing can tilt at that side (i.e. the minimum vertical clearance at that
point between the upper and lower parts of the bearing). It is illustrated
below for specific types of bearing, but must be measured for all bearings
that have upper and lower parts that can rotate relative to each other
about a horizontal axis. The tilting gap should be measured at the four
locations A, B, C and D as shown on horizontal section X-X.
The guidebar gap, s3, is the clearance between the sliding material on the
guide bar and its opposing surface. It is illustrated below for specific types
of bearing, but must be measured for all guided sliding bearings. The
guidebar gap should be measured in the four sectors of the bearing, A, B,
C and D (which contain the measurement points A, B, C and D in horizontal Horizontal section X-X
section X-X, respectively).
The measuring device (e.g. feeler gauge) must project at least 10 mm into the gap in each case. In the case
of s3, the gauge should extend as far as possible into the gap (ideally as far as the bearing’s axis).
Measurement of the gaps may require the temporary removal of dust protection.
AW 8850
Illustration of dimensions h, s1 and s3:

RESTON®POT bearings:
RESTON®SPHERICAL bearings:
RESTON®DISC bearings:
AW 8850
Notes / Sketches
AW 8850
Notes / Sketches
AW 8850
If correctly installed, and properly inspected and maintained, mageba bearings can be expected to perform
well for many years – as demonstrated by the thousands of bridges and other structures around the world
that already rely on mageba bearings. Please enable the bearings you install to perform just as well.
RESTON®POT bearings: Hong Kong Convention Center, with RESTON®SPHERICAL bearings: Tran Thi Ly Bridge, Vietnam,
loads of up to 209,000 kN on a single bearing each carrying loads of up to 250,000 kN
RESTON®PENDULUM seismic isolators: Stavros Niarchos Special bearings: Golden Ears Bridge, Canada. Precompressed
Foundation Cultural Center, Athens, Greece uplift bearings allowing 3.1m movements
RESTON®DISC bearings: Bandra Worli Sea Link, India LASTO®BLOCK bearings: Oakland Airport shuttle train, USA

Bearings and Seismic Isolators - Installation Manual

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Bearings and Seismic Isolators - Installation Manual

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AW 8850

Installation manual for

Copyright © 2016 mageba Group, Bülach, Switzerland. All rights reserved.

3 Importance of proper installation......................................................................................... 4

4 Purpose of this Installation Manual ..................................................................................... 5

5 Introduction to structural bearings ...................................................................................... 5

6 Planning and preparation of installation work .................................................................... 5

7 Competence of installation personnel ................................................................................. 6

8 Supervision of installation work .......................................................................................... 6

9 Health and Safety issues during installation....................................................................... 7

10 Care of bearings during and after installation .................................................................... 7

11 Recording of work carried out.............................................................................................. 8

12 Key bearing features ............................................................................................................. 8

13 Transport, checking and storage of bearings ................................................................... 12

13.2 Checking of bearings .................................................................................................................12

14 Design of connecting structures........................................................................................ 13

15 Positioning of bearings ...................................................................................................... 13

16 General installation requirements ...................................................................................... 15

17 Support of bearings and connection to substructure ...................................................... 16

18 Connection of bearings to superstructure ........................................................................ 19

19 Cutting / removal of transport fittings ............................................................................... 20

20 Installation beneath an existing superstructure ............................................................... 20

21 Installation of elastomeric bearings .................................................................................. 26

22 Final checking and cleaning of fully installed bearings ................................................... 28

Appendix 1: Tools etc. to be provided by the contractor ......................................................... 29

Appendix 2: Installation Report ................................................................................................. 30

3 Importance of proper installation

4 Purpose of this Installation Manual

5 Introduction to structural bearings

6 Planning and preparation of installation work

6.1.1 Structure-specific drawings, etc.

6.1.2 Further instruction documents relating to installation

6.1.3 General product information

6.2 Materials, tools and equipment

7 Competence of installation personnel

8 Supervision of installation work

9 Health and Safety issues during installation

9.1 Risk of falling from a height

9.2 Risk of being hit by a large, heavy object during lifting

9.4 Risk during welding (if applicable)

9.5 Risk from general construction hazards – use of appropriate PPE

10 Care of bearings during and after installation

11 Recording of work carried out

12 Key bearing features

12.1 Type plate

Location = Bearing location on the structure

12.2 Movement Scale

12.4 Transportation fittings

12.5 Markings on top of bearing

12.6 Levelling surfaces

12.7 Dust protection

12.8 Anchor plates

13 Transport, checking and storage of bearings

13.1 Transport and handling

13.2 Checking of bearings

14 Design of connecting structures

15.2 Adjustment of presetting

15.3 Precise positioning of bearings

15.4 Possible method for adjusting elevation or inclination

16 General installation requirements

17 Support of bearings and connection to substructure

17.1 Concrete substructure

17.2 Steel substructure