2004-306 - Maurer D80C - v6

Agrément Certificate 2004/306
Copyright © Agrément South

Subject:
Africa, February 2004 Maurer D80C (FP) Bridge Deck
Expansion Joint
The master copy of this
document appears on the Certificate holder:
website:
http://www.agrement.co.za DSC-Zendon cc
P O Box 6221 DUNSWART 1508
Validity Telephone: 011 894 1129 Fax: 011 894 2612
Users of any Agrément e-mail: info@zendon.co.za
certificate should check its
status: all currently valid
certificates are listed on the
website. In addition, check
whether the certificate is Active
or Inactive.
The certificate holder is in
possession of a confirmation
certificate attesting to his
status.
Description and use

Quick guide
The Maurer D80C (FP) is a single gland and claw bridge deck
expansion joint. The joint is manufactured in South Africa
Contents page 3 under license from Maurer Söhne. Except for the hot-
rolled/extruded metal claw, which is imported, all materials are
Preamble page 4 procured locally. The joint is intended for use in concrete
Conditions of structures in all climatic regions of South Africa and in all types
certification page 5 of corrosive environment.
Assessment page 7 The Maurer D80C (FP) joint is assessed as being suitable for
bridge deck expansion joints in all areas of South Africa.
Technical
description page 10 This certificate and Agrément South Africa’s assessment set
out in detail in Part 2 Table 1, apply only to the Maurer D80C
(FP) bridge deck expansion joints manufactured by DSC-
Zendon cc and installed as described and illustrated in this
certificate, and where the terms and conditions of certification
are adhered to.
P O Box 395 Pretoria 0001

Telephone 012 841 708
Fax 012 841 2539
e-mail agrement@csir.co.za
http://www.agrement.co.za/
Figure 1: Typical Section through D80C (FP) bridge deck expansion joint
(new installation or joint replacement)
Figure 2: Definition of movement range

and angle of skew
Criteria for application of the Maurer D80C (FP)

bridge deck expansion joint
The Maurer B80C (FP) bridge deck expansion joint is suitable
Movement range - combination for use where:
of contraction and expansion in
• the movement range is not greater than 80 mm, and
the direction of movement.
• the skew angles of joints are not greater than 45 degrees.
Agrément Certificate 2004/306: Maurer D80C (FP) Bridge Deck Expansion Joint Page 2 of 18
CONTENTS
PREAMBLE
PART 1: CONDITIONS OF CERTIFICATION

General conditions
Reappraisal
PART 2: ASSESSMENT
Scope of assessment
Assessment
Table 1: Assessment
PART 3: TECHNICAL DESCRIPTION

General description
Manufacture
Materials
Joint installation (new installations)
Joint installation (existing joint replacements)
PREAMBLE
This certificate is issued by Agrément South Africa in terms of
the powers granted to it by the Minister of Public Works. This
certificate:
• has been granted after a technical appraisal of the
performance of Maurer D80C (FP) bridge deck expansion
joints for the uses covered by the certificate,
• is independent of any patent rights that may or may not
subsist in the subject of the certificate,
• does not relieve the certificate holder of the obligation to
obtain the prior approval of the appropriate roads
authority for the use of the subject.
Agrément South Africa considers that the quality and
performance of Maurer D80C (FP) bridge deck expansion
joints will be satisfactory provided that the requirements
stipulated in this certificate are adhered to. However,
Agrément South Africa does not on behalf of itself, or the
State, or any of its employees or agents, guarantee such
quality or performance.
Where required, guarantees for the product must be agreed
between the client and the certificate holder.
Responsibility for the proper exercise of the quality system
and compliance with the requirements of this certificate
resides with the certificate holder.
No action for damages, or any other claim whatsoever, lies
against Agrément South Africa, its members, the State or any
of its employees should the said components and materials
fail to comply with the standard set out in the certificate issued
by Agrément South Africa.
Interested parties who are in any doubt about any detail or
variation should contact Agrément South Africa.
Notices affecting the validity of this certificate will be published
on Agrément South Africa’s web site and in the Government
Gazette.
This certificate is subject to a validity review every three
years. The certificate shall remain valid for so long as
Agrément South Africa is satisfied that:
• the certificate holder complies with the general and
specific conditions of certification as stipulated in the
certificate;
• the performance-in-use of the subject is acceptable;
• any changes in relevant standards or Agrément criteria
have not invalidated the technical assessment which
formed the basis of certification.
Agrément South Africa reserves the right to withdraw the
certificate at any time, should reasonable cause exist.
PART 1: CONDITIONS OF CERTIFICATION
This certificate covers only Maurer D80C (FP) bridge deck

expansion joints that comply strictly with:
• drawings DZ3 and DZ5 (dated 01/07/04)
• DSC-Zendon’s specifications and quality system
• the requirements of this certificate
and which are installed by the certificate holder or a licensee
Licensee –any person or appointed and trained by the certificate holder and registered
company appointed and trained as such with Agrément South Africa.
by the certificate holder and
registered with Agrément South
This certificate does not apply to any other product marketed,
Africa to manufacture and/or manufactured or installed by DSC-Zendon cc or by any other
install Maurer D80C (FP) bridge entity.
deck expansion joints in Any person needing to check on details of construction must
accordance with the certificate refer to the documentation listed above, which is available
and authorised by him to claim from the certificate holder.
compliance with the certificate. It
is the certificate holder’s A change to any one aspect of the Maurer D80C (FP) bridge
responsibility to ensure that a deck expansion joint could result in changes in the
licensee carries out the work in performance of installed joints. For this reason, no change
compliance with this certificate may be made to Maurer D80C (FP) bridge deck expansion
joints unless any such change is approved in writing by
Agrément South Africa before it is implemented.
General conditions
The validity of this certificate is subject to the continued
participation of the certificate holder in Agrément South
Africa’s post-certification quality management monitoring
programme.
An identification plate having a minimum size of 65 mm by
100 mm, as illustrated below, must be attached to the bridge
balustrade.
Agrément South Africa’s logo, as shown in the lower part of
the plate, is to be printed on all DSC-Zendon’s Maurer D80C
(FP) bridge deck expansion joint promotional material.
Reappraisal
• must be requested by the certificate holder prior to
implementing changes to materials or the method of
installation
• will be required by Agrément South Africa if there are
changes to Agrément criteria or if deemed necessary for
any other reason.
This certificate may be withdrawn if the certificate holder or a
registered licensee fails to comply with these requirements.
On behalf of the Board of Agrément South Africa
Chairman
20 February 2004
PART 2: ASSESSMENT
Scope of assessment
The assessment is based on guidelines for the evaluation of
Guidelines - Steyn, Silbernagl and
Nordengen. Guideline document bridge deck joints adopted by Agrément South Africa, as
for evaluation of bridge deck joints. applicable to modular bridge deck expansion joints with hot-
CSIR Transportek, May 2001 rolled/extruded metal claws and single glands. The joint has
been assessed as an integral part of a concrete bridge deck
structure and road surface, as described and illustrated in this
certificate. Aspects of the bridge deck or road surface affected
by the installation or performance of this joint, where
applicable, have also been assessed.
Assessment
In the opinion of Agrément South Africa, when the Maurer
D80C (FP) bridge deck expansion joints are manufactured
and installed by DSC-Zendon or one of their licensees in
accordance with DSC-Zendon’s drawings DZ/3 and DZ/5
(dated July 2003), specifications and quality manual, they are
suitable for the uses specified.
Agrément South Africa’s comments on the properties of
materials used and the various aspects of performance of the
Maurer D80C (FP) bridge deck expansion joint are set out in
Table 1 below. Each aspect of performance was assessed by
experts in that field.
Table 1: Assessment
Aspect of assessment Opinion of Explanatory notes

Agrément South
Africa
Maintenance plan Satisfactory DSC-Zendon’s maintenance plan for
Maurer D80C (FP) bridge deck
expansion joints is satisfactory; the
specified inspection/maintenance
interval of two years is considered
adequate.
Movement range Satisfactory Maurer D80C (FP) bridge deck
expansion joints have been assessed
as fit-for-purpose for applications where:
• the movement range in the direction
of movement of the bridge structure
is not greater than 80 mm
• the skew angles of joints are not
greater than 45 degrees.
Vertical movements at the joint are not
considered critical but a maximum of 5
mm is recommended.
Strength Satisfactory Maurer D80C (FP) bridge deck
expansion joints have been designed
and tested in accordance with TL/TP-
FÜ92. Design loads, including dynamic
factors, are in accordance with DIN
1072 requirements. These requirements
are comparable to the Austrian RVS
requirements adopted by Agrément
South Africa and are as follows:
• Vertical: 140 kN
• Horizontal: 42 kN
acting over a width of 500 mm. Loads
are inclusive of a dynamic factor.
Fatigue Satisfactory Assessments and testing carried out
overseas and current in-service
performance of Maurer D80C (FP) joints
in South Africa indicate that fatigue
behaviour of the various components
will be fit-for-purpose over the joint’s
service life. Of critical importance to
satisfactory fatigue resistance of the
joint is the proper welding of the claws
to the fish-plate anchors.
Table 1: Assessment (continued)
Aspect of assessment Opinion of Explanatory notes

Agrément South
Africa
Durability and Satisfactory Based on knowledge of the materials
environmental used in the manufacture of the joints and
resistance the in-service performance of the joints,
the durability and the environmental
resistance of elements of the Maurer
D80C (FP) bridge deck expansion joints,
the useful service life is assessed as
being not less than 15 years.
The smooth surfaces of the extruded or
hot-rolled beams and gland claws make
this joint suitable for use in aggressive
environments.
Water-tightness Satisfactory When manufactured and installed as
specified, joints will be within acceptable
limits.
In the workshop, a 10% NaCl solution
having a 30 mm head must be applied
over a selected portion of joint for a period
of 8 hours. Vulcanised sections of the seal
must be included in the section of seal
being tested. The seal is to be deformed,
both along and across the joint, to 20 %
more than the design deformation.
On site the complete installation must be
flushed for half-an-hour and each end of
the joint ponded for a length of 1 m, with a
head of 150 mm for 2 hours.
In both tests no moisture may appear on
the underside of the seal.
Quality management Satisfactory The quality system is based on SANS
9001 and, if properly applied to the
SANS 9001 Quality management manufacture and installation of Maurer
systems – Requirements D80C (FP) bridge deck expansion joints,
will ensure that the quality will be
consistently satisfactory.
Skid resistance Satisfactory Given the wood-float finish applied to the
cast-in-situ concrete nosings and the
narrow width of the joint, skid resistance is
not deemed to be an issue for concern.
Practicality of Satisfactory Observations of installations in progress
installation indicate that, given adequate training of
staff, the presence of suitable supervisory
staff and suitable equipment, and
adherence to established quality
procedures, joints can be readily and
successfully installed.
PART 3: TECHNICAL DESCRIPTION
General description
The Maurer D80C (FP) is a single gland and claw bridge deck
expansion joint which may be installed in new concrete
structures or replace damaged joints in rehabilitation projects.
The joint is intended for use in all climatic regions of South
Africa and in all types of corrosive environment where:
• the joint movement range is not greater than 80 mm
• the skew angles of joints are not greater than 45 degrees.
Manufacture
The joint is manufactured in South Africa under licence from
Maurer Söhne. Except for the hot-rolled/extruded metal claw,
which is imported, all materials are procured locally.
Pre-cut 12 mm thick steel fish-plate anchors, as shown below,
are welded to the hot-rolled/extruded claw and longitudinal
plate/s or bars at 200 mm centres.
Figure 3: Claw and fish-plate anchors
The imported hot-rolled/extruded claw is manufactured from

Grade RST 37-2 steel to DIN 17100 while other structural
sections are manufactured from Grade 300W steel to SANS
1431.
The joints’ components are manufactured in lengths to suit
available transportation and handling requirements. Where
short lengths of joint are to be joined on site, depending on
project specifications, they may be either site-welded or bolted
together by means of connecting plates welded to the ends of
metal claws. Where necessary, joints may be trimmed on site
to suit the as-built situation.
The gland, the detail of which is shown below and which is
installed in the joint only once the joint has been cast in
position, is manufactured from extruded vulcanised rubber
with a base polymer consisting of 100% EPDM rubber. The
EPDM, with one exception, meets the requirements of ASTM
D5973. The exception is the oil swell requirement, which may
be 100%.
Figure 4: Detail of gland
Steel plates (cover plates) for covering the expansion joint

gap at bridge parapets and across sidewalks (including
kerbs), where specified, are manufactured from Grade 300W
steel to SANS 1431.
The manufactured joint and cover plates are hot-dip
galvanised, after the completion of welding, slotting and
drilling, where appropriate, in accordance with the
requirements of SANS 121 with a galvanised coating of not
less than 105 microns.
The portions of galvanised surfaces which have been
damaged and which do not have at least 40 mm of concrete
cover once the nosings have been cast, must be repaired.
Repairs are carried out by abrasive cleaning of the areas
affected and applying two coats of a proprietary brand zinc
rich galvanising repair coating (Galvaroid, Spanjaard Cold
Zinc spray, or similar) in accordance with the manufacturer’s
specifications.
Joint installation procedure (new installations)

Joint installation follows the asphalt surfacing of the
carriageway over the bridge deck and abutment. Surfacing
follows the temporary filling of the expansion gap and the joint
recess with suitable material.
Saw cuts are made through the asphalt surfacing along the
edges of the joint recess and all temporary filling material is
removed using pneumatic or hydro demolishing techniques.
Care is taken to ensure that the joint gap is clean and free of
any material which may cause impediment to the movement
of the structure. Surfaces of the joint recess are scabbled to
remove all laitance. Saw cuts are also made in parapet and
end-block faces to facilitate the formation of recesses to
accommodate the edge beam (nosings) at the ends of joints.
Once the recess has been prepared, the reinforcement which
projects into the joint recess is straightened and checked.
Should there be inadequate reinforcement found, additional
reinforcement is provided either by drilling and epoxy grouting
or by tying-in loops. Where additional reinforcement is to be
installed by drilling and epoxy grouting, bars are pre-bent
where possible prior to placing in epoxy-grout-filled holes.
Epoxy grout is applied strictly in accordance with the
manufacturer’s recommendations. Further bending of the
reinforcement, if required, is carried out only once the epoxy
grout has achieved sufficient strength, to prevent damage to
the anchorage.
The recess and reinforcement are cleaned, where necessary,
to ensure that no contaminants are present which could
encourage corrosion or affect the concrete bond to the
reinforcement.
The expansion joint components are bolted to joint hangers to

form joint assemblies. Care is taken to ensure that the
expansion joint gap is set to the correct predetermined
dimension.
The joint assembly is carefully installed in the joint recess,
suspended from the joint hangers. Where necessary, joint
assemblies are bolted or welded together, as specified, to
form continuous lengths.
Longitudinal reinforcement is placed, as specified, and the
previously straightened reinforcement is re-bent to form
stirrups. The use of cutting torches or other heating equipment
to facilitate bending is avoided. Attention is paid to ensuring
specified concrete cover. Where reinforcement is cut, heated
and bent, and possibly welded during installation, affected
areas are treated with two coats of zinc-rich paint as referred
to above.
In order to prevent concrete from entering the expansion gap
during the casting of the concrete nosings, a compressible
vertical former is installed between both halves of the joint,
which extends down into the expansion gap between the deck
and the abutment.
Prior to the casting of the nosings, the joint is checked for the
following:
• joint alignment (both vertical and horizontal), gap-setting
and joining
• the amount, placing and fixing of, and concrete cover to
the reinforcement
• shuttering and blockouts.
Where specified a new-to-old epoxy resin bonding agent is
applied to the exposed concrete surface of the joint recess, in
accordance with the manufacturer’s specifications.
Concrete having a characteristic strength of 40 MPa at 28
days, with a maximum aggregate size of 19 mm or 13 mm
and meeting the requirements of the project specification, is
carefully placed in the joint recess and compacted.
Once the concrete has attained its initial set, the hangers are
removed and the surface of the concrete nosing is given a
wood-float finish.
Concrete is cured by means of an acrylic emulsion curing
compound applied in two coats, the first coat being applied
within 30 minutes of the concrete surface being finished, and
the second approximately 15 minutes thereafter.
The concrete nosings must not be subjected to any vehicular
loads until the concrete has attained a minimum strength of 30
MPa. Should it be necessary for joints to be subjected to
traffic, plates must be fitted over the joints to protect the
concrete until the required strength has been attained.
Once concrete nosings have attained the minimum required
strength (30 Mpa) and the protecting metal plates, where
installed, have been removed, preparations can be made for
the installation of the EPDM gland. These preparations
consist of the following:
• the removal of expansion-gap forming material
• the cleaning of gland-anchorage recesses in the metal
claws
• the lubrication of the ‘anchor zone’, using a liquid-
detergent solution. The use of diesel, paraffin or similar
hydrocarbon-based oil or grease as a lubricant is not
permitted
• the application of a silicone or similar sealant to the gland-
anchorage recess at positions where site jointing has
been carried out. Sealant is applied over a short length of
the recess on each side of the joint to ensure water-
tightness of the joint.
A continuous length of gland is then installed in the recesses
of the metal claws.
Finally, balustrades, paveways, medians, etc are finished and
cover plates fitted, as specified.
Permissible movement range of joint
Figure 5: Detail at traffic lanes and shoulders
Joint installation procedure (existing joint
replacement)
The existing cover plates, where provided, are removed and
the presence and depth of existing reinforcement in the
confines of the proposed new concrete nosings established.
The asphalt surfacing and underlying concrete is saw-cut
each side of the joint, to form the edge of the proposed joint
recess. The existing concrete is broken out between the saw
cuts to the specified depth to accommodate the new joint.
Care is taken during cutting and removal of concrete not to
damage the existing reinforcement, structural members,
services and/or service ducts.
The expansion gap is cleared of all jointing material and
debris over the full width and depth of the bridge deck.
Where the existing reinforcement which has been exposed in
the joint recess is less than that specified, additional
reinforcement is provided, as specified.
All other aspects of the joint installation are as for a new
installation, as described above.

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Agrément Certificate 2004/306

Copyright © Agrément South

Description and use

P O Box 395 Pretoria 0001

Figure 2: Definition of movement range

Criteria for application of the Maurer D80C (FP)

PART 1: CONDITIONS OF CERTIFICATION

PART 3: TECHNICAL DESCRIPTION

This certificate covers only Maurer D80C (FP) bridge deck

On behalf of the Board of Agrément South Africa

Aspect of assessment Opinion of Explanatory notes

Aspect of assessment Opinion of Explanatory notes

The imported hot-rolled/extruded claw is manufactured from

Steel plates (cover plates) for covering the expansion joint

Joint installation procedure (new installations)

The expansion joint components are bolted to joint hangers to

Figure 5: Detail at traffic lanes and shoulders

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