THE HIGHWAYS AGENCY BD 33/94

THE SCOTTISH OFFICE DEVELOPMENT DEPARTMENT

THE WELSH OFFICE

Y SWYDDFA GYMREIG

THE DEPARTMENT OF THE ENVIRONMENT

FOR NORTHERN IRELAND

Expansion Joints for Use in

Highway Bridge Decks

Summary: This Standard supersedes BD 33/88 and covers the requirements for the use of
expansion joints in highway bridge decks.
Volume 2 Section 3
Part 6 BD 33/94 Registration of Amendments

REGISTRATION OF AMENDMENTS

Amend Page No Signature & Date of Amend Page No Signature & Date of
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Registration of Amendments Part 6 BD 33/94

REGISTRATION OF AMENDMENTS

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 DESIGN MANUAL FOR ROADS AND BRIDGES

VOLUME 2 HIGHWAY
STRUCTURES: DESIGN
(SUBSTRUCTURES AND
SPECIAL STRUCTURES),
MATERIALS
SECTION 3 MATERIALS AND
COMPONENTS

PART 6

BD 33/94

EXPANSION JOINTS FOR USE IN

HIGHWAY BRIDGE DECKS

Contents

Chapter

1. Introduction

2. Definitions

3. General Requirements

4. Design

5. Loads

6. Movements

7. Joint Type Options

8. Drainage

9. References

10. Enquiries

Annex A Requirements for Departmental Type

Approval of Bridge Deck Expansion Joints

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Volume 2 Section 3 Chapter 1
Part 6 BD 33/94 Introduction

1. INTRODUCTION
1.1 This Standard supersedes BD 33/88. Scope

1.2 Except where a standard specified in this 1.3 This Standard describes the loads and movements
document implements or is technically equivalent to a to be used for the design of bridge deck expansion
Harmonised European Standard or to a European joints, and the requirements for their selection, and
Standard adopted for use within the European Departmental type approval.
Economic Area after 31 December 1985, any
requirement for products or materials to comply with 1.4 The associated Advice Note BA 26
the specified standard shall be satisfied by compliance (DMRB 2.3.7) gives guidance on joint selection.
with

i. a relevant standard or code of practice of Departmental Type Approval

a national standards institution or equivalent body
of any member state of the European Economic 1.5 Bridge deck expansion joints are required to have
Area a Departmental type approval certificate before they
may be installed on bridge decks constructed, improved
or ii. a relevant international standard or maintained in compliance with the Specification for
recognised in any member state of the European Highway Works (MCHW 1). Requirements for
Economic Area Departmental type approval are set out in Annex A.
The type approval scheme is administered by the
or iii. a relevant specification acknowledged Highways Agency on behalf of all the Overseeing
for use as a standard by a public authority of any Organisations.
member state of the European Economic Area

or iv. traditional procedures of manufacture of Implementation

a member state of the European Economic Area
where these are the subject of a written technical 1.6 This Standard should be used forthwith for all
description sufficiently detailed to permit schemes currently being prepared provided that, in the
assessment of the goods or materials for the use opinion of the Overseeing Organisation, this would not
specified result in significant additional expense or delay
progress. Design Organisations should confirm its
or v. a European Technical Approval (ETA) application to particular schemes with the Overseeing
issued in accordance with the Construction Organisation.
Products Directive 89/106/EEC (or, until
procedures are available for the issue of ETAs, a
specification sufficiently detailed to permit
assessment) for goods or materials of an
innovative nature or subject to innovative
processes of manufacture and which fulfil the
purpose provided for by the specified standard

provided that the proposed standard, code of practice,

technical specification, technical description, or
European Technical Approval provides in use levels of
safety, suitability and fitness for purpose equivalent to
those required by the specified standard in so far as they
are not inconsistent with the "Essential Requirements"
of the Construction Products Directive (89/106/EEC).

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Volume 2 Section 3 Chapter 2
Part 6 BD 33/94 Definitions

2. DEFINITIONS
2.1 Deck Joint Gap The gap between adjacent spans 2.12 Sub-surface Drainage A system for draining
in a bridge deck or between a bridge deck and an water from within the surfacing.
abutment curtain wall. The joint gap width will vary
where the joint is designed to accommodate thermal and 2.13 Working Life Period for which it is envisaged
other movements. the joint will function satisfactorily without the need for
excessive maintenance.
2.2 Expansion Joint Gap The continuous gap
within an expansion joint system at surfacing level 2.14 Effective Bridge Deck Temperature The
along the line of the joint. temperature of the bridge deck at the time of installation
of the joint determined in accordance with TRRL
2.3 Buried Joint A joint which is formed in-situ Supplementary Report 479.
using components, such as an elastomeric pad or a
flashing, to support the surfacing which is continuous 2.15 Cover Plate Plate forming part of an expansion
over the deck joint gap. joint system at surfacing level to cover the expansion
joint gap.
2.4 Asphaltic Plug Joint An in-situ joint comprising
a band of specially formulated flexible material, which
also forms the surfacing, supported over the deck joint
gap by thin metal plates or other suitable components.

2.5 Nosing In-situ material or fabricated component

to protect the adjacent edges of the surfacing at the
expansion joint.

2.6 Reinforced Elastomeric Joint A prefabricated

joint comprising an elastomer with or without bonded
metal plates.

2.7 Elastomeric in Metal Runners A pre-fabricated

joint comprising an elastomeric seal fixed between
metal runners, either in a single element or multi-
element form.

2.8 Cantilever Comb or Tooth Joint A pre-

fabricated joint comprising principally mating metal
comb or saw-tooth plates which bridge the deck joint
gap.

2.9 Transition Strip A narrow strip of infill material

between a prefabricated expansion joint and the
adjacent cut edge of the surfacing.

2.10 Waterproofing System A concrete bridge deck

waterproofing system which has been granted
Departmental Registration in accordance with
BD 47 (DMRB 2.3.4).

2.11 Surfacing Carriageway or footway wearing

course and basecourse materials.

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Volume 2 Section 3 Chapter 3
Part 6 BD 33/94 General Requirements

3. GENERAL REQUIREMENTS
3.1 Expansion joints shall have good riding quality 3.10 The interface between the expansion joint and the
and skid resistance and shall not cause a hazard to any deck waterproofing system shall be watertight.
class of road user, including cyclists, pedestrians and
animals where they have access. 3.11 Where prefabricated units are used the seal
between each unit shall be made watertight and in
3.2 Expansion joints in highway bridge decks shall addition a secondary waterproofing system in the form
be capable of sustaining the loads and movements of a continuous membrane shall be installed. See BA
described in the following chapters of this Standard 26 (DMRB 2.3.7).
without damage to the surfacing or the supporting
structure during their working lives. 3.12 Expansion joints shall be generally installed in a
straight line and where there is an expansion joint gap it
3.3 When the total horizontal movement is less than shall be of a uniform width never less than 10% of the
5mm and vertical movement is less than 0.5mm, there range of movement or 6mm whichever is the greater.
is no need to provide an expansion joint but the
waterproofing shall be detailed to accommodate any 3.13 The maximum width of open gap in the
likely small movements to ensure its continuity across expansion joint at carriageway level which is acceptable
the deck joint gap. for motor vehicles is 65mm. Where necessary load
bearing elastomeric elements shall be used to ensure
3.4 Different joint systems shall not normally be that this dimension is not exceeded.
combined at one end of a deck. The same joint system,
seal or sealant shall continue across the 3.14 Kerb cover plates shall be provided to protect the
full width of the deck including footway, verge, expansion joint at the kerb line.
hardshoulder and central reserve.
3.15 Where pedestrians have access, all expansion
3.5 The fixing or bonding to the bridge structure of joint gaps in the footway shall be closed using either a
the appropriate components of all expansion joints shall load bearing seal or cover plate. The top surface of the
be in accordance with the manufacturer's instructions. load bearing seal shall be 52mm below the top surface
of the joint.
3.6 The skid resistance of an expansion joint shall be
at least equal to the minimum requirement of the 3.16 Where cyclists have access and the expansion
adjacent carriageway surfacing, during its working life. joint consists of toothed or comb plates with the spaces
between the mating teeth generally orientated in the
3.7 The upper surfaces, when new, of expansion direction of the traffic flow, these spaces shall not
joints in footways shall have a slip resistant finish exceed 150mm in length or 20mm in width. If these
which has a skid resistance of not less than 65 under dimensions are exceeded then cover plates shall be
wet conditions. The finish shall have an effective life of provided.
at least 5 years and shall retain a skid resistance of not
less than 45 under wet conditions throughout this
period. The skid resistance of footway surfacings shall
be confirmed by the portable skid resistance pendulum
tester as described in the Transport and Road Research
Laboratory's Road Note 27.

3.8 Where described in the manufacturer's details the

expansion joint gap shall be sealed with a compression
seal, elastomeric element or sealant.

3.9 All limited design life components of a joint shall

be designed so that they can be easily replaced with the
minimum of delay to road users.

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Volume 2 Section 3 Chapter 4
Part 6 BD 33/94 Design

4. DESIGN
Limit State Requirements Design Resistance

4.1 Joints designed in accordance with this Standard 4.5 The design of steel elements, and reinforced
shall unless specified otherwise meet the following limit concrete components shall be in accordance with BS
state requirements. 5400 Parts 3 and 4 as implemented by BD 13 (DMRB
1.3) and BD 24 (DMRB 1.3.1) respectively. The design
i. Serviceability Limit State. resistance shall be calculated from the expression
The design shall be such that joints will
function correctly without the need for (f )
R( 'function k
excessive maintenance during their ((m)
working lives.

ii. Ultimate Limit State where fk is the characteristic (or nominal) strength of the
The joint and its installation shall be material and (m is the appropriate partial material
capable of withstanding the ultimate factor. Values of fk and (m shall be obtained from
design loads and the movement range BS 5400 Parts 3 and 4 as appropriate.
given in this Standard ie R* $ S*, where
R* is the design resistance and S* is the Elastomeric Joints and Elements
design load effect.
4.6 Elastomeric joints and elastomeric elements shall
Design Values be designed for the serviceability limit state only using
the appropriate values of (fL and with (f3 = 1.0.
4.2 The loads and movements given in this Standard
shall be used to derive the design load effects for each Fatigue
limit state. Various combinations of movements and
loads shall be considered to obtain the most severe 4.7 Where any components of the joint such as
effect on the joint. In addition the joints shall be anchor bolts are subject to fluctuating traffic loads their
capable of meeting the requirements of Clause 5.4.8.1 fatigue lives shall be calculated in accordance with
of the composite version of BS 5400 Part 2, as BS 5400 Part 10 as implemented by BD 9 (DMRB 1.3).
implemented by BD 37 (DMRB 1.3) without structural
damage occurring.

Design Loads and Movements

4.3 The design loads Q* shall be determined from the

nominal loads specified in Chapter 5 by multiplying by
the appropriate value of the partial load factor (fL also
as specified in Chapter 5. The design movements shall
be determined from the nominal movements specified
in Chapter 6 multiplied by the appropriate value of (fL
also specified in Chapter 6.

Design Load Effects

4.4 The design load effect S* shall be determined by

multiplying the effects obtained by applying the design
loads and movements by (f3. The values of (f3 shall be
taken as 1.0 for the serviceability limit state and 1.1 for
the ultimate limit state.

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Volume 2 Section 3 Chapter 5
Part 6 BD 33/94 Loads

5. LOADS
General

5.1 This section specifies nominal loads and values

of (fL to be taken into account in the design of the joint
and its constituent elements, including the anchorage
arrangements but excluding the seal.

Vertical

5.2 The nominal load shall be taken either as a single

wheel load of 100kN or a 200kN axle with a 1.8m
track. The load from each wheel shall be uniformly
distributed over a circular area assuming an effective
pressure of 1.1 N/mm2 (ie 340mm diameter). It shall be
applied separately to either edge of the joint to
determine which gives the more severe effect.

Horizontal

5.3 The nominal traffic load shall be taken as a

uniformly distributed load of 80 kN/m run of joint,
acting at right angles to the joint at carriageway level.
This shall be combined with any loads that may result
from strain of the joint filler or seal over the nominal
range of movements in accordance with Chapter 6.

5.4 Values of (fL

Wheel Horizontal
Loads Load
Ultimate
Limit State 1.50 1.25

Servicability
Limit State 1.20 1.00

Dispersal of Loads

5.5 Where the joint or joint element is sufficiently

stiff the wheel loads may be spread along a length of
joint up to a maximum length of 1000mm.

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Volume 2 Section 3 Chapter 6
Part 6 BD 33/94 Movements

6. MOVEMENTS
General

6.1 This chapter describes the various types of

movements that shall be taken into consideration
including the relative vertical and horizontal
movements between two sides of an expansion joint,
arising from the passage of a live load along the bridge.
Nominal values of movement that can occur
simultaneously shall be combined to determine the most
severe effect on the joint in question.

Values of (fL

6.2 The value of (fL shall be taken as 1.0 for both the
serviceability and the ultimate limit state.

Temperature Movement

6.3 The range of longitudinal movement due to

changes in temperature shall be calculated in
accordance with the composite version of BS 5400 Part
2 as implemented by BD 37 (DMRB 1.3).

Creep and Shrinkage

6.4 Irreversible movements due to creep and

shrinkage of concrete shall be calculated in accordance
with BS 5400 Parts 4 and 5 as implemented by BD 24
(DMRB 1.3.1) and BD 16 (DMRB 1.3) respectively
(see also para 9.1).

Lateral Movement

6.5 In wide, curved or skew bridges transverse

movement of the deck shall be considered in association
with longitudinal movement and joints designed
accordingly.

Settlement

6.6 Any longitudinal and vertical movement at joints

arising from the predicted differential settlement of the
bridge supports shall be taken into account. If
movement due to mining subsidence is expected the
joint shall be designed so that it can be released or
replaced with a temporary joint and reinstated after the
subsidence wave has passed.

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Volume 2 Section 3 Chapter 7
Part 6 BD 33/94 Joint Type Options

7. JOINT TYPE OPTIONS

General

7.1 The installation of an appropriate type of joint is residential property special consideration shall be
primarily determined by the total design range of given to the noise generated by traffic crossing the joint,
movement expected for the serviceability limit state and since some joints generate much more noise than others.
more than one type of joint may be suitable for a
particular range of movement. This movement shall not Details of Various Types of Joint
exceed the maximum value given in Table 1 for the
type of joint in question. 7.3 Typical details and sketches of joint referred to in
Table 1 are given in BA 26 (DMRB 2.3.7).
Traffic Noise

7.2 Where the installation is adjacent to

TABLE 1

(Limiting Joint Movement at SLS)

MAXIMUM
TOTAL ACCEPTABLE ACCEPTABLE
LONGITUDINAL MOVEMENT VERTICAL
JOINT TYPE MOVEMENT
Minimum Maximum BETWEEN TWO
mm mm SIDES OF JOINT
mm

1. Buried joint under continuous surfacing 5 20 1.3

2. Asphaltic Plug joint 5 40 3

3. Nosing joint with poured sealant 5 12 3

4. Nosing with preformed compression seal 5 40 3

5. Reinforced Elastometric 5 * 3

6. Elastomeric in metal runners 5 * 3

7. Cantilever comb or tooth joint 25 * 3

(i) the minimum of the range is given to indicate when the type of joint may not be economical.

* Maximum value varies according to manufacturer or type.

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Volume 2 Section 3 Chapter 8
Part 6 BD 33/94 Drainage

8. DRAINAGE
General

8.1 The provision of road gullies on the uphill side of

expansion joints is required in order to collect as much
surface water as possible before it reaches the joint.
When Porous Asphalt surfacing is specified road and
kerb gullies are essential and the detailing around the
joint need to be considered at the design stage. See
BA57 (DMRB 1.3.7).

8.2 An effective drainage system shall be provided

immediately beneath the expansion joint with adequate
access for its inspection and maintenance. Water from
the drainage system shall be discharged away from the
structure into a suitable road drainage system or
soakaway.

Sub-surface Drainage

8.2 Where the presence of a joint will impede the

movement of water within the basecourse or wearing
course materials, sub-surface drainage shall also be
provided and is essential when Porous Asphalt
surfacing is specified. Examples are shown in BA 26
(DMRB 2.3.7).

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Volume 2 Section 3 Chapter 9
Part 6 BD 33/94 References

9. REFERENCES
1. Design Manual for Roads and Bridges
(DMRB)

Volume 1: Section 3 General Design

BD 13 Design of Steel Bridges. Use of BS 5400:

Part 3 (DMRB 1.3)

BD 37 Loads for Highway Bridges (DMRB 1.3)

BD 16 Design of Composite Bridges. Use of BS

5400: Part 5 (DMRB 1.3)

BD 24 Design of Concrete Bridges. Use of BS

5400: Part 4 (DMRB 1.3.1)

BD 9 Implementation of BS 5400: Part 10. Code

of Practice for Fatigue (DMRB 1.3).

BA 57 Design for Durability (DMRB 1.3.7).

Volume 2: Section 3 Materials and Components

BA 26 Expansion Joints for Use in Highway

Bridge Decks (DMRB 2.3.7)

BD 47 Waterproofing and Surfacing of Concrete

Bridge Decks (DMRB 2.3.4)

2. Manual of Contract Documents for Highway

Works (MCHW)

Volume 1: Specification for Highway Works (MCHW

1)

3. SR 479. Bridge temperature for setting bearings

and expansion joints. M Emerson TRRL.

4. Road Note 27. Instructions for using the portable

skid-resistance tester. TRRL

5. BS 812. Testing of Aggregates:

Parts 1, 2 and 3: 1975
Parts 101 and 102: 1984
Part 103.1: 1985

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Volume 2 Section 3 Chapter 10
Part 6 BD 33/94 Enquiries

10. ENQUIRIES
All technical enquiries or comments on this Standard should be sent in writing as appropriate to:-

Chief Highway Engineer

The Highways Agency
St Christopher House
Southwark Street T A ROCHESTER
London SE1 OTE Chief Highway Engineer

The Deputy Chief Engineer

The Scottish Office Industry Department
Roads Directorate
New St Andrew's House J INNES
Edinburgh EH1 3TG Deputy Chief Engineer

The Director of Highways

Welsh Office
Y Swyddfa Gymreig
Government Buildings
Ty Glas Road
Llanishen K J THOMAS
Cardiff CF4 5PL Director of Highways

Chief Engineer - Roads Service

Dept. of the Environment for
Northern Ireland
Clarence Court
10-18 Adelaide Street
Belfast BT2 8GB W J McCOUBREY
Chief Engineer - Roads Service

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Volume 2 Section 3
Part 6 BD 33/94 Annex A

REQUIREMENTS FOR DEPARTMENTAL TYPE

APPROVAL OF BRIDGE DECK EXPANSION
JOINTS
A1 General A1.2. Asphaltic Plug Joints

For all types of expansion joint the manufacturer or The manufacturer or supplier shall arrange for testing of
supplier shall submit in duplicate to the Highways the binder material, for the physical properties shown in
Agency (HA) full details of the expansion joint system Table 1, to be carried out by a testing laboratory
including installation procedures and where relevant the accredited in accordance with BS 7502 by the National
corrosion protection system. Where the system Measurement Accreditation Service (NAMAS) for such
incorporate a transition strip or is of the Asphaltic Plug or tests, or by a laboratory in a member state of the European
In-situ Nosing type, full details of the formulation for the Economic Area which can offer suitable and satisfactory
expansion joint materials, including primer and aggregate evidence of technical and professional competence and
shall also be submitted under "Commercial in independence for the tests concerned, and forward the
Confidence". The following are relevant requirements for results to the HA. Testing and supply of information to
specific joint types. the HA shall all be at the manufacturer's or supplier's
expense. The information will be retained by the HA in
A1.1 Asphaltic Plug, In-situ Nosings and Transition the strictest confidence and constituent materials shall not
Strips be subsequently changed without the agreement of the
Overseeing Organisation.
The manufacturer or supplier shall submit to the HA the
following information about the aggregate specified in the A1.3 In-situ Nosings and Transition Strips
formulation:
The manufacturer or supplier shall arrange for testing of
i. The classification, in accordance with BS the hardener and resin composition, including
812: Part 1: 1975, Parts 101 and 102:1984 spectrographic analysis, by a testing laboratory accredited
and Part 103.1:1985, and source of the in accordance with BS 7502 by the National Measurement
aggregate. These shall not be changed Accreditation Service (NAMAS) for such tests, or by a
without the agreement of the HA. laboratory in a member state of the European Economic
Area which can offer suitable and satisfactory evidence of
ii. The all-in aggregate grading curve technical and professional competence and independence
determined and presented as a cumulative for the tests concerned, and forward the results to the HA.
percentage passing in accordance with BS The tests and criteria shall be as in Table A2. All testing
812:Part 1:1975, Parts 101 and 102:1984 and supply of information shall be at the manufacturer's
and Part 103.1:1985. The grading curve of or supplier's expense.
the aggregates supplied shall not vary
from the grading curve submitted by more A.1.4 Testing Laboratories in Other Member States
than 10% of the value for any given
sieve size. Where tests are carried out in other member states the
requirements for laboratories given in clauses A1.2 and
iii. The water absorption, impact, crushing A1.3 will be satisfied if the laboratory is accredited in a
and abrasion properties of the aggregates member state of the European Economic Area in
determined in accordance with BS 812: accordance with the relevant parts of the EN 45000 series
Parts 1 and 2: 1975. of standards for the tests carried out.

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 Volume 2 Section 3
Annex A Part 6 BD 33/94

A2 Field Trial

A2.1 On satisfactory completion of the relevant

requirements the manufacturer or supplier shall undertake
a field trial for workmanship and performance. It will be
necessary to install a complete expansion joint, using
material to the formulation submitted in accordance with
paragraph A1, on a bridge carrying not less than 20,000
vehicles per day on a single carriageway of a dual two
lane road or its equivalent. However an equivalent trial to
the foregoing criteria in another member state of the
European Economic Area will be acceptable. The trial
period will be a minimum of 12 months, after which time
the joint will be inspected for any defects. Where
premature failure occurs the HA reserves the right to
cancel the trial extend the trial period or call for a new
trial, subject to notifying the manufacturer of supplier of
the reason for doing so. There is no guarantee that a site
will be immediately available for a new trial.

A2.2 The manufacturer or supplier will be required to

meet the costs of both successful and unsuccessful field
trials including traffic management costs.

A3. Previous Tests and Trials

Expansion joint systems already in the Motorway and

Trunk Road Network do not need further assessment for
Departmental type approval provided that they satisfy the
criteria of paragraphs A1 and A2 with respect to test
results and successful trials.

A4. Departmental Type Approval Certificate

A4.1. Subject to satisfactory compliance with the

foregoing requirements the manufacturer's or supplier's
expansion joint system will receive a Departmental type
approval certificate

A4.2. The HA reserves the right to revoke a certificate

subject to notifying the manufacturer or supplier of the
reasons for doing so.

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Volume 2 Section 3
Part 6 BD 33/94 Annex A

TABLE 1

TESTS FOR PHYSICAL REQUIREMENTS FOR DEPARTMENTAL TYPE APPROVAL

OF MATERIALS FOR USE IN ASPHALTIC PLUG BRIDGE DECK EXPANSION
JOINTS
STANDARD TEST METHOD TYPICAL RESULT

BS 2000: Part 58: 1988

Softening Point R & B, EC

BS 2499: 1973 Flow Resistance:

@ 45EC, 5 Hours. @ 60EC, 5 Hours

ASTM D1190 - Flow Resistance:

5 Hours/60E/75E Slope mm

Penetration ASTM D5
@ 25EC, @ 0EC

Specific Gravity @ 25EC

Flash Point - COC (Clevelend Open Cup)

Manufacturer's Recommended
Application Temperature

Manufacturer's Recommended Maximum

Safe Heating Temperature

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 Volume 2 Section 3
Annex A Part 6 BD 33/94

TABLE 2

TESTS AND RELATED CRITERIA FOR DEPARTMENTAL TYPE APPROVAL OF MATERIALS FOR USE IN
BRIDGE DECK EXPANSION JOINT IN SITU NOSINGS AND TRANSITION STRIPS

TEST MATERIAL TEMP. OF MORTAR ACCEPTANCE CRITERIA

CHARACTERISTICS TEST FILLED Min Max
OR UNFILLED

FERFA Test No.2 Compressive strength 20EC Filled 12N/mm2 -

FERFA Test No.4 Tensile strength 20EC Unfilled 3N/mm2 -

FERFA Test No.4 Elongation 20EC Unfilled 20% -

FERFA Test No.5 Elastic Modulus in - 10EC Unfilled 1600N/mm2

Tension

* Aggregate Grading To conform with manufacturer's stated

Test to BS 812 grading curves

*Spectrographic Components of mortar to remain

Analysis unchanged

NOTES:

1. FERFA refers to the Federation of Resin Formulators and Applicators.

2. *Test to identify the manufacturer's formulation and for the subsequent quality control tests.

3. The above testing information is strictly confidential.

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