1. Laying out and asphalt cutting (Figure a)
Prior to the asphalt laying over the bridge deck, the location of the expansion joint width is marked for the reference later. For easy removal of the asphalt, a wooden template can be nailed to the bridge deck to act as bond breaker. After the laying of the asphalt, the suitable blockout width of asphalt layer is saw out and removed later.
2. Concrete levelling (Figure b)
The mortar screed is applied on the concrete surface of the concrete surface to achieve an uniform level over the entire expansion joint blackout. To maintain the concrete gap width, a suitable thickness of expanded polystyrene foam is inserted and removed later.
3. Anchor studs installation (Figure c)
Distance between two rolls of anchor studs are determined depending on the ambient temperature and in accordance with the distance between the anchors of the specific type of MULTIPLEX expansion joint. (See Table 2) Holes of suitable size and height to accommodate the bolt size are drilled using a rotary percussion hammer and with the help of the template or a joint unit to ensure its correct position. Anchor studs are then placed in vertically together with the use of epoxy resin as binder.
4. MULTIFLEX unit laying (Figure d)
When the studs are firmly set, the first MULTIFLEX unit is positioned onto the anchorage studs starting at the lowest watering level. The joint is lightened with nuts and washers to the specified torque. The subsequent piece of MULTIFLEX is installed likewise. The tongue and groove sections are sealed using proprietary adhesive to achieve leakproof condition. For the closing units, butt joints are made and the end cutting surface are sealed with the bonding agent.
5. Transition strips (Figure e)
After the installation of MULTIPLEX joints, the transition strip was made by filling the gaps between the joints and the asphalt using the asphalt joint filler. Generally the transition strip form a gradual gradient (+0-3mm) from the road surface to the joint surface.
6. Final assembly (Figure f)
After the fixing of all the MULTIFLEX joints, all the nuts are re-tightened. Finally, the longitudinal bolt holes are filled with sealant.