Bridge Expansion Joint Installation

Expansion joints accommodate thermal movement between bridge deck sections, preventing stress damage.
Types include asphaltic plug joints, nosing joints, modular joints, and elastomeric strip seals.
Installation often requires cutting out the existing joint and road surface using disc cutters and breakers.
Work takes place on bridge decks above water, roads, or railways, creating fall and struck-by hazards.
Hot bitumen or epoxy compounds are used to seal and bond joint components at high temperatures.
Bridge joints on live highways require lane closures or full road closures with traffic management.
Noise and vibration from concrete cutting and breaking affect workers and nearby residents.
Precise alignment and levelling of joint components is essential for ride quality and joint longevity.
The work area on a bridge deck is confined by parapets, barriers, and traffic management.
CDM 2015, COSHH 2002, and the Safety at Street Works Code of Practice all apply.

Falls from bridges	Working on bridge decks above water or roads creates fall hazards through joint openings and over parapets.
Traffic exposure	Joint replacement on live highways exposes workers to passing traffic at close proximity for extended periods.
Chemical burns	Hot bitumen and epoxy binders used in joint installation cause severe burns and chemical skin reactions.

Do

Don't

Install edge protection and covers over the open joint gap during replacement.
Set up traffic management before starting any joint work on live highways.
Use water suppression when cutting concrete around the existing joint.
Wear thermal gloves and face protection when handling hot binder materials.
Ensure safe access to the work area with barriers preventing falls from edges.
Align and level joint components precisely to the specification before fixing.
Brief the team on the traffic plan, fall hazards, and chemical handling daily.
Use hearing protection during concrete cutting and breaking on the bridge deck.
Clean the joint housing thoroughly before installing replacement components.
Record joint installation details including temperatures and alignment for handover.

DON'T work over open joint gaps on bridges without covers or edge protection.
DON'T replace joints on live roads without traffic management in place.
DON'T cut concrete without water suppression for silica dust control.
DON'T handle hot binder materials without thermal PPE and skin protection.
DON'T leave the bridge deck work area unprotected near live traffic lanes.
DON'T force joint components into position if alignment is incorrect.
DON'T dispose of old joint materials containing bitumen without waste classification.
DON'T work over water or roads below without confirming fall protection is in place.
DON'T rush joint alignment; poor fit causes premature failure and dangerous ride quality.
DON'T ignore vibration and noise exposure during extended cutting and breaking work.

See also: Bridge Construction Safety Awareness | Bridge Deck Construction

Presenter		Project
Location		Date

Toolbox Talk Record