Expansion joint profiles are structural elements crucial to the durability and reliability of industrial, warehouse, commercial, and infrastructure floors. Their primary function is to absorb structural deformations, compensate for material movement, and protect the edges of expansion joints from damage. However, it's worth emphasizing that even the highest-quality profile will fail if installed incorrectly.
In practice, installation mistakes are relatively common. Their consequences can be serious: from cracked floors, through leaks and accelerated wear, to costly repairs to entire sections of flooring. Below, we present the five most common errors made when installing expansion joint profiles, along with tips on how to effectively avoid them.
Incorrect Profile Selection for Technical Conditions
Many problems begin even before construction begins. Using a profile that doesn't match the specific load, floor type, or environmental conditions significantly increases the risk of damage.
Recommendation:
Profile selection should always take into account the type and intensity of loads (pedestrian traffic, road transport, machinery), environmental conditions (e.g., exposure to chemicals, high humidity, temperature changes), and the type of structure (e.g., reinforced concrete, resin flooring). If in doubt, consult with Conecto Profiles or an expansion joint system designer – this decision affects the long-term durability of the entire project.
Incorrect Profile Alignment with the Expansion Joint Axis
For the expansion joint to function properly, the profile must be positioned precisely in the axis of the designed joint. Even a misalignment of just a few millimeters can lead to impaired joint operation and cracking in the concrete.
Recommendation:
Before concreting begins, precisely determine the course of the expansion joints. It's recommended to use a laser level or a level. Installation should be performed in accordance with the design documentation and manufacturer's recommendations.
Insufficient profile anchoring
Anchoring that is too shallow or unstable can cause the profile to shift under load, which can result in damage to the joint or the profile separating from the substrate.
Recommendation:
Only manufacturer-recommended anchors – mechanical, chemical, or steel – should be used, appropriate for the flooring type. The anchoring depth should be consistent with the design documentation and take into account the thickness of the concrete slab. The quality of the fasteners themselves is also crucial.
Installation at an inappropriate time or conditions
Unwisely postponing installation to a later stage or performing work in unfavorable weather conditions can affect the durability and functionality of the expansion joint.
Recommendation:
It is recommended to install expansion joint profiles before concreting begins, preferably in a single process run. Avoid installation in extremely low or high temperatures unless the system has been designed for this purpose.
Surface misalignment and lack of leveling control
Improper leveling of the profile can result in imperfections, which impede operation and increase wear and tear on vehicles driving over the floor.
Recommendation:
It is recommended to use laser levels and installation spacers during installation. Before the final pour, recheck the position and level of the profile and make adjustments if necessary.
Summary
Installing expansion joint profiles is a step that requires precision, technical knowledge, and experience. Mistakes made at this stage can lead to serious structural and operational problems, resulting in additional costs for the investor. Therefore, not only the selection of the appropriate system but also careful execution in accordance with the design and technology is crucial.
Investing in high-quality profiles and trained installation personnel directly translates into the durability, functionality, and safety of the floor for many years to come.