Learn how expansion joints protect concrete, rail, roadway, and seismic structures from damage and how Maurer solutions supplied by KES meet those demands.

Movement is a constant in structural systems, whether due to thermal expansion, load cycling, or seismic activity. If left unmanaged, this movement leads to cracking or long-term service disruptions.

Expansion joints are the engineered solution to this unavoidable reality. By accommodating displacement while preserving structural integrity, they protect the service life of infrastructure and ensure that movement happens without damage. Through our exclusive partnership with Maurer, Kubri Engineered Solutions delivers these precision-engineered systems that are adapted to Australian standards and project conditions.

What Causes Structural Movement in Infrastructure?

Movement in infrastructure is often the result of predictable forces that act on different components of a built structure. Understanding these sources is the first step in choosing the right expansion joint system.

1. Temperature Changes

Thermal expansion and contraction affect all materials, especially steel and concrete. A 100-metre bridge deck can expand by as much as 60 mm between seasonal temperature extremes. Without a joint, this movement creates internal pressure that can cause the concrete to crack or deform the supporting frame.

2. Live and Cyclic Loads

Every vehicle crossing a bridge or train braking on a viaduct introduces live loads. Over time, these repeated cycles impose flexural stress on decks and beams.

3. Shrinkage and Wind

Concrete shrinkage during curing and lateral wind loads contribute to small but continuous structural movement. These forces may not be immediately apparent, but over time, they can compromise load paths and stress distribution.

4. Seismic Activity

In seismically active regions, decks and substructures can shift abruptly in multiple directions. Expansion joints must not only absorb this energy but also remain operational, especially on lifeline routes needed for emergency response.

Inside an Expansion Joint: Components & How They Work Together

Expansion joints absorb movement while maintaining safety and stability. Each component has a distinct role, and the way they interact determines the joint’s ability to accommodate thermal shifts and dynamic loads.

1. Load-Bearing Beams

Steel edge or center beams that span the joint and transfer traffic loads into the substructure. Their shape and connection method vary depending on the joint type (single-seal, modular, or swivel), but their function is consistent: to carry vertical loads while allowing horizontal displacement.

2. Support Bars and Control Springs

In modular systems, center beams are supported by crossbars and separated by polyurethane control springs. These springs compress and expand under motion, evenly distributing displacement across the joint.

3. Sliding Bearings

Pre-tensioned sliding bearings are inserted beneath center beams to accommodate rotation and vertical movement.

4. Sealing System

Elastomeric strip seals are clamped between beams to create a continuous, watertight barrier. This reduces installation time and eliminates common failure points like bolt loosening and extrusion.

5. Anchorage System

The joint is anchored to the surrounding concrete using welded loops or cast-in plates. Hybrid stainless-steel options are available for high-corrosion environments.

How they all work together:

When the structure expands or contracts, the beams slide or rotate slightly, the control springs compress or extend, and the seal stretches in multiple directions, all while maintaining load capacity and watertightness. The result is a durable, flexible connection that lets the structure move as designed without compromising safety or serviceability.

Maurer Expansion Joints: Precision Systems Built for Longevity

Founded in Munich in 1876, Maurer began as a sheet-metal workshop. Over the following decades, the company evolved into a recognized steel-construction firm, expanding into bridge structures and airport hangars. Today, as a global, family-owned enterprise, the company combines deep engineering heritage with modern innovation. Maurer’s modern expansion joint systems reflect this legacy. 

1. Expansion Joints for Concrete and Road Infrastructure

I. Single-Seal Joints: Compact, Watertight Performance

Maurer XW1 and XW2 single-seal joints offer a displacement capacity of up to 100 mm. The form-fit seal design eliminates the need for mechanical fasteners, enhancing long-term watertight performance and simplifying installation.

II. Girder Grid Joints: Modular Strength for Large Movements

Maurer’s DT, XD, and XT series modular joints are designed for heavy-load applications with displacement ranges exceeding 400 mm. They incorporate:

• Welded edge and center beams
• Drop-in elastomeric seals
• Support bars with control springs

III. Swivel-Joist Joints: Multi-Axis Flexibility for Curved and Complex Decks

For structures with non-linear alignment, Maurer’s DS and XS Swivel Joist joints allow for multi-directional rotation. Each center beam is suspended on a support bar that can swivel in both vertical and horizontal planes, making the system ideal for ramps or curved bridge geometries.

2. Expansion Joints for Railway Bridges and Viaducts

Guided Cross-Tie Systems: Rail-Ready and High-Speed Certified

Maurer’s Railway Expansion Joints are engineered for high-load, low-maintenance performance, specifically on railway bridges and viaducts subject to continuous axial and vertical forces. These systems include:

• Fixed or sliding rail connections with defined expansion allowances
• Track-guided tie systems that maintain rail alignment while decoupling from substructure movement
• Damped sliding plates to reduce wear and vibration
• Noise-control configurations for urban or residential corridors
• Certified compatibility with high-speed rail systems

3. Expansion Joints for Seismic Zones

I. Fuse-Box Joints: Controlled Failure for Structural Survival

Maurer’s Fuse-Box Expansion Joint System protects the superstructure by sacrificing replaceable joint modules. During a seismic event, the fuse elements yield or detach in a controlled sequence, absorbing extreme energy while maintaining the structural integrity of the frame.

• Designed for one-time seismic activation
• Joint elements can be replaced post-event without substructure intervention.
• Suitable for lifeline infrastructure and critical transport corridors
• Installed on bridges across Europe and the Asia-Pacific seismic zones

This system is ideal for structures that must remain functional after an earthquake, enabling rapid recovery and controlled repair.

II. Full-Capacity Seismic Joints: Built to Absorb Earthquake Displacement

For continuous operability in areas with regular seismic activity, Maurer’s modular and swivel joints can be designed with enhanced displacement tolerances:

• Swivel Joist XS-S joints offer longitudinal + transverse movement, plus uplift tolerance.
• Seismic buffer zones integrate into beam supports to handle rapid deflection.
• Fatigue-tested to simulate decades of seismic activity without performance loss

4. Expansion Joints for Architectural Applications

Whether running through lobbies, corridors, facades, or atriums, joints must accommodate movement while preserving the design intent of high-finish spaces.

Maurer’s architectural joint systems are engineered for this exact balance. They offer reliable performance across floors, walls, ceilings, and roofs, with features such as:

• Low-profile covers are available in stainless steel, anodized aluminum, or elastomer.
• Custom surface finishes for blending with concrete, tile, carpet, or stone.
• Multidirectional movement (up to ±150 mm) for thermal, seismic, or shrinkage displacement
• Fire-rated, waterproof, and ADA-compliant variants available
• Flush-mount, surface-mount, or recessed anchor systems

5. Special Designs & Accessories

I. Maurer Betoflex® Anchoring System

Betoflex is a rapid-curing polymer concrete used for anchoring modular joints. It significantly reduces block-out depth and eliminates the need for additional reinforcement or composite anchors. It also enables fast joint replacement, lowering both cost and installation time.

II. Hybrid Profile Systems for Corrosive Environments

Maurer’s hybrid profiles combine standard steel edge beams with stainless steel holding claws. This enhances resistance to salt corrosion and improves sustainability.

III. Curved Low-Point Seal Designs

To prevent water accumulation in the lowest point of architectural or outdoor joints, Maurer offers curved seal geometry with optional integrated flushing outlets. This ensures seal integrity over time and simplifies the removal of debris and moisture.

IV. Maintenance-Focused Accessories

• GU‑f Noise Reduction Units: Added underneath modular joints to cut noise transmission by up to 60%
• Integrated Drainage Channels: Sloped gutter systems to manage runoff
• Debris-Protection Inserts: Mesh or internal barriers to prevent obstruction of sliding and seals

Visit our portfolio of Maurer expansion joints to download technical brochures and product specifications.

How to Select the Right Expansion Joint for Your Structure

The right choice depends on the type of movement, site conditions, load cases, and long-term maintenance requirements:

Movement and Displacement Requirements

The first step is defining how the structure moves, whether due to thermal expansion, creep, settlement, or seismic activity. For major bridges, Maurer modular joints (DT or XT series) are suitable for multi-directional movements. Compact strip seal joints like Maurer XW are more appropriate for smaller spans and lower movement ranges.

Load and Fatigue Considerations

Traffic loading influences joint selection as much as movement. Maurer’s modular and railway joints are fatigue-tested and designed to handle dynamic loads with consistent performance. Optional noise-reduction modules are available for surface impact dampening where required.

Environmental and Site Constraints

Joints in coastal or chemically aggressive environments benefit from stainless steel hybrid profiles and corrosion-resistant seals. Where access is restricted, Maurer’s Betoflex anchoring system offers a low-depth, polymer concrete alternative for fast installation, making it ideal for retrofits or precast structures.

Inspection and Maintenance Access

Top-down access to wear parts is critical for minimizing disruption. Maurer joints are designed for easy inspection and component replacement, reducing lifecycle costs without compromising performance.

Kubri Engineered Solutions & Maurer: German Engineering Built for Australian Conditions

As the exclusive agents for Maurer in Australia, Kubri Engineered Solutions bridges the gap between Maurer’s global innovation and the specific needs of Australian infrastructure through direct access to the full portfolio of expansion joints, configured for Australian codes and site conditions.

What Kubri Brings to Your Project:

Standards Compliance: Kubri provides technical documentation, design consultation, and verification support throughout the project lifecycle.

Local Engineering Support: Kubri’s experienced infrastructure team works directly with project engineers and consultants to recommend and implement the most suitable expansion joint solution.

Warranty and Reliability: All Maurer joints supplied through Kubri come with a warranty of up to 25 years, giving stakeholders confidence in both system longevity and service continuity.

See our work with Maurer systems across a range of structural applications.

Kubri Engineered Solutions offers more than product delivery. We provide engineering support from design review through installation, ensuring your expansion joint system is tailored to your project’s needs and compliant with Australian standards.

Speak to our team to discuss your project requirements and explore the most effective expansion joint systems for your infrastructure.