Professional Documents
Culture Documents
Inspection & Maintenance Manual
for
mageba bridge bearings
and seismic isolators
Inspection & Maintenance Created: COSU Revision: 01
Manual for mageba bridge Checked: MDEL Date: 22 Aug 2014
bearings and seismic isolators Approved: NMEN Page: 2/32
TABLE OF CONTENTS
1 APPLICABILITY ..................................................................................................................... 3
2 INTRODUCTION ................................................................................................................... 3
2.1 IMPORTANCE OF INSPECTION AND MAINTENANCE ............................................................................................... 3
2.2 PURPOSE OF THE INSPECTION & MAINTENANCE MANUAL .................................................................................... 3
2.3 PURPOSES OF BEARINGS AND SEISMIC ISOLATORS ................................................................................................ 3
2.4 DIFFERENT TYPES OF BEARING (NON‐SEISMIC) ....................................................................................................... 4
2.5 DIFFERENT TYPES OF SEISMIC ISOLATOR ................................................................................................................ 5
3 KEY BEARING FEATURES ...................................................................................................... 6
3.1 TYPE PLATE .............................................................................................................................................................. 6
3.2 MOVEMENT SCALE .................................................................................................................................................. 6
3.3 DUST PROTECTION .................................................................................................................................................. 7
4 INSPECTIONS ....................................................................................................................... 8
4.1 INSPECTION INTERVALS ........................................................................................................................................... 8
4.2 GENERAL APPROACH TO THE INSPECTION .............................................................................................................. 8
4.3 RESULTS AND ACTIVITIES ......................................................................................................................................... 8
4.4 RECORDING OF INSPECTIONS .................................................................................................................................. 9
4.5 CLEANING OF BEARING BEFORE INSPECTION ......................................................................................................... 9
4.6 ELEMENTS OF INSPECTION .................................................................................................................................... 10
4.6.1 Condition of steel and its corrosion protection ( 1 ) .............................................................................................. 10
4.6.2 Condition of elastomeric pad ( 2 ) – elastomeric bearings/isolators only ............................................................. 10
4.6.3 Condition of bolts / anchorages ( 3 ) .................................................................................................................... 11
4.6.4 Condition of welds ( 4 ) ......................................................................................................................................... 11
4.6.5 Condition of the adjacent bridge structure ( 5 ) .................................................................................................... 11
4.6.6 Condition of sliding surfaces ( 6 ) – sliding bearings only ...................................................................................... 11
4.6.7 Movement capacities ( 7 ) – sliding/deforming bearings only .............................................................................. 12
4.6.8 Sliding, tilting and guidebar gaps ........................................................................................................................... 13
5 MAINTENANCE .................................................................................................................. 16
5.1 REPAIR WORK ON BEARING .................................................................................................................................. 16
5.2 REPAIR OF CORROSION PROTECTION .................................................................................................................... 16
5.3 RECORDING OF WORK CARRIED OUT .................................................................................................................... 16
6 COMPETENCE OF INSPECTION AND MAINTENANCE PERSONNEL ...................................... 16
7 SUPERVISION OF INSPECTION AND MAINTENANCE WORK ............................................... 16
APPENDIX 1: INSPECTION REPORT ............................................................................................... 17
APPENDIX 2: POT BEARINGS ......................................................................................................... 18
APPENDIX 3: SPHERICAL BEARINGS .............................................................................................. 19
APPENDIX 4: DISC BEARINGS ........................................................................................................ 20
APPENDIX 5: LINEAR ROCKER BEARINGS ...................................................................................... 21
APPENDIX 6: HORIZONTAL FORCE BEARINGS ............................................................................... 22
APPENDIX 7: ELASTOMERIC BEARINGS ......................................................................................... 23
APPENDIX 8: HIGH DAMPING RUBBER BEARINGS (HDRB) ............................................................ 24
APPENDIX 9: LEAD RUBBER BEARINGS (LRB) ................................................................................ 25
APPENDIX 10: CURVED SURFACE SLIDER SEISMIC ISOLATORS ...................................................... 26
APPENDIX 12: DRAWINGS ............................................................................................................ 28
APPENDIX 13: REPAIR OF CORROSION PROTECTION .................................................................... 29
Inspection & Maintenance Created: COSU Revision: 01
Manual for mageba bridge Checked: MDEL Date: 22 Aug 2014
bearings and seismic isolators Approved: NMEN Page: 3/32
1 APPLICABILITY
This manual can be used in connection with the inspection and maintenance of all types of mageba bridge
bearing, including RESTON®POT, RESTON®SPHERICAL, RESTON®DISC, RESTON®FORCE, RESTON®LINEAR and
LASTO®BLOCK.
It also applies to the inspection and maintenance of all types of mageba seismic isolator, including LASTO®LRB,
LASTO®HDRB and RESTON®PENDULUM, since these can be considered a particular type of bearing. The term
“bearing”, where it appears in this manual, can thus be understood to apply also to mageba seismic isolators.
This manual can also be used, as appropriate, where such bearings or seismic isolators are installed in buildings
and other non‐bridge structures.
The extent to which the general guidelines in this manual should be applied to any particular bearing (or
isolator) type and situation requires some basic engineering judgement, and mageba should be contacted in
case of any doubt.
2 INTRODUCTION
2.1 Importance of inspection and maintenance
Starting on the day of installation, a bridge bearing is continually exposed to natural elements (temperature
changes, rain, snow, moisture, ozone, carbon dioxide, ultraviolet rays etc) and effects that are introduced by
humans (traffic loading, chemical influences such as de‐icing salts and industrial pollutants, etc) and animals.
The combined effect of these elements on the bearing’s components is a steady and unavoidable deterioration
process. Regular inspection and maintenance are vital measures for a long lifespan of the bearing.
2.2 Purpose of the Inspection & Maintenance Manual
This manual describes how the inspection, maintenance and repair of mageba bearings should be carried out,
and how any such works should be recorded (see Section 4.4 and Appendix 1). Complying with these
instructions should ensure that the bearing will continue to perform well throughout its lifetime. However, the
work should not rely entirely on the guidance given in this document – the engineering judgement of the
responsible personnel should also play a role. The most up‐to‐date drawings of the bearings and the
connecting bridge structure must be at hand and referenced so that special features and the functioning of
the bearing can be fully understood.
This manual does not seek to address non‐technical aspects of bearing inspection, maintenance or repair. Thus,
issues such as safe access, Personal Protective Equipment (PPE) and other Health, Safety & Environment (HSE)
considerations are outside the scope of this document.
2.3 Purposes of bearings and seismic isolators
Bridge bearings are used to form the connections between a bridge’s deck and the deck’s support abutments
or piers. They typically transmit vertical loading (including weight of deck and traffic etc., and possibly uplift
forces), and allow the bridge deck to move as required by the bridge’s design. Movements of the deck may
arise due to expansion and contraction of the deck due to temperature changes, shrinkage/creep of concrete,
wind, traffic forces, settlement of abutments, seismic effects and/or other sources. These movements may
take the form of translations in any direction (insofar as these are permitted by the bridge design), and
rotations about any axis. Conversely, bridge bearings may be designed, as required by the bridge’s design, to
resist horizontal (transverse or longitudinal) forces.
Inspection & Maintenance Created: COSU Revision: 01
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bearings and seismic isolators Approved: NMEN Page: 4/32
Seismic isolators are also used to form connections between a bridge’s deck and the deck’s support abutments
or piers, also typically transmitting vertical loading, but are designed to perform in a very specific way during
an earthquake, protecting the main structure. For optimal performance, a seismic isolator should offer the
following benefits:
‐ Isolation of the superstructure from violent, potentially damaging ground movements
‐ Energy dissipation – so that the seismic energy is released in a safe, controlled manner
‐ Re‐centering – so that the superstructure will return to its former position after the earthquake
In order to fulfil these functions, seismic isolators do not have a horizontal sliding interface to allow free
translations; elastomeric isolators, for example, accommodate superstructure movements by deformation
alone, meaning that there is a certain amount of resistance to all such movements.
2.4 Different types of bearing (non‐seismic)
There are various types of non‐seismic bearing, each of which offers its own advantages in certain situations.
For example, the degree to which a bearing can be designed to accommodate deck movements (longitudinal,
transverse and vertical), and rotations about the deck’s longitudinal, transverse and vertical axes, varies from
one type to another.
A number of bearing types are particularly important and are therefore specifically referenced in this manual:
pot bearings, such as mageba’s RESTON®POT (see Appendix 2),
spherical bearings,such as mageba’s RESTON®SPHERICAL (see Appendix 3),
disc bearings, such as mageba’s RESTON®DISC (see Appendix 4),
linear rocker bearings, such as mageba’s RESTON®LINEAR (see Appendix 5),
horizontal force bearings, such as mageba’s RESTON®FORCE (see Appendix 6), and
elastomeric bearings, such as mageba’s LASTO®BLOCK, featuring anchor plates, sliding surfaces and/or
movement restraints (see Appendix 7).
Other types are generally less complex, and their inspection and maintenance does not require the
presentation of bearing‐specific details in this manual. Where possible and applicable, the inspection of other
types should be based on the guidelines presented for the above types.
Each bearing type typically has three main sub‐types, which differ depending on the freedom for horizontal
movement they allow the connected bridge deck, as follows:
Free sliding/deforming ‐ can accommodate horizontal movements in any direction (longitudinal or
transverse).
Guided sliding/deforming ‐ can accommodate horizontal movements in either the longitudinal or
transverse direction, while resisting movement (and force) in the other direction.
Fixed ‐ cannot accommodate any horizontal movements – but rather resists the forces which would
tend to cause any such movements.
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bearings and seismic isolators Approved: NMEN Page: 5/32
An overview of the above‐mentioned key non‐seismic bearing types, and their individual sub‐types, is
presented below.
These sub‐types are illustrated in Appendices 2 to 7. Details of other bearing types can be obtained from
mageba’s website, or provided by mageba on request.
2.5 Different types of seismic isolator
There are various types of seismic isolator, each of which offers its own advantages in certain situations.
A number of isolator types are particularly important and are therefore specifically referenced in this manual:
High Damping Rubber Bearings (HDRB), such as mageba’s LASTO®HDRB. These are similar to
LASTO®BLOCK elastomeric bearings with anchor plates and with no sliding surfaces, but fabricated using
a special high‐density elastomer which provides high stiffness and results in high energy dissipation
during seismic movements (see Appendix 8),
Lead Rubber Bearings (LRB), such as mageba’s LASTO®LRB. These are similar to LASTO®BLOCK
elastomeric bearings with anchor plates and with no sliding surfaces, but also featuring a vertical lead
core which provides high stiffness and results in high energy dissipation during seismic movements (see
Appendix 9),
Curved Surface Sliders, such as mageba’s RESTON®PENDULUM (see Appendix 10).
Other types are generally less complex, and their inspection and maintenance does not require the
presentation of bearing‐specific details in this manual. Where possible and applicable, the inspection of other
types should be based on the guidelines presented for the above types.
Inspection & Maintenance Created: COSU Revision: 01
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bearings and seismic isolators Approved: NMEN Page: 6/32
3 KEY BEARING FEATURES
The following features and aspects apply to many bearing types, and their purpose and functioning must be
understood as appropriate.
3.1 Type plate
The type plate, if provided, contains key data relating to the bearing and its design.
P‐No. = mageba project number
Year = Year of manufacture (not of installation)
Location = Bearing location on the bridge
vx / vy = Movement range in x and y directions
ex / ey = Pre‐setting values
NEd,max / VEd, max = Max. normal and transverse design level (ULS) forces, respectively
3.2 Movement Scale
Movement scales are typically provided for sliding bearings with a movement range of over 100mm. These
enable current values of bearing displacements to be easily read at any time.
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3.3 Dust protection
Bearings that accommodate sliding movements are typically provided with some form of dust protection to
prevent contamination of the sliding surface. Such contamination can result in scratching or other damage to
sliding surfaces such as stainless steel and PTFE/Robo®Slide, and loss of performance of any grease that is
applied to the surfaces.
This dust protection is typically in the form of a rubber skirt which hangs around the bearing, or a multiple leaf
skirt (a folding sheet similar to that used in a bellows or an accordian) which is placed horizontally across the
sliding surface at each end of the bearing.
Rubber skirt protection: This type of protection is attached to the bearing by Velcro tape and is therefore
easy to remove and re‐attach, to allow the bearing to be cleaned and inspected.
Multiple leaf skirt (bellows) protection: Dismantling of this type of protection requires more effort so
the extent to which it must be temporarily removed for any inspection should be considered based on
the circumstances.
The dust protection should only be removed if necessary (e.g. if required during inspections), and must then
be replaced as soon as possible, after ensuring that no contamination of the sliding surfaces etc. has occurred.
Any contamination must be properly cleaned immediately, without damaging surfaces. The proper condition
and functioning of the dust protection must be ensured at all times.
Inspection & Maintenance Created: COSU Revision: 01
Manual for mageba bridge Checked: MDEL Date: 22 Aug 2014
bearings and seismic isolators Approved: NMEN Page: 8/32
4 INSPECTIONS
Refer to Sections 6 and 7 of this manual for comments relating to competence of workers and supervision of
the work. A list of typically required tools is included in Appendix 11.
4.1 Inspection intervals
Inspections should be carried out at the following intervals:
The first regular inspection must be carried out shortly after the structure has been put into service (at
the latest 1 year after the installation of the bearing).
Thereafter at least every 5 years.
Further inspections should be carried out as otherwise defined or appropriate, e.g.
o following any unforeseen incidents which could affect bearing condition or performance;
o considering particularly onerous demands such as local environmental conditions or bridge
movement characteristics (e.g. high accumulated total movement);
o depending on the findings of previous inspections;
o according to the owner’s needs; or
o in accordance with local or other relevant regulations.
4.2 General approach to the inspection
The purpose of the inspection is primarily to identify possible defects or issues requiring attention. The
inspection elements defined in Section 4.6 must be included in each inspection, but the inspection should not
necessarily be limited to this – the engineering judgement of the responsible inspector should also play a role.
The most up‐to‐date drawings of the bearing must be at hand and referenced so that special features and the
functioning of the bearing can be fully understood by the inspector.
Records from the installation of the bearing, and from previous inspections and maintenance work, must be
at hand and referenced. This will draw the inspector’s attention to issues that may require particular attention,
and will enable him to note any progressive deterioration. It will also enable him to check that any required
actions have been carried out, and that these have been successful in fulfilling the intended objectives.
4.3 Results and activities
Based on the findings of the inspection, conclusions should be arrived at for each item in the scope of the
inspection, with classification in each case as follows (unless otherwise defined/required):
1 No action necessary
2 Further inspection / design analysis required (e.g. considering extreme temperatures,
different loads, long‐term monitoring). Actions to be outlined in the report.
3 Repair or replacement of entire bearing or parts thereof. Actions to be outlined in the report.
Possible actions are given under each check point of Section 4.6.
Proper execution of actions must be ensured through well‐defined procedures and controls.
In cases where the cause of any deficiency, or the necessary actions, cannot be determined by the inspecting
person or the responsible bridge engineer, mageba must be consulted.
Inspection & Maintenance Created: COSU Revision: 01
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bearings and seismic isolators Approved: NMEN Page: 9/32
4.4 Recording of inspections
The results of each inspection should be carefully and clearly recorded in the attached Inspection Report
(Appendix 1).
A photographic record should be created using a digital camera.
After completion of all works and all necessary measures have been taken and confirmed, all reports and
records must be carefully filed for future reference – see Section 4.2.
4.5 Cleaning of bearing before inspection
Careful cleaning of the bearing should precede the inspection.
For cleaning purposes alone, removal of any dust protection (see above) is generally not required unless it is
damaged or it is suspected that foreign particles or debris are trapped inside. However, the dust protection
must be partially removed for inspection activities such as measuring of sliding and tilting gaps.
Depending on the actual contamination of the bearing (e.g. salt deposits, debris or dust), the cleaning method
should be chosen to achieve the desired result without damaging the bearing or structure, in particular without
excessive pressure, dampness, heat or abrasion. Special care should be taken to avoid damaging sensitive parts
of the bearing (for example, in the case of a pot bearing, the dust seal at the rim of the pot ‐ see Appendix 2).
Possible methods typically include hand brushing and pressurised air.
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Manual for mageba bridge Checked: MDEL Date: 22 Aug 2014
bearings and seismic isolators Approved: NMEN Page: 10/32
4.6 Elements of inspection
A bearing inspection should cover all aspects of the bearing’s condition and performance. Aspects which should
typically be included (where appropriate) are listed below, but the inspection should not be limited to these.
The engineering judgement of a suitably qualified and experienced inspector should always play a role.
The number in parentheses ( ) after the title of each element of the inspection below is a reference number
for cross‐referencing to the Inspection Report (see Appendix 1).
For carrying out each element of the inspection as listed below, guidance is given under the following three
points:
Acceptance criteria
When to take action
Remedial action
4.6.1 Condition of steel and its corrosion protection ( 1 )
The surfaces of mageba bearings are treated with corrosion protection (normally paint) as detailed on the
contract drawings (refer Appendix 12).
The bearing must be carefully inspected to identify any possible defects in its steel or corrosion protection.
Early identification and repair of damaged corrosion protection can prevent much more substantial repairs in
the future. If neglected, exposed or rusted steel elements may result in expensive repair work or full
replacement of the bearing.
During inspection, the steel parts must be carefully examined for the following indications of defective
corrosion protection:
damaged or deformed steel
peeling, cracking or other serious deterioration of corrosion protection
red‐coloured areas caused by rust staining
Acceptance criteria: No defects visible.
When to take action: Any of the above defects appears.
Remedial action: Refer to Section 5 of this document.
Note: After the discovery (and repair) of defects, the cause must be identified and addressed in order to
prevent recurrence.
4.6.2 Condition of elastomeric pad ( 2 ) – elastomeric bearings/isolators only
Bearings/seismic isolators consisting entirely of elastomeric pads (e.g. LASTO®BLOCK Type NB), or featuring
elastomeric pads in their construction (e.g. LASTO®BLOCK Types NBa, NBe or NBf, or isolator types LASTO®LRB
and LASTO®HDRB), must be carefully inspected to identify any possible defects, such as:
Cracking or spalling of elastomer
excessive bulging of elastomer
excessive shear deformation or torsion
separation of elastomer from connecting steel plates
Acceptance criteria: No defects visible.
When to take action: Any of the above defects appears.
Remedial action: Consult with mageba.
Inspection & Maintenance Created: COSU Revision: 01
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bearings and seismic isolators Approved: NMEN Page: 11/32
4.6.3 Condition of bolts / anchorages ( 3 )
A visual inspection of the bolts (which should look for signs of lack of tightness) should normally be sufficient.
If fissures in the corrosion protection are visible, it is recommended to check with a torque‐measuring spanner
that the bolts are properly tightened to the recommended torque defined by the standard to which the bolts
were manufactured (refer to bearing fabrication drawings as listed in Appendix 12).
Acceptance criteria: Bolts visually in order, and all bolts checked are sufficiently tight.
When to take action: Any bolt is found not to be sufficiently tight, or other visual signs observed that any
bolt requires attention.
Remedial action: All bolts, nuts, washers etc. must be checked and addressed (tightened, replaced
or otherwise) as appropriate. If more than one bolt is found to need attention, the
root cause should be investigated and addressed.
Note: Pre‐tensioned bolts that are found to have loosened may not be reused replace with new bolts.
4.6.4 Condition of welds ( 4 )
It is normally sufficient to check welds visually for cracks or fissures. If any cracks or fissures are discovered,
further tests (e.g. magnetic particle method) to detect the full extent of the damage must be considered.
Acceptance criteria: No cracks, fissures or other signs of damage noticeable on welds.
When to take action: Cracks and/or fissures exist.
Remedial action: Shall be taken following further appropriate investigations by welding experts
and/or mageba as appropriate. It must be recognised that the heat arising during
welding can seriously damage a bearing, in particular its sliding materials.
4.6.5 Condition of the adjacent bridge structure ( 5 )
The inspection of the bearing should include inspection of the adjacent bridge structure. Any damage should
be repaired as soon as possible to avoid possible damage to the bearing. Such damage may include:
broken off concrete or mortar edges, or exposed reinforcement
cracks or fissures in the structure
rust spots on concrete or other surfaces, or other signs of water leakage from aboveAcceptance criteria:
No defects observed
When to take action: Any defects observed.
Remedial action: According to the instructions of the responsible engineer.
4.6.6 Condition of sliding surfaces ( 6 ) – sliding bearings only
A visual check of the bearing’s sliding surfaces (the stainless steel on the bearing’s sliding plate, and the
PTFE/Robo®Slide sheet that slides against it) should be carried out.
Acceptance criteria: No irregularities on the sliding surfaces.
When to take action: Irregularities on the sliding surfaces (e.g. cracks, unusual spots, rust on the stainless
steel plate or irregular wear of the PTFE/Robo®Slide).
Remedial action: Clean as required and protect against further contamination or damage. In
exceptional situations further remedial action (e.g. replacement of
PTFE/Robo®Slide disc and/or stainless steel sliding plate) may be required and
should be undertaken, with the guidance of mageba, following further appropriate
investigation by the bridge engineer and mageba.
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4.6.7 Movement capacities ( 7 ) – sliding/deforming bearings only
The longitudinal and transverse movement capacities (if any) of the bearing must be checked to ensure that
the bearing continues to satisfy the movement requirements of the bridge.
Longitudinal sliding displacements can often be easily read using the movement scale and pointer which may
be included at delivery (on bearings that allow significant movements).
For transverse sliding movements, and longitudinal sliding movements that cannot be read using a provided
movement scale, the horizontal displacement can be measured as follows: The centre lines of the bearing’s
upper and lower parts should already be marked with yellow paint and punch marks. The measured distance
between these centre line marks is the current value of the horizontal displacement.
The magnitude of maximum sliding movements to date can often be ascertained from the grease/dust
markings on a sliding bearing’s stainless steel sliding sheet.
Displacements can also arise in elastomeric bearings or seismic isolators, from deformation of the bearings’
elastomeric material. The displacements vx and vy, as illustrated below for the bearing’s x and y axes, should
be recorded and checked. In general, the deviation of the edge of the bearing from vertical (the angle caused
by such deformation) should not exceed 30°, and mageba should be consulted if it does.
vx, vy
Values are recorded in the Inspection Report, and compared with the design movement capacity (considering
current structure temperature) to ensure that the bearing’s remaining movement capacity is sufficient.
Acceptance criteria: No irregularities with movement capacities.
When to take action: Irregularities with movement capacities or excessive angular deformation. The
reasons for this must be assessed to ensure that the movement capacity of the
bearing will not be exceeded. Increased monitoring, e.g. at least annual, then
required, the timing of which should coincide with the most adverse likely
movements (e.g. coldest or warmest time of year).
Remedial action: In exceptional situations, where the risk of a bearing’s movement/deformation
capacity being exceeded cannot be ruled out or managed, remedial action
should be taken following investigation by the bridge engineer and mageba.
The initial displacements/deformations must be measured shortly after the structure has been put into service,
in order to have a reference for later measurements.
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4.6.8 Sliding, tilting and guidebar gaps
Sliding gaps (h), tilting gaps (s1) and guidebar gaps (s3) must be measured according to the following sketchs
(or in accordance with the same principals for other bearing types) and as noted in Section 4.6.8.1 to 4.6.8.3
respectively, where appropriate.
Reston®Pot bearings:
Guidebar gap (s3)
Sliding gap (h)
Tilting gap (s1)
Reston®Spherical bearings:
Sliding gap (h)
Tilting gap (s1)
Guidebar gap (s3)
Reston®Disc bearings:
Sliding gap (h)
Guidebar gap (s3) Tilting gap (s1)
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4.6.8.1 Sliding gaps, “h” ( 8.1 ) – sliding bearings only
The sliding gap, h, is the thickness of sliding material (PTFE/Robo®Slide) which can be seen from the side, i.e.
which extends from the steel plate in which it is recessed. It is illustrated in the above drawings, for specific
types of bearing, but must be measured for all sliding bearings.
The sliding gap should be measured at the four locations A, B, C and D as shown on horizontal section X‐X
below.
Depending on the measured values, the following actions must be taken:
Acceptance criteria: h 1.0 mm at all locations.
When to take action: h between 1.0mm and 0.5 mm. Annual monitoring required.
Remedial action: h 0.5 mm. Immediate replacement of the PTFE/Robo®Slide sheet required.
In exceptional circumstances, additional action may be required following
investigation by the bridge engineer and/or mageba.
4.6.8.2 Tilting gaps, “s1” ( 8.2 ) – tilting bearings only
The tilting gap, s1, at any side of a bearing is the vertical distance that the bearing can tilt at that side (i.e. the
minimum vertical clearance at that point between the upper and lower parts of the bearing). It is illustrated in
the above drawings, for pot, spherical and disc bearings, but must be measured for all bearings that have upper
and lower parts which can rotate relative to each other about a horizontal axis.
The tilting gap should be measured at the four locations A, B, C and D as shown on horizontal section X‐X below,
and an average value should be calculated. The measured values should be compared to the initial gap values
(measured shortly after installation) or, if unavailable, to the values and tolerances stated in the “Internal
Quality Control Card” from the production of the bearing.
Depending on the calculated values, the following actions must be taken:
Acceptance criteria: No irregularities in the tilting gaps.
When to take action: Irregularities in the tilting gaps. The reasons for this must be assessed to
ensure that the tilting capacity of the bearing will not be exceeded. Increased
monitoring, e.g. at least annual, then required.
Remedial action: In exceptional situations, where the risk of the tilting capacity of the bearing
being exceeded cannot be ruled out or managed, remedial action should be
taken following appropriate investigation by the bridge engineer and mageba.
4.6.8.3 Guidebar gaps, “s3” ( 8.3 ) – guided sliding bearings only
The guidebar gap, s3, is the clearance between the sliding material on the guide bar and its opposing surface.
It is illustrated in the above drawings, for specific types of bearing, but must be measured for all guided sliding
bearings.
The guidebar gap should be measured in the four sectors of the bearing, A, B, C and D (which contain the
measurement points A, B, C and D in horizontal section X‐X below, respectively).
The values measured for s3 at both sides of the bearing at each end of the sliding plate must be added together
(i.e. A + B, and separately C + D) to determine the total transverse movement capacity of that end of the
bearing.
Depending on the calculated values, the following actions must be taken:
Acceptance criteria: s3total (A+B, or C+D) 0.2 mm and 2.0 mm.
When to take action: If s3total is outside the above limits, then the situation must be discussed with
the bridge engineer and mageba, to determine if remedial action is necessary.
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4.6.8.4 Details and recording of results
Locations A, B, C and D as referred to in the preceding sections are defined on the following Horizontal
Section X‐X:
Direction of main sliding movement
(if any)
Horizontal Section X‐X
The measured gap widths should be inserted into the following section of the Inspection Report (Appendix
1), and average values calculated and conclusions drawn (e.g. “OK” / “Not OK – See below”) as indicated.
Type of action
Element of Inspection Results / Remarks
(see section 4.3)
(8.1) Sliding gap h (4 locations) A: B: C: D:
– sliding bearings only
[4.6.8.1] Conclusion:
(8.2) Tilting gap s1 (4 locations) A: B: C: D:
‐ tilting bearings only
[4.6.8.2] Average = (A+B+C+D)/4 = _____ Conclusion:
(8.3) Guidebar clearance s3 (4 sectors) A: B: C: D:
– guided sliding bearings only
[4.6.8.3] A+B= _____ Conclusion: C+D= _____ Conclusion:
The initial sliding, tilting and guidebar gaps must be measured shortly after the structure has been put into
service, in order to have a reference for later measurements.
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5 MAINTENANCE
In general, mageba bearings are largely maintenance‐free during their design life, apart from regular
inspections and cleaning, and renewal of corrosion protection as appropriate. However, unexpected damage
may occur at some time. If the above instructions are not appropriate for any given situation, mageba should
be consulted. Refer also to Sections 6 and 7 of this manual for comments relating to competence of workers
and supervision of the work.
5.1 Repair work on bearing
Minor repair work may be done by skilled workers with suitable experience. However, these bearings are
specialised pieces of equipment, and adjustment or repair requires appropriate training and experience. Such
work can impact negatively on the condition and functioning of the bearing if not carried out correctly.
Therefore the following rule should generally be considered to apply, except if otherwise agreed in writing
with mageba:
Any repair work having an influence on the functioning of the bearing must be carried out or supervised by
mageba or mageba’s appointed bearing experts.
mageba bearings use specific components that ensure proper functioning of the bearing as a complete unit.
Therefore, only original mageba components should be used.
5.2 Repair of corrosion protection
Damaged or otherwise defective/inadequate corrosion protection should be addressed as soon as possible to
prevent it from deteriorating. Appendix 13 describes the recommended repair procedure and materials.
5.3 Recording of work carried out
All work carried out should be recorded. A photographic record should be created using a digital camera. After
completion of all works and all necessary measures have been taken and confirmed, all reports and records
must be carefully filed for future reference
6 COMPETENCE OF INSPECTION AND MAINTENANCE PERSONNEL
Inspection and maintenance of bridge bearings must be carried out by competent and properly
informed/inducted personnel. These should have good knowledge of mechanical structures in general and of
the relevant type of bridge bearing in particular.
Inspection personnel should be appropriately trained to detect slight changes in the condition of the bearing
or of the adjacent bridge structure, and provided with the appropriate information and records (including
drawings and records of previous work and inspections) to enable them to undertake the work properly.
Should repair work be required for any reason, in particular any work which could impact on the correct
functioning of the bearing, mageba should be consulted in advance.
7 SUPERVISION OF INSPECTION AND MAINTENANCE WORK
All work should be carried out under the supervision of a suitably qualified and competent professional bridge
engineer, who should ensure the appropriateness of the actions taken, the competence of the staff, and the
correct completion and recording of the work, and be ultimately responsible for all work.
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APPENDIX 1: INSPECTION REPORT
Date of inspection: Name and company of inspector:
Bearing No. (according to drawing): Drawing No. (refer Appendix 12):
Bearing location (according to drawing): Type of bearing:
Avg. bridge temperature during inspection (°C/F): Time of inspection (start, end):
Type of action
Element of Inspection Results / Remarks
(see section 4.3)
(1) Condition of steel and its corrosion
protection [4.6.1]
(2) Condition of elast. block [4.6.2]
‐ bearings with elast. blocks only
(3) Condition of bolts / anchorages
[4.6.3]
(4) Condition of welds
[4.6.4]
(5) Condition of connecting bridge
structure [4.6.5]
(6) Condition of sliding surfaces [4.6.6]
‐ sliding bearings only
(7) Movement capacities [4.6.7]
‐ sliding/deforming bearings only
(8.1) Sliding gap h [4.6.8.1] A: B: C: D:
‐ sliding bearings only
(4 locations) Conclusion:
(8.2) Tilting gap s1 [4.6.8.2] A: B: C: D:
‐ tilting bearings only
(4 locations) Average = (A+B+C+D)/4 = _____ Conclusion:
(8.3) Guidebar clearance s3 [4.6.8.3] A: B: C: D:
‐ guided sliding bearings only
(4 sectors) A+B= _____ Conclusion: C+D= _____ Conclusion:
Further comments on condition
(incl. dust protection, mortar bed etc.)
Were photographs taken? If so, where
are they saved?
APPENDIX 2: POT BEARINGS
A mageba RESTON®POT bearing typically contains parts as shown on the following cross‐section of a typical
Type TE (guided sliding) bearing.
Note that certain features, such as anchor plates, are optional, and that the type of guided sliding bearing
shown has external guide bars (as opposed to internal guide bars which are often used for large bearings).
Anchorage: Screwed dowels
(or welded studs)
Sliding interface:
Anchor plate (optional)
Stainless steel on sliding plate,
Sliding plate PTFE/Robo®Slide on piston
Guide bars (each side of piston)
Piston
Elastomeric pad Pot
The build‐up of the various types of pot bearing is illustrated by the following exploded views.
Free sliding (Type TA): Guided sliding* (Type TE): Fixed (Type TF):
* with external guide bars
Further information about pot bearings can be found in mageba’s product brochures or on the mageba website.
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APPENDIX 3: SPHERICAL BEARINGS
A mageba RESTON®SPHERICAL bearing typically contains parts as indicated on the following cross‐section
showing a typical guided sliding bearing.
Anchorage: Screwed dowels
(or welded studs)
Sliding interface: Stainless
Anchor plate (optional)
steel on sliding plate,
Sliding plate PTFE/Robo®Slide on calotte
Guide bars Calotte
(each side of
base plate) Concave base plate Rotation interface:
Hard chrome finish on calotte,
Robo®Slide on base plate
The build‐up of the various types of spherical bearing is illustrated by the following exploded views.
Free sliding (Type KA): Guided sliding (Type KE): Fixed (Type KF):
Further information about spherical bearings can be found in mageba’s product brochures or on the mageba
website.
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APPENDIX 4: DISC BEARINGS
A mageba RESTON®DISC bearing typically contains parts as shown on the following cross‐section of a typical
Type DE (guided sliding) bearing.
Anchorage: Welded studs Sliding interface:
(or screwed dowels) Stainless steel on sliding plate,
PTFE/Robo®Slide on upper plate
Anchor plate (optional)
Sliding plate Guide bars
Upper plate (each side of upper plate)
PU Disc
Base plate
Anchor plate (optional)
The build‐up of the various types of disc bearing is illustrated by the following exploded views.
Free sliding (Type DA): Guided sliding (Type DE): Fixed (Type DF):
Further information about disc bearings can be found in mageba’s product brochures or on the mageba
website.
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APPENDIX 5: LINEAR ROCKER BEARINGS
Mageba’s linear rocker bearings are known by the name RESTON®LINEAR. These typically contains parts as
shown on the following illustration (exploded view) of a typical Type LGe (guided sliding) bearing.
Sliding plate with stainless
steel on lower surface
Guide bar for sliding interface
PTFE/Robo®Slide of sliding interface
Key for transfer of transverse
forces at rotating interface Holes for keying of steel parts
(Type LGe bearings only) across the rotating interface
Holes for anchor bolts
The main variations are as follows:
Further information about linear rocker bearings can be found in mageba’s product brochure or on the mageba
website.
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APPENDIX 6: HORIZONTAL FORCE BEARINGS
Mageba RESTON®FORCE horizontal force bearings are designed to resist significant horizontal forces without
resisting any vertical loads, like shear keys. Two main types are available, depending on whether the bearing
should resist loads in all horizontal directions or not:
‐ RESTON®FORCE Type S bearings resist forces (and movements) in all horizontal directions
‐ RESTON®FORCE Type F bearings allow movements along one horizontal axis and resist all transverse
forces (and movements)
RESTON®FORCE Type S RESTON®FORCE Type F
Piston of
Level of bottom
upper part
of superstructure
Level of top
of substructure
The following pictures show RESTON®FORCE horizontal force bearings as installed in bridges.
RESTON®FORCE Type S RESTON®FORCE Type F
Further information about horizontal force bearings can be found in mageba’s product brochure or on the
mageba website.
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APPENDIX 7: ELASTOMERIC BEARINGS
Mageba’s elastomeric bearings are known by the name LASTO®BLOCK. The
basic version, known as Type NB, is simply an elastomeric block, of natural
rubber (NR) or chloroprene rubber (CR), which may or may not feature
internal steel reinforcing plates.
LASTO®BLOCK bearings can facilitate movements by deformation of the
elastomer. In many cases, the bearing must be anchored to prevent its
becoming displaced, and to control the deformations (movements) and/or
equip the bearing to resist longitudinal or transverse forces. In such cases,
the bearing typically has steel plates vulcanised into its top and/or bottom
surfaces, and separate steel anchor plates. The following cross‐section shows
a typical Type NBa (free deforming) bearing.
Anchorage: Screwed dowels
(or welded studs)
Anchor plate (optional)
Elastomeric block with
horizontal steel
reinforcing plates
Steel plate vulcanised
into lower surface of
elastomeric block
Steel keys to resist
horizontal loads and
prevent displacement
of elastomeric block
The main variations are as follows:
Free deforming (Type NBa): Guided deforming (Type NBe): Fixed (Type NBf):
A mageba elastomeric bearing featuring a PTFE (Teflon) or Robo®Slide sliding surface on one side, which can
thus facilitate movements by sliding as opposed to deformation, is known by the name LASTO®FLONBLOCK
(whereby FLON stands for Teflon).
Further information can be found in mageba’s product brochure or on the mageba website.
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APPENDIX 8: HIGH DAMPING RUBBER BEARINGS (HDRB)
A mageba LASTO®HDRB seismic isolator typically contains parts as shown on the following illustration.
Anchor plate (optional)
Connectors to transfer
horizontal loads
Elastomeric block with
horizontal steel reinforcing plates
Anchor plate (optional)
The following picture shows a LASTO®HDRB seismic isolator as installed in a bridge.
Further information about LASTO®HDRB seismic isolators can be found in mageba’s product brochures or on
the mageba website.
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APPENDIX 9: LEAD RUBBER BEARINGS (LRB)
A mageba LASTO®LRB seismic isolator typically contains parts as shown on the following illustration.
Anchor plate (optional)
Connectors to transfer
horizontal loads
Elastomeric block with
horizontal steel reinforcing plates
Lead core
Anchor plate (optional)
The following picture shows LASTO®LRB seismic isolators as installed in a bridge.
Further information about LASTO®LRB seismic isolators can be found in mageba’s product brochures or on the
mageba website.
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APPENDIX 10: CURVED SURFACE SLIDER SEISMIC ISOLATORS
Mageba’s curved surface sliders, from mageba’s range of seismic isolators, are known by the name
RESTON®PENDULUM. The main variations are as follows (illustrated by 3D sections, and cross‐section drawings
showing bearing in both service case (central) and seismic case (extreme horizontal movement):
RESTON®PENDULUM Mono (featuring a single primary sliding surface for displacements):
RESTON®PENDULUM Duplo (featuring two primary sliding surfaces for displacements):
Further information about curved surface sliders can be found in mageba’s product brochures or on the
mageba website.
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APPENDIX 11: TOOLS FOR INSPECTION
For an inspection including all the previously mentioned elements, the following tools should be available to
the inspector:
Measuring tape
Spirit level
Feeler gauge for sliding gap, measuring range 0 ‐ 2 mm
Telescopic gauge for tilting gap, measuring range 20 ‐ 50 mm
Two straight edges (typically of lengths 300mm and 500mm) for control of flatness of sliding surface
Blunt scraper and brush/cloths for cleaning
Camera to create photographic records
Thermometer
Optional: Corrosion protection thickness measuring device
Optional: Torque‐measuring spanner
Feeler gauge Telescopic gauge
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APPENDIX 12: DRAWINGS
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APPENDIX 13: REPAIR OF CORROSION PROTECTION
1. Aim
‐ The adequate rectification of all corrosion protection defects on site.
‐ Assuring a lifetime of the site‐made corrosion protection like the corrosion protection in the workshop.
2. Scope
‐ Each corrosion protection defect which must be repaired on site.
‐ This work instruction is only valid if the below‐mentioned products are used.
3. Products
‐ Stelpant–PU–Zinc (by Steelpaint)
‐ Stelpant–PU–Mica (by Steelpaint)
‐ Stelpant–PU–Repair (by Steelpaint)
Generally, the use of zinc spray is not allowed.
4. Application
The following steps must be executed according to the manufacturer’s recommendations:
1) Wire brushing by hand or powertool and cleaning of the affected area.
2) The standard grade of cleanliness PMa (according to EN ISO 12944‐4) is to be achieved at minimum.
This may be achieved e.g. by sandblasting with broken mineral grit or by grinding. Poorly adhering mill
scale, rust, paint coatings and foreign matter are to be removed. After treatment, the surface should
have a metallic sheen. If this surface preparation is not possible, the primer coat Stelpant–PU–Repair
must be applied (20µm).
3) Application of Stelpant–PU–Zinc by brush (80µm).
4) Allow drying time as specified by the product’s data sheet.
5) Application of Stelpant–PU–Mica by brush (2 x 80µm).
6) Allow drying time as specified by the product’s data sheet.
7) Application of Stelpant–PU–Mica by brush (1 x 80µm) with the correct colour shade as required.
8) Allow drying time as specified by the product’s data sheet.
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If correctly installed, and inspected and maintained in accordance with this manual, mageba structural
bearings can be expected to perform well for many years – as demonstrated by the thousands of bridges
around the world that already rely on mageba bearings. Please enable your bearings to perform just as well.
RESTON®POT bearings: Hong Kong Convention Center, with
RESTON®SPHERICAL bearings: Tran Thi Ly Bridge, Vietnam,
loads of up to 209,000 kN on a single bearing each carrying loads of up to 250,000 kN
RESTON®DISC bearings: Bandra Worli Sea Link, India LASTO®BLOCK bearings: Oakland Airport shuttle train, USA
RESTON®PENDULUM seismic isolators: Stavros Niarchos
RESTON®UPLIFT bearings: Golden Ears Bridge, Canada ‐
Foundation Cultural Center, Athens, Greece Precompressed uplift bearings allowing 3.1m movements
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Notes / sketches
WORLDWIDE CONNECTIONS
HEADQUARTERS / SWITZERLAND
mageba sa
Solistrasse 68
8180 Bülach ‐ Switzerland
Tel. +41 44 872 40 50
info@mageba.ch
www.mageba.ch
AUSTRALIA AUSTRIA CANADA / LATIN AMERICA CHINA
mageba (Australia) Pty Ltd mageba gmbh mageba International LLC mageba (Shanghai) Ltd.
17 Manto Street Böhmerwaldstraße 39 575 Lexington Avenue 4th Floor No. 388 Bei Huan Road
Bungarribee NSW 2767 4600 Wels New York, NY 10022 Shanghai (201402)
Australia Austria USA China
Tel. +61 423 182 913 Tel. +43 7242 469910 Tel. +1 212 317 1991 Tel. +86 21 5740 7637
info@mageba.com.au info@mageba.at info@mageba.net info@mageba.cn
www.mageba.com.au www.mageba.at www.mageba.net www.mageba.cn
CROATIA CZECH REPUBLIC GERMANY HUNGARY
mageba Adria d.o.o. mageba CS s.r.o. mageba gmbh mageba Hungary Kft.
Karlovačka cesta 4c Novoměstská 1c Im Rinschenrott 3a Ipari u. 5
Lanište, 10020 Zagreb 621 00, Brno 37079 Göttingen 4461 Nyírtelek
Croatia Czech Republic Germany Hungary
Tel. +3851 6142 390 Tel. +41 44 872 40 50 Tel. +49 551 389 040 Tel. +36 42 210 424 Mellék 12
info@mageba.hr info@mageba.ch germany@mageba.ch info@mageba.hu
www.mageba.hr www.mageba.ch www.mageba‐germany.de www.mageba.hu
INDIA MEXICO RUSSIA SOUTH KOREA
mageba bridge products Pvt. Ltd. mageba Mexico mageba St. Petersburg mageba (Korea) Co., Ltd.
45, Jhowtala Road Av. Patriotismo No. 229, Piso 8 Vladimirsky Pr. 23, lit. A, off. 705 Hanshin Intervalley 24 Bldg.,
3rd Floor Col. San Pedro de los Pinos, 191002, St. Petersburg West Hall #1118, Teheran‐ro 322
700 019 Kolkata CP 03800, Mexico D.F. Russia Gangnam‐gu, Seoul 135‐918
India Mexico Tel. +7 812 313 92 81 South Korea
Tel. +91 33 229 00 250 Tel. +52 55 2881 0260 info@mageba‐russia.ru Tel. +82 2 2183 2020
info@mageba.in info@mageba.mx www.mageba‐russia.ru info@mageba.co.kr
www.mageba.in www.mageba.mx www.mageba.co.kr
TURKEY UNITED KINGDOM USA (EAST) USA (WEST)
mageba Türkiye A.Ş. mageba (UK) Ltd. mageba USA LLC mageba USA LLC
Marmara Geri Dönüşümcüler 77 Leonard Street 575 Lexington Avenue 4th Floor 188 Hillsdale Avenue
San.Sit. Şekerpınar Mah. EC2A 4QS New York, NY 10022 San Jose, CA 95136
Ayçiçeği Sk. No:17 London ‐ England USA USA
Çayırova / Kocaeli ‐ Turkey Tel. +41 44 872 40 50 Tel. +1 212 644 3335 Tel. +1 408 281 9700
Tel. +90 262 658 23 80 info@mageba.ch east@magebausa.com west@magebausa.com
info@mageba.com.tr www.mageba.ch www.magebausa.com www.magebausa.com
www.mageba.com.tr