Expansion joints are a critical part of any concrete slab, they allow the concrete to expand and contract with temperature changes without cracking. The Connolly EXJ Expansion Joint System is a professional-grade solution designed for easy, accurate installation in commercial and residential concrete projects.
Here's a step-by-step guide to installing the Connolly EXJ system correctly.
What You'll Need
- Connolly EXJ Expansion Joint profile
- Supplied pegs and wedges
- Universal Dowel Sleeves and dowels
- Permanent capping or rebate mould (if applicable)
- Reinforcement mesh or rebar
- Sealant (if using rebate mould)
- Hammer
- Concrete and finishing tools
Step-by-Step Installation Guide
Step 1 — Fit the Capping or Rebate Mould (If Applicable)
If you are using a permanent capping or a rebate mould, push it firmly onto the top of the EXJ system prior to placement. Ensure it is fully seated before proceeding.
Step 2 — Position the Profile and Drive in the Pegs
Place the expansion joint profile in the desired location on the substrate. Drive in the supplied pegs to hold the profile in position. Ensure the top of each peg sits at least 20mm below the intended finished concrete level — this is critical to avoid the pegs interfering with the surface finish.
Step 3 — Adjust Height and Secure with Wedges
Adjust the profile to the correct height to match your intended finished slab level. Once at the correct height, secure the profile firmly by tapping in the supplied wedges. Check the profile is level and straight before moving on.
Step 4 — Insert Dowels into the Universal Dowel Sleeves
Insert the dowels into the Universal Dowel Sleeves, pressing each dowel all the way to the end of the sleeve. Full insertion ensures correct load transfer across the joint once the concrete is poured.
Step 5 — Install the Universal Dowel Sleeve into the Profile
Install the Universal Dowel Sleeve into the profile by pushing the dowel through the foam at the centre of the pre-punched holes. Twist the sleeve 90 degrees to lock it firmly in place. The sleeve should be secure and not able to move during the pour.
Step 6 — Place Reinforcement and Pour Concrete
Place your reinforcement mesh or rebar to both sides of the expansion joint. Pour concrete evenly to both sides of the joint at the same time — this is important to prevent the profile from shifting or tilting during the pour. Finish the surface as normal and ensure the top of the joint profile is clear of any concrete.
Step 7 — Remove Profile and Apply Sealant (Rebate Mould Only)
Once the concrete has sufficiently set, pull out the top profile. Apply sealant to the manufacturer's specifications to seal the joint.
Note: This step only applies when a rebate mould is used.
Key Installation Tips
- Always ensure pegs are driven at least 20mm below the finished concrete level
- Pour concrete evenly to both sides of the joint simultaneously to keep the profile stable
- Keep the top of the joint clear of concrete during finishing
- Twist dowel sleeves a full 90 degrees to ensure they are locked in place
- Check the profile is level and at the correct height before pouring
Why Use the Connolly EXJ System?
The Connolly EXJ Expansion Joint System is engineered for precision and reliability. The Universal Dowel Sleeve design allows for movement across the joint while maintaining load transfer, essential for slabs subject to heavy traffic or significant temperature variation. The system is suitable for both commercial and residential applications.
For technical support or product enquiries, contact Connolly on Freecall: 1800 335 215 or visit connollykeyjoint.com.
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