Even the highest-quality, most expensive expansion joint systems are guaranteed to fail if installed incorrectly. In Saudi Arabia’s challenging construction environment, we have seen costly failures on projects where these critical systems were treated as an afterthought or installed by non-specialists. The result is almost always the same: water leaks, cracked finishes, and significant safety hazards.

These failures are not product failures; they are installation failures. Understanding these common mistakes is the key to protecting your investment and ensuring your building performs as designed.

Failure 1: The Failed Waterproofing Tie-In

This is the single most common and most damaging failure for any exterior joint (roofs, parking decks, plazas). A non-specialist installer will often just lay the joint’s built-in membrane (“wing”) on top of the concrete and hope the cover plate keeps water out. It will not.

The Correct Method: A specialist installer meticulously integrates the joint’s vapor barrier with the deck’s primary waterproofing membrane. This often involves heat-welding, chemical bonding, or specialized termination bars to create a single, seamless, 100% watertight system. A failure here guarantees leaks to the floors below.

Failure 2: Incorrect Fire Barrier Installation

For life-safety, this is the most critical error. To meet Saudi Building Code (SBC), any joint in a rated barrier must include a fire-rated assembly. We often find these barriers installed incorrectly:

• Improper Compression: The fire blanket is “stuffed” into the gap too loosely and will fall out, or compressed too tightly, which damages its integrity.
• Incorrect Splicing: The blanket sections are not overlapped or spliced according to the UL-listed system, creating gaps for fire.
• Wrong Material: A standard (non-fire-rated) foam backer rod is used instead of the specified high-temperature mineral wool or ceramic fiber.

Failure 3: Poor Substrate Prep & Ignoring Block-Outs

Many systems, especially flush-mount floor joints, are designed to be installed into a precise concrete “block-out” or recess. General contractors often pour the slab flat, forcing the installer to surface-mount the joint. This creates a prominent “speed bump” that is a major trip hazard and is easily damaged by carts or traffic. The concrete edges must be clean, level, and sound for the joint anchors to hold properly.

Failure 4: Choosing the Wrong System for the Load

This is a selection error that leads to an installation failure. A non-specialist may install a lightweight, pedestrian-grade joint (meant for a mall corridor) in a hospital service area or back-of-house. The first time a heavy-laden cart or vehicle rolls over it, the cover will break, bend, or dislodge, creating a dangerous hazard. A specialist would have identified the load class and installed a heavy-duty or all-steel system.

“In our experience repairing failed projects, 90% of expansion joint failures are not due to the product. They are due to the installation. It is a specialist task, not a general one.”

Conclusion: Installation is Everything

As our past projects demonstrate, the long-term performance of expansion joint systems is 100% dependent on the quality of the installation. These are complex systems that integrate with a building’s waterproofing, fire safety, and structural integrity.

As a core part of our specialized architectural services, we ensure that every system is selected correctly and installed with the precision required to prevent these common, costly failures, guaranteeing a safe, compliant, and durable building.

Don’t risk a costly failure. Get your expansion joint systems installed right the first time.

Contact Our Certified Installation Team Today