Insert Plate ArmourMate

Joint Edge Protection

Insert Plate
ArmourMate
Joint Edge Protection
INDUSTRIAL SLAB ON GROUND

Accommodates larger

concrete shrinkage gaps

Facilities thermal
movement

Prevents spalling on
construction joints

Extends the life-cycle of

the floor and the asset

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Insert Plate ArmourMate

Joint Edge Protection

Features

Product Description

1. A drop in cover plate that can be re-sized and retrofitted to bridge

large joint gaps

Insert Plate ArmourMate systems are designed

to provide the total joint system solution by
incorporating three systems in the one solution, being
the Insert Plate ArmourMate steel angles and plate
as the armour edging, the Square Dowel and Flanged
Dowel Box as the load transfer system and the
galvanised separation plate as the sacrificial formwork
that takes place of the traditional wooden formboard.

2. Used with high capacity Grade 300 square dowels and Flanged
Dowel Boxes.
3. Shear Studs tested at 34 kN breaking strain, shears at shank.
4. The cover plate covers the joint gap between slabs preventing
debris from filling joint gap.

Insert Plate ArmourMate is made to customer

specification and is designed to be used in situations
where larger shrinkage and thermal movement is
expected. It allows for future expansion with each
replacement plate used in the joint. The plate over the
gap provides a smooth ride for traffic travelling over
the joint, minimising wheel damage and impacts.

5. Patented twist and lock stake bracket system for an easy setup.

Insert Plate ArmourMate replacement plates are

available to customer specification. The standard
65 mm plates are designed to open up to 15 mm, if
more movement is required or the gap at the top
of the concrete needs to be reduced replacement
plates can be ordered to suit.

6. Galvanised formwork plate on all systems.

Advantages

Insert Plate ArmourMate provides slab

edge protection to prevent concrete spalling.

Range Options

Full Joint Systems specifications

Black or hot-dip galvanized steel

to AS/NZS 4680

Multiple dowel options

Infill lengths available on request

Made to custom configurations

Removable cover plate

I ncorporates the joint cover, edge protection, load transfer device

and formwork in a single system.
Provides slab edge protection to prevent concrete spalling.
The cover plate remains supported either side of the gap once the
joint has opened up.
Smooth wheel transition over large gap openings.

Benefits
Concreter Benefits

Asset Protection Benefits

Full system configuration

eliminates formboards.

Reduces concrete spalling

damage at the joints.

Staking system eliminates

Hot Work (on-site welding).

Provides a safer operating

environment for tenant
employees.

Twist and lock stake system

provides fine height and
level adjustment.
Provides a straight edge
and screed rail.

Extends the life-cycle of the

asset by protecting the floor.
Reduces floor maintenance
and downtime costs over the
lifecycle of the facility.
Increased tenant satisfaction
and return on investment.

Engineering Benefits
Provides a bridge across
the construction joint.

Transfers load across the joint

and into the slab panel.

Provides the ability to resize

and retrofit the coverplate.

Accuracy of dowel placement

ensures the most effective load
transfer performance.

Facilitates movement while

maintaining cover over
joint gap.

(1)

Insert Plate ArmourMate

Joint Edge Protection

Joint Section - After Sab Shrinkage

Removable sliding cover plate

Initial movement 15 mm max. due to slab shrinkage *

Armoured edge

Cover plate covers

joint gap eliminating
the need for fillers

* Initial cover plate (65 mm) allows for a maximum of 15 mm joint opening. Additional opening can be accommodated by replacing the initial cover plate with a wider
custom cover plate giving an additional 15 mm of opening.

Joint Section - At Install

Field and Product Support

We pride ourselves on our ability to provide on-site
product and installation support. Our field sales and
support teams are available to advise and work side
by side with the industry when on site clarification or
problem solving is required.
Material Technical Data
COMPONENT

DIMENSION
(mm)

MATERIAL TYPE

MATERIAL
STANDARDS

STEEL GRADE
EQUIVALENT

YIELD
STRESS
(MPa)

TENSILE
STRENGTH
(MPa)

STANDARDS
COMPLIANCE

Angles

50 x 50 x 6

Hot Rolled
Steel

AS/NZS 3679.1

Grade 300

340

500

AS/NZS 3679.1

Flat

20 x 10

Hot Rolled
Steel

AS/NZS 3679.1

Grade 300

365

520

AS/NZS 3679.1

Insert Plate

65 x 10

Hot Rolled
Steel

AS/NZS 3679.1

Grade 300

345

510

AS/NZS 3679.1

Shear Stud

100 x 10

Cold Drawn

DIN 1.040 C22

1010

415

520

AS1443

Formwork

1.95

Galv. G2 Z275

AS1365

Grade 300

340

370

AS1397

Square Dowel

20 x 20 x
400

Mild Steel Bar

AS/NZS 3679.1

Grade 300

360

510

AS/NZS 3679.1

Flanged
Dowel Box

0.77

Galv. G2 Z275

AS1365

Grade 300

310

360

AS1397:2011

Manufacturing Tolerances
OVERALL LENGTH

2 mm

OVERALL HEIGHT

1 mm

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Insert Plate ArmourMate

TOOLS REQUIRED: Danley Stakes (Six Per Length) | Hammer

Small Shifter | Spirit Level | String Line | Extra Bracing
And Stakes As Required (Customer To Supply) | Cordless Drill
3.5 mm X 20 mm Self-Tapping Screws | Drill Bit

Step 1.

Step 4.

INSTALLATION

INSTALLATION

Install the separately supplied Flanged Dowel Boxes using the self-tapping
screws at the provided dowel cut-outs, ensuring the flange is facing towards
the top of the joint.

Step 2.
INSTALLATION

Check sub-grade for levelness and grade. Set a string line along the joint path
and position the first length of ArmourMate.
Ensure the sleeves go on the side of first concrete pour will occur. Insert stakes (six per
length) through the stake brackets attached to the ArmourMate separation plate.
Hammer the stakes into the ground until they are 50mm below the top of
the joint. Additional staking and bracing may be required to keep sections
steady during the concrete pour.

The ArmourMate length are flush on the ends. They need to be joined
together with the supplied joiner plate and fixing bolts.
Ensure a 5 mm gap is left between each length. This allows for the lateral
movement of the joint. Repeat the process for each section until the desired
length is achieved.

Step 5.
INSTALLATION

Install the any required concrete reinforcing. Pour the concrete insuring to
vibrate along the joint at regular intervals.
The top of the ArmourMate rails can be used to screed along.

Step 3.

Step 6.

INSTALLATION

INSTALLATION

Adjust the height of the joint until it is level and at the required slab depth.
Turn the stakes 90 degrees using the shifter to lock the joint in place.

After the first pour has set remove any additional staking. Place the dowels
through the separation plate slots into the sleeves in the first pour before
pouring the second pour. Dowels should be placed within 36 hours of the
first pour.

(3)

Installation

Installation Process
(Initial Setup)

Joint Edge Protection

Insert Plate ArmourMate

Joint Edge Protection

Joint Placement For Mesh Reinforced Slabs

Correct Mesh Placement - The following points are recommended when placing mesh at the joint
1. Mesh should be located externally of stud position
2. The mesh should be supported by bar chairs to rest
approximately of the slab height.
3. The mesh should never rest on the dowel or the dowel cover.

4. The mesh edge should be located approximately 50 mm from

the formwork plate (on either side).
5. Continuous mesh wire should be broken at the edge of the
sheet to prevent cracking. Failing to do so may induce a crack
in-line with the edge of the mesh.
6. Dowel sleeves should always be located on the stake bracket
side of the joint.

Mesh Reinforced Slab Design - Typical Install

Mesh to be spaced a minimum of 50 mm from the joint (either side)

Slab height
(5%)

Slab height

Reinforcing mesh
supported by bar chairs
( the slab cover)

Thermal Movement Gap Detail

Movement Gap - Plan Detail

Please Note: During installation a 5 mm min. gap must be provided between lengths to allow for any thermal movement of the joint.
(4)

5 mm min.

Insert Plate ArmourMate

Joint Edge Protection

IMPORTANT - Replacing anchors on-site cut lengths

If Danley ArmourMate rails are cut to length on-site, and the remaining
anchors on the rails are in excess of 100 mm from the cut, it is the
responsibility of the contractor to secure an anchor or anchors onto
the rail to be cast into the concrete, before pouring concrete. The
replacement anchor or anchors may be removed from the off-cut, or
a device similar to the anchor on the off-cut may be used; and should
be tack welded to the rail within 75 mm of the cut end.

Similarly, it is the responsibility of the contractor, when setting out

the ArmourMate rails prior to pouring concrete, to examine the
location of any saw-cut contraction joint that may pass through the
ArmourMate rails, and add additional anchors within 75 mm each
side of the proposed saw-cut on each side of the rail. Both these
actions will ensure that the ends of the Danley ArmourMate rails
are anchored appropriately when the concrete is poured.

Insert Plate ArmourMate Typical Stud Placement (Plan View)

Max. 75-100 mm
from cut infill ends

Max. 75-100 mm from

soff saw-cut (both sides)

Cut infill end

Weld loose stud

to rail on-site

Soff saw cut

Typical Companion Product

Flanged Dowel Boxes
Flanged Dowel Boxes are multi-directional metal sleeves with high capacity square dowels. They are attached
to metal or wooden formwork with integral nailing flanges and location marks. They allow for both contraction
and expansion at the joint, as well as having a large lateral movement capacity. They are designed for construction
joints in both ground and elevated slabs and are available in a number of different standard sizes.

dowel length
Square dowel inserted
into Flanged Dowel
Box after first pour

Second pour

First pour

(5)

Compressible foam
in sleeve allows for
expansion capacity

Insert Plate ArmourMate

Joint Edge Protection

Insert Plate Installation Steps (Replacement Plate)

Insert Plate ArmourMate Replacement Plates are made to customer specification. The standard 65 mm plates
are designed to open up to 15 mm, if more movement is required or the gap at the top of the concrete needs to
be reduced replacement plates can be ordered to suit. It is the responsibility of the customer to conduct on site
measuring to determine the plate lengths, widths and hole locations.

Insert Plate ArmourMate Dimension Details (Replacement Plates)

Length to be specified by customer
W
Bolt centres
Width to be specified by customer
Common Widths
75 mm, 90 mm,
100 mm and 110 mm

TOOLS REQUIRED: Tape Measure | 5 mm Hex Key Drill Bit Or

Allen Key | Cordless Drill | Flat Head Screw Driver

Step 1.

Step 3.

INSTALLATION

INSTALLATION

The existing joint openings need to be measured to calculate required

replacement plates widths. Any infills need to be measured for required
length and bolt centres as well. This should be recorded and submitted to
Danley for quoting and manufacturing.

Step 2.
INSTALLATION

Once the plates have been received the old insert plates can be removed
by undoing the screws and star washers with the 5 mm Hex Key drill bit
and drill. Please keep the screws for reuse.

Ensure that the channel is free of any debris or concrete by scraping with
a screwdriver and place the new width plate where the previous had been
making sure to align the holes in the plate with the holes in the cast in
angles.

Step 4.
INSTALLATION

The screws can be reinserted in the holes and fastened with the drill.
Old insert plates can be discarded or kept for spare parts.

(6)

Installation

Replacement Insert Plate

Installation Process

Insert Plate ArmourMate

Durability Testing

Joint Edge Protection

APPLICATION

HYPER

PLATE 60

INSERT
PLATE

Small, hard wheeled traffic (pallet jacks)

Cushioned wheel traffic (forklifts & trucks)

Heavy loads

Warehouse internal slabs

External slabs, pavements & carparks

Large slab shrinkage & movement at joint (PT)

Our in-house test rig is on the job

consistently running cycle testing for
durability of our Insert Plate ArmourMate.

High FF & FL floors

JOINT

STOCKED

POUR
THROUGH

EXPANSION
JOINTS

Hyper ArmourMate
(Full Joint)

Hyper ArmourMate
(Top Rail)

POST
TENSIONING

DIAMOND
DOWEL

FLANGED
DOWEL BOX

INFILLS

INTERSECTIONS

Plate 60 ArmourMate

Insert Plate
ArmourMate

(7)

Insert Plate ArmourMate

Joint Edge Protection

Project Information
The Insert Plate ArmourMate technology was used within an
RAAF (Royal Australian Air Force's Base) development project
located 8 km southwest of Ipswich. Insert Plate ArmourMate
was predominantly used as the Armour Edging, for its effective
ability to remove and replace the cover plate.

Location

Amberley, QLD

Client

Leightons Contracting

Installer

QR Concrete

Specifier
SKM

Installation Date
March 2014

Site Photos

Danley Products Used

Insert Plate ArmourMate

Diamond Dowel
Plate Dowel Cradle

(8)

Case Study

RAAF Base Warehouses

Insert Plate ArmourMate

Joint Edge Protection

Specification

How to write a (custom) specification

Product specification for custom Insert Plate ArmourMate
consists of a standard full joint system.
In order for Danley to help with your project requirements please
have the following information available for when you contact your
sales representative.

REQUIRED INFORMATION FOR QUOTATION

Slab Height

Joint Finish
(Blk/Galv.)

Roadbase
(10 mm Typical)

Dowel Type

Dowel Size

Dowel Centres

Stand or Stakes

Slab height

Slab height

Section At Joint - When Poured

Specified roadbase
(10 mm typ.)

Dowel type/size

Insert Plate ArmourMate (Full Formwork Systems) - Dimension Details

3000 mm overall length

Slab height

Dowel centres as specified

(9)

Insert Plate ArmourMate

Joint Edge Protection

Local Manufacture
We pride ourselves in being a local manufacturer
of Edge Protection Systems in Australia with all
systems being fabricated and assembled at our QLD
manufacturing facility in Morningside, Brisbane.
Maintaining local manufacture and growth in
Australia generates local employment and ensures
we are able react quickly to providing non-standard
design solution for tough applications.

Danley Insert Plate Armourmate Panel Layout

Construction Joints
ArmourMate or loose dowels (Flanged
Dowel Box) positioned around the
perimeter of each concrete pour.

Contraction Joints
Square Dowel Cradles positioned
at the soffcut joint lines.
Typical 30 x 30 meter slab panel.
( 10 )

1.

Companion Products
1. Flanged Dowel Box
Flanged Dowel Boxes are multi-directional metal sleeves with high capacity square dowels. They are able to be
attached to metal or wooden formwork with ease there integral nailing flanges and location marks. They allow for
both contraction and expansion at the joint, as well as having a large lateral movement capacity. They are ideal for
construction joints in both ground and elevated slabs and are available in a number of different standard sizes.

2.

2. Square Dowel Cradle

Square Dowel Cradles are designed to provide a total contraction joint system solution by incorporating two systems
in the one solution. The square dowels act as the load transfer system with the dowel sleeves to provide lateral and
longitudinal movement capabilities and reduces the risk of restraint. The wire cage acts as a chair and spacer to ensure
the dowels are aligned and maintained at the correct height and spacing during the pouring of the slab.

3. Crack-A-Joint
As an option to saw cutting, place Crack-A-Joint into the wet concrete along the joint line (above the centre of
the Dowel Cradle), to induce a crack for the full depth of the concrete. The Crack -A-Joint is available in standard
3 m lengths formed from galvanised sheet steel to a height of 25 mm. It can be supplied as a plain joint or with a
permanent Rip-A-Strip capping in three different colour options (Black, Grey or Sandstone).

3.

4. Ground Crack Inducer

An inverted V-shaped PVC extrusion, 3 m long and available in 25 mm and 50 mm heights. It is positioned on the subgrade before the Dowel Cradles are placed. It produces a weakening in the slab that initiates a crack from the bottom
up. Ground Crack Inducer is optional and should only be used when Crack-A-Joint is used, or when saw cuts are to
made in the slab on the same day as the slab is poured.

4.

5. Cradle Hold Down Hook

A small optional wire hook that allows you to anchor the base of your Cradles into the site sub-base. It prevents the
Dowel Cradles from moving during the pour process. They hook over the bottom wire of the Cradles securing them to
the ground.

1300 DANLEY (1300 326 539)

5.

www.danley.com.au | sales@danley.com.au

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Disclaimer: The information contained in this publication is intended to give a fair description of the products and their capabilities.
No responsibility or liability by the manufacturers will be accepted for misuse, misreading or deviation from the recommended guidelines of these products.
As new technology is introduced, or industry standards are altered, ITWCS reserves the right to alter the information without notice.