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This study aims to address the degradation and damage of traditional bridge expansion joints by proposing a seamless expansion joint device based on polyurethane elastomer (PUE).

A series of laboratory experiments were conducted to evaluate the performance of PUE, including elasticity recovery, interfacial bonding and hygrothermal aging tests. Indoor model tests were also designed to analyze PUE's performance in actual bridge expansion structures. Based on these evaluations, the design of a seamless PUE expansion joint structure was completed.

The study reveals that PUE achieves optimal interfacial bond strength with PUC at −30°C after 7 h of curing and adhesive application, with a tensile strength of 9.2 MPa. PUE's elongation at break exceeds 3% at −30°C and retains its toughness and tensile strength after hygrothermal aging. When the beam end rotation reaches 0.0144 rad, PUE maintains a linear elastic state. With a groove width of 340 mm, PUE can withstand compressive displacements over 40 mm and tensile displacements up to 60 mm.

The findings highlight the excellent elasticity recovery and toughness characteristics of PUE, demonstrating the significant improvement in durability of the PUE seamless expansion joint structure and the rationality of the groove width calculation method based on the elongation at break of PUE. The broader impact of this study lies in its potential to innovate the design and maintenance strategies of bridge expansion joints.