Designation: D 545 – 08

Standard Test Methods for

Preformed Expansion Joint Fillers for Concrete
Construction (Nonextruding and Resilient Types)1
This standard is issued under the fixed designation D 545; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense.

1. Scope E 177 Practice for Use of the Terms Precision and Bias in
1.1 These test methods cover the physical properties asso- ASTM Test Methods
ciated with preformed expansion joint fillers. The test methods E 691 Practice for Conducting an Interlaboratory Study to
include: Determine the Precision of a Test Method
Property Section
Expansion in Boiling Water 7.1
3. Significance and Use
Recovery and Compression 7.2 3.1 The compression resistance perpendicular to the faces,
Extrusion 7.3
Boiling in Hydrochloric Acid 7.4
the resistance to the extrusion during compression, and the
Asphalt Content 7.5 ability to recover after release of the load are indicative of a
Water Absorption 7.6 joint filler’s ability to fill continuously a concrete expansion
Density 7.7
joint and thereby prevent damage that might otherwise occur
NOTE 1—Specific test methods are applicable only to certain types of during thermal expansion. The asphalt content is a measure of
joint fillers, as stated herein. the fiber-type joint filler’s durability and life expectancy. In the
1.2 The values stated in inch-pound units are to be regarded case of cork-type fillers, the resistance to water absorption and
as standard. The values given in parentheses are mathematical resistance to boiling hydrochloric acid are relative measures of
conversions to SI units that are provided for information only durability and life expectancy.
and are not considered standard.
1.3 This standard does not purport to address all of the 4. Apparatus
safety concerns, if any, associated with its use. It is the 4.1 Balance, for weighing joint fillers capable of weighing
responsibility of the user of this standard to consult and test specimens within 0.01 g.
establish appropriate safety and health practices and deter- 4.2 Mechanical Convection Oven, capable of maintaining
mine the applicability of regulatory limitations prior to use. 220 6 5.0°F (104 6 3°C).
4.3 Desiccator, of sufficient size to accommodate the test
2. Referenced Documents specimens.
2.1 ASTM Standards: 2 4.4 Vernier Caliper, for measuring length and width of
D 147 Discontinued 1985; Methods of Testing Bituminous specimens with accuracy within 60.01 in. (0.25 mm).
Mastics3 4.5 Dial Micrometer, or other measuring device, graduated
D 1037 Test Methods for Evaluating Properties of Wood- to read in 0.001-in. (0.02-mm) units.
Base Fiber and Particle Panel Materials 4.6 Extrusion Mold—Three-sided steel mold to confine
lateral movement of specimens under compression to one side
only. Interior dimensions shall be 4 by 4 in. (102 by 102 mm)
1
These methods are under the jurisdiction of ASTM Committee D04 on Road with permissible variations in length and width of 60.015 in.
and Paving Materials and are the direct responsibility of Subcommittee D04.34 on
Preformed Joint Fillers, Sealers and Sealing Systems.
(0.38 mm). Mold sides shall be of such height as to extend at
Current edition approved July 1, 2008. Published August 2008. Originally least 0.5 in. (13 mm) above the test specimens. A typical mold
approved in 1939. Last previous edition approved in 2005 as D 545 – 99 (2005).
2
can be made from a steel base 1⁄2 by 4 by 4 6 0.015 in. (13 by
For referenced ASTM standards, visit the ASTM website, www.astm.org, or 102 by 102 6 0.3 mm) and three bolted steel side plates 1⁄4 in.
contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on (6.35 mm) thick, extending approximately 11⁄2 in. (38 mm)
the ASTM website. above the base plate, thus forming a three-sided open-top box.
3
Withdrawn.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 D 545 – 08
4.7 Template—One steel template 4 by 4 in. (102 by 102 102 mm). Each specimen shall be freshly and squarely cut
mm), machined from 1⁄2-in. (6.4-mm) steel plate to fit the using a metal plate as a cutting template, as described in 4.7.
extrusion mold. The template shall fit the mold within −0.005 6.2 For self-expanding cork only, after boiling the speci-
in. (0.13 mm) in length and width. mens in water as described in 7.1.1, air dry in ambient air 24
4.8 Metal Plate, 41⁄2 by 41⁄2 in. 6 0.1 in. (114 by 114 6 2.5 h. Then cut specimens to the size described in 6.1.
mm) with parallel faces machined from 1⁄2-in. (6.4-mm) steel 6.3 Determine the thickness of each specimen to the nearest
plate. 0.001 in. (0.03 mm).
4.9 Compression Tester, either hydraulic- or screw-type
equipment with sufficient opening between upper- and lower- 7. Procedures
bearing surfaces to permit the use of verifying apparatus. The
load applied to the test specimen shall be indicated with an 7.1 Expansion in Boiling Water:
accuracy of 61.0 %. The upper-bearing device shall be a 7.1.1 For self-expanding cork joint filler only, use five of the
spherically seated, hardened metal block firmly attached at the test specimens supplied by the manufacture as described in 5.2.
center of the upper head of the machine. The center of the Determine the thickness of each specimen to the nearest 0.001
sphere shall lie at the center of the surface of the block in in. (0.03 mm). Immerse the specimens in boiling water for 1 h;
contact with the specimen. The block shall be closely held in its remove and allow to cool to room temperature for 15 min.
spherical seat, but free to tilt in any direction. Load shall be Measure the final thickness of each specimen to the nearest
applied without shock at 0.05 in. (1.3 mm) per min. 0.001 in. Calculate the expansion as follows:
4.10 Extractor Apparatus, similar to Fig. 1 of Methods A
D 147 with thermostatically controlled heating element. Expansion, %, of original thickness 5 B 3 100 (1)

5. Sampling where:
5.1 One representative sample approximately 2 ft2/1000 ft2 A = thickness in inches after boiling in water, and
of joint filler shall be obtained and properly packaged for safe B = thickness in inches before boiling in water.
transporting to the testing agency. 7.1.2 Prepare the test specimens for testing as described in
5.2 For self-expanding cork joint filler, a minimum of five 6.2.
41⁄2 by 41⁄2-in. (114 by 114-mm) square specimens properly 7.2 Recovery and Compression:
banded and plastic wrapped at point of manufacture shall be 7.2.1 Test Specimen—For these tests use one of the speci-
submitted for testing. mens prepared and described in 6.1 and 6.2. For the cork,
sponge rubber, bituminous cork, and fiber joint fillers; make
6. Preparation of Test Specimens these tests on material as received. If the cork filler fails to
6.1 For the joint fillers made of cork, sponge rubber, meet the specified requirements, make check tests on speci-
bituminous cork, or fiber, cut five specimens 4 by 4 in. (102 by mens that have been immersed in water for 24 h and then

1—Flat Metal Plate. 5—Measuring Device.

2—Specimen. 6—Hollow Cylinder.
3—Metal Plate 41⁄2 by 41⁄2 by 1⁄2 in. (102 by 102 by 13 mm). 7—Spherical Bearing Block.
4—U-Shape Bridge.
FIG. 1 Typical Mounting of the Specimen for Recovery and Compression Tests

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 D 545 – 08
air-dried at ambient conditions for 24 h. Acceptance is based on load. Acceptance shall be based on the results of these check
the results of the check tests. tests. Calculate the percentage of recovery as follows:
7.2.2 Mounting—Place the test specimen on a flat metal t1
plate and center a 4 by 41⁄2 by 1⁄2-in. (114 by 114 by 13-mm) Recovery, % 5 t 3 100 (3)
metal plate, ground to have plane parallel faces, on the top
surface of the specimen. Use a simple U-shaped bridge to where:
support a dial gage or other suitable measuring device reading t = thickness of the specimen before test, and
to the nearest 0.001 in. (0.03 mm) above the center of the t 1 = thickness 1 h after completion of the third application
specimen. Place a hollow metal load transfer cylinder with of load.
slots for inserting the U-shape bridge and an opening for 7.2.5 Compression—Calculate the unit pressure by dividing
reading the measuring device between the moving head of the the maximum load in lbf (N) as determined in 7.2.4 by the area,
testing machine and the plate covering the specimen. A typical 16 in.2 (0.0104 m2), and record as the unit pressure in psi (kPa).
mounting is shown in Fig. 1, but other suitable devices may be 7.3 Extrusion:
used. Mount a spherical bearing block between the upper end 7.3.1 Test Specimens—For this test, use one of the test
of the cylinder and the moving head of the testing machine. specimens prepared as described in 6.1 (or one of the self-
Center accurately both the hollow metal cylinder or other expanding cork specimens prepared in 6.2). In the case of cork,
device and the spherical bearing block so that the load will be sponge rubber, bituminous cork, and fiber expansion joint
applied uniformly to the test specimen. fillers, make these tests on specimens of the materials as
7.2.3 Measurement of Thickness—When the specimen has received. If the cork filler fails to meet the requirements of the
been mounted as described in 7.2.2 and is subjected only to the specifications, make check tests on specimens that have been
pressure of the dead weight of the 41⁄2 by 41⁄2 by 1⁄2-in. (114 by immersed in water for 24 h and subsequently air-dried for 24 h.
114 by 13-mm) metal plate, determine its thickness by means Base acceptance on the results of these check tests.
of the measuring device. When the load-transferring apparatus 7.3.2 Mounting—Place the test specimen in a suitable steel
and spherical bearing block are placed on the test specimen, mold so constructed as to confine the lateral movement of the
some compression may result. Consider this reduction in specimen under compression to one side only, as described in
thickness as part of the 50 % reduction in thickness to be 4.6. Cover the specimen with a 1⁄2 by 4 by 4-in. (13 by 102 by
applied. 102-mm) metal plate ground to have plane parallel faces, as
7.2.4 Recovery—For the determination of the percentage of described in 4.7. Use a simple U-shaped bridge to support
recovery, give the specimen a single application of a load above the center of the specimen a dial or other suitable
sufficient to compress it to 50 % of its thickness before test. measuring device reading to 0.001 in. (0.03 mm). Place upon
Apply the load without shock and at such a rate that the the plate metal cylinder or other device for transferring the load
specimen will be compressed approximately 0.05 in. (1.3 from the moving head of the testing machine around the
mm)/min. Record this applied load. Immediately release the measuring apparatus to the plate covering the specimen.
load after application and permit to recover 10 min, after which 7.3.3 Measurement of Thickness—When the specimen has
measure the thickness. Remove the load-transferring apparatus been mounted as described in 7.3.2 and is subjected only to the
and spherical bearing block from the test specimen following pressure of the dead weight of the 1⁄2 by 4 by 4-in. (13 by 102
the load application. Calculate the percentage of recovery as by 102-mm) metal plate, determine its thickness by means of
follows: the measuring device. When the load-transferring apparatus
and spherical bearing block are placed on the test specimen,
t1
Recovery, % 5 t 3 100 (2) some compression may result. Consider this reduction in
thickness as part of the 50 % reduction in thickness to be
where: applied.
t = thickness of the specimen before test, and 7.3.4 Extrusion—For the determination of the amount of
t 1 = thickness 10 min after completion of the application extrusion, give the specimen one application of a load suffi-
of load. cient to compress it to 50 % of its thickness before test. Apply
7.2.4.1 Retest Provision—In case the specimen fails to the load without shock at such a rate that the specimen will be
comply with requirements of the specification, test a specimen compressed approximately 0.05 in. (1.3 mm)/min. Determine
in accordance with the following procedure. Give the test the amount of extrusion in inches by measuring the maximum
specimen three applications of a load sufficient to compress it movement of the free edge of the test specimen during the
to 50 % of its thickness before test. Apply the load without 50 % compression of the specimen. Measure the extrusion by
shock and at such a rate that the specimen will be compressed means of a dial micrometer or other suitable device reading to
approximately 0.05 in. (1.3 mm)/min. After the first and second 0.001 in. (0.03 mm).
applications, release the load immediately, and permit the 7.4 Boiling in Hydrochloric Acid:
specimen to recover 30 min before the load is again applied. 7.4.1 In the case of cork and self-expanding cork expansion
After the third application, release the load immediately and joint fillers only, use one of the test specimens prepared as
permit the specimen to recover 1 h; then measure the thickness described in 6.1 (or one of the expanded specimens prepared as
again. Remove the load-transferring apparatus and spherical described in 6.2). Immerse the specimen in hydrochloric acid
bearing block from the test specimen during recovery periods (HCl, sp gr 1.19) and boil for 1 h. Examine the test specimen
between compressions and following the third application of for evidences of disintegration.

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 D 545 – 08
7.5 Asphalt Content: 7.7.1 Using a specimen prepared as described in Section 6
7.5.1 From the test specimens prepared as described in 6.1, and, after air drying, weigh to the nearest 0.1 g. For air dry
cut narrow strips of sufficient length to pack the thimble of the material the specimen shall come to constant weight and
Soxhlet Extractor; approximately 45 g is sufficient. Oven dry moisture in a conditioning atmosphere described in Test
the strips at 220 6 5°F (104 6 3°C) to constant weight in an Methods D 1037 for “wood based fiber and particle panel
open tared weighing dish, then cool in a desiccator. Weigh to materials,” 65 6 1 % RH at 68 6 6°F. Constant weight is
the nearest 0.01 g, and subtract tare to obtain initial oven dry defined as no change greater than 1 % sample weight after 24
weight of specimen. h.
7.7.2 For fiber joint only, oven dry the specimen at 220 6
NOTE 2—Extraction apparatus is similar to Fig. 1 of Methods D 147.
5°F (104 6 3°C) for 2 h. After oven drying, cool the specimen
7.5.2 Transfer the test strips to the extraction thimble of to room temperature in a covered desiccator and weigh to
known oven dry weight. Extract the asphalt in the Soxhlet nearest 0.1 g.
Extractor using a chlorinated solvent, such as trichlorethylene, 7.7.3 Calculate the density in lb/ft3, as follows:
until the extract is essentially clear (color of weak tea). 0.238 W
7.5.3 After extraction, allow excess solvent to drain from Density 5 t (7)
the thimble before transferring to an open tared weighing dish
and oven dry at 220 6 5°F (104 6 3°C) for 1 h. Cool in a where:
desiccator, then weigh and subtract weighing dish and thimble W = weight, g, and
to obtain the oven dry weight of the extracted fiber. t = thickness, in.
7.7.4 In the event that the metal template or the test
7.5.4 Calculate the percentage asphalt content by weight on
specimen or both does not measure to within the tolerances
an oven dry basis as follows:
established in 4.7, the length and width of the specimen must
W1 2 W be measured to within 0.01 in. and density calculated in lb/ft3
Asphalt, % 5 3 100 (4)
W1 as follows:
3.81 W
where: Density 5 l 3 w 3 t (8)
W 1 = initial oven dry weight of test strips, and
W = oven dry weight of extracted fiber. where:
7.6 Water Absorption: W = weight, g,
7.6.1 Using a test specimen prepared as described in 6.1, dry l = length, in.,
the specimen in air, weigh to the nearest 0.1 g, and immerse in w = width, in., and
water at a temperature of 65 to 75°F (18 to 25°C) in a t = thickness, in.
horizontal position supported from the bottom of the container
with 1 in. (25 mm) of water over the specimen for 24 h. 8. Precision and Bias
Remove the specimen from the water and remove the excess 8.1 The precision of these test methods are based on an
surface water from all sides of the specimen with blotting paper interlaboratory study (ILS) of this standard conducted in 2007.
or a paper towel. Quickly weigh the specimen to the nearest 0.1 Results in this study were obtained from a total of six
g. Calculate percent water absorption by volume as follows: laboratories, testing five different joint-filler materials. Every
W1 2 W
“test result” reported represents an individual determination.
Absorption by Volume, % 5 262t 3 100 (5) Each participating laboratory reported up to ten replicate test
results for each material. Except for the inability of every
where: participating laboratory to provide test results for all study
W 1 = weight after immersion, g, parameters, Practice E 691 was followed for the design and
W = weight before immersion, g, and analysis of the data; the details are given in ASTM Research
t = thickness, in. Report No. D04-1027.4
7.6.2 In the event that the metal template or the test 8.1.1 Repeatability Limit (r)—Two test results obtained
specimen or both does not measure to within the tolerances within one laboratory shall be judged not equivalent if they
established in 4.7, the length and width of the test specimen differ by more than the “r” value for that material; “r” is the
must be measured to within 0.01 in. and percent water interval representing the critical difference between two test
absorption by volume calculated as follows: results for the same material, obtained by the same operator
W1 2 W using the same equipment on the same day in the same
Absorption by Volume, % 5 16.41 3 l 3 w 3 t 3 100 (6) laboratory.
8.1.1.1 Repeatability limits are listed in Tables 1-7.
where: 8.1.2 Reproducibility Limit (R)—Two test results shall be
W 1 = weight after immersion, g, judged not equivalent if they differ by more than the “R” value
W = weight before immersion, g, for that material; “R” is the interval representing the critical
l = length of specimen, in.,
w = width of specimen, in., and
t = thickness of specimen, in. 4
Supporting data have been filed at ASTM International Headquarters and may
7.7 Density: be obtained by requesting Research Report RR: D04-1027.

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 D 545 – 08
TABLE 1 Expansion (%)
Repeatability Standard Reproducibility Standard
Joint Filler Average (X)A Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
B 161.4 12.9 43.5 36.0 121.9
A
The average of the laboratories’ calculated averages.

TABLE 2 Density (lbs/cu ft)

Repeatability Standard Reproducibility Standard
Joint Filler Average (X)A Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
C 30.06 0.77 7.02 2.16 19.66
D 2.15 0.02 0.14 0.05 0.39
E 19.32 0.47 1.29 1.32 3.62
A
The average of the laboratories’ calculated averages.

TABLE 3 Compression (psi)

A Repeatability Standard Reproducibility Standard
Joint Filler Average (X) Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
A 212.4 14.3 46.7 40.0 130.8
B 225.1 24.9 192.6 69.8 539.3
C 96.6 18.1 66.9 50.5 187.2
D 17.0 1.1 5.5 3.0 15.3
E 327.8 23.6 63.8 65.9 178.6
A
The average of the laboratories’ calculated averages.

TABLE 4 Water Absorption (%)

Repeatability Standard Reproducibility Standard
Joint Filler Average (X)A Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
E 10.9 0.4 4.3 1.3 12.0
A
The average of the laboratories’ calculated averages.

TABLE 5 Asphalt Content (%)

A Repeatability Standard Reproducibility Standard
Joint Filler Average (X) Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
E 39.1 0.5 3.3 1.3 9.2
A
The average of the laboratories’ calculated averages.

TABLE 6 Recovery (%)

Repeatability Standard Reproducibility Standard
Joint Filler Average (X)A Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
A 89.4 9.0 9.5 25.3 26.7
B 91.7 3.8 4.9 10.5 13.7
C 98.3 0.3 1.2 0.7 3.4
D 96.6 0.9 2.0 2.5 5.5
E 84.4 6.0 8.4 16.8 23.6
A
The average of the laboratories’ calculated averages.

TABLE 7 Extrusion (in.)

Repeatability Standard Reproducibility Standard
Joint Filler Average (X)A Repeatability Limit (r) Reproducibility Limit (R)
Deviation (Sr) Deviation (SR)
A 0.032 0.009 0.022 0.024 0.062
B 0.060 0.083 0.083 0.232 0.232
C 0.068 0.025 0.048 0.071 0.133
D 0.021 0.009 0.019 0.027 0.055
E 0.018 0.011 0.015 0.031 0.041
A
The average of the laboratories’ calculated averages.

difference between two test results for the same material, 8.1.2.1 Reproducibility limits are listed in Tables 1-7.
obtained by different operators using different equipment in 8.1.3 The above terms (repeatability limit and reproducibil-
different laboratories. ity limit) are used as specified in Practice E 177.

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 D 545 – 08
8.1.4 Any judgment in accordance with statements 8.1.1 8.3 The precision statement was determined through statis-
and 8.1.2 would normally have an approximate 95 % probabil- tical examination of 328 results, from six laboratories, on five
ity of being correct, however the precision statistics obtained in materials. These five joint fillers were described as the follow-
this ILS must not be treated as exact mathematical quantities ing:
which are applicable to all circumstances and uses. The limited Filler A Cork
number of laboratories reporting results guarantees that there Filler B Self-Expanding Cork
Filler C Sponge Rubber
will be times when differences greater than predicted by the Filler D Closed-Cell Polyolefin Foam
ILS results will arise, sometimes with considerably greater or Filler E Preformed Expansion Joint, Bituminous Type
smaller frequency than the 95 % probability limit would imply.
To judge the equivalency of two test results, it is recom-
The repeatability limit and the reproducibility limit should be
mended to choose the joint filler closest in characteristics to the
considered as general guides, and the associated probability of
test filler.
95 % as only a rough indicator of what can be expected.
8.2 Bias—At the time of the study, there was no accepted
reference material suitable for determining the bias for these 9. Keywords
test methods, therefore no statement on bias is being made. 9.1 joint fillers; nonextruding; resilient types

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