IS 1838 (Part 2) : 2000preformed fillers for expansion joints in concrete pavement and structure (non-extruding and resilient type) Part 2 CNSL Aldehyde resin and coconut pith - Specification
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IS 1838:2000 (Part 2) is the Indian Standard (BIS) for preformed fillers for expansion joints in concrete pavement and structure (non-extruding and resilient type) part 2 cnsl aldehyde resin and coconut pith - specification. This standard lays down the specifications for preformed, non-extruding, and resilient expansion joint fillers made from Cashew Nut Shell Liquid (CNSL) aldehyde resin and coconut pith. These filler boards are designed to absorb thermal expansion in concrete pavements and structures without extruding above the joint level.
preformed fillers for expansion joints in concrete pavement and structure (non-extruding and resilient type) Part 2 CNSL Aldehyde resin and coconut pith - Specification
Overview
Status
Current
Usage level
Specialized
Domain
Transportation — Building Construction Practices incl. Painting, Varnishing
! Ensure the filler board is recessed slightly below the concrete surface to provide adequate depth for the installation of the joint sealing compound.
! Store filler boards flat in a dry, well-ventilated space prior to installation to prevent warping, moisture absorption, and dimensional changes.
! Prior to placing the concrete, rigidly secure the filler board to prevent displacement or floating during pouring and vibration.
Standard Specification for Preformed Expansion Joint Filler for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)
Specifies materials for preformed, nonextruding, resilient bituminous fibre joint fillers for concrete.
AASHTO M 213-19American Association of State Highway and Transportation Officials (AASHTO), USA
HighCurrent
Standard Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous Types)
Almost identical to ASTM D1751, focused on highway and transportation applications.
US Federal Specification HH-F-341FGeneral Services Administration (GSA), USA
HighWithdrawn
Filler, Expansion Joint, Preformed, Fibrous Type
Was the governing US federal specification for this material before being replaced by ASTM D1751.
BS 1142:1989British Standards Institution (BSI), UK
LowWithdrawn
Specification for fibre building boards
Part 3 of this standard covered bitumen-impregnated fibreboards, but it was not solely for joint fillers.
Key Differences
≠The maximum water absorption allowed in IS 1838 is 25% by volume, which is significantly higher than the 15% by volume limit specified in ASTM D1751.
≠ASTM D1751 specifies a minimum density requirement of 304 kg/m³ (19 lb/ft³), whereas IS 1838 does not specify a minimum density for the material.
≠ASTM D1751 includes an optional but defined weathering test to assess durability after accelerated aging, a test which is absent in IS 1838.
≠The maximum extrusion allowed in IS 1838 is 6.0 mm, while the equivalent in ASTM D1751 is 6.4 mm (0.25 inches), a minor difference likely due to unit system conversion and rounding.
Key Similarities
≈Both IS 1838 and ASTM D1751 mandate a minimum recovery of 70% after the material is compressed to 50% of its original thickness.
≈Both standards specify a minimum bitumen content of not less than 35% by mass, ensuring sufficient impregnation for durability and water resistance.
≈The required compressive stress to reduce the filler's thickness by 50% is almost identical (IS 1838: 0.7-5.2 MPa; ASTM D1751: 0.69-5.17 MPa).
≈The fundamental material composition is the same across standards: a preformed board made from cane or other suitable vegetable fibres impregnated with a bituminous binder.
Parameter Comparison
Parameter
IS Value
International
Source
Recovery, min
70%
70%
ASTM D1751
Water Absorption, max (24 hr)
25% by volume
15% by volume
ASTM D1751
Compression Stress (at 50% strain)
0.7 to 5.2 MPa
0.69 to 5.17 MPa (100 to 750 psi)
ASTM D1751
Bitumen Content, min
35% by mass
35% by mass
ASTM D1751
Extrusion, max
6.0 mm
6.4 mm (0.25 in)
ASTM D1751
Density, min
Not specified
304 kg/m³ (19 lb/ft³)
ASTM D1751
Brittleness Test
Not specified
Shall not crack or shatter when dropped from 1.2 m height
ASTM D1751
⚠ Verify details from original standards before use
Key Values5
Quick Reference Values
Minimum recovery after compression70%
Compression load required for 50% deflection0.7 to 5.2 MPa
Maximum extrusion during compression6.4 mm
Maximum water absorption10% by volume
Maximum reduction in compressive strength after weathering20%
Tables & Referenced Sections
Key Tables
Table 1 - Physical Requirements for Preformed Fillers
Why are CNSL resin and coconut pith used for these fillers?+
Coconut pith provides natural compressibility and resilience, while CNSL (Cashew Nut Shell Liquid) resin acts as a durable, non-extruding waterproof binder.
What is the maximum allowable extrusion for this filler?+
The maximum extrusion allowed is 6.4 mm when compressed to 50% of its original thickness, ensuring it does not bulge out and get damaged by traffic.
Does this filler board need a sealant on top?+
Yes, joint filler boards should not be left exposed to traffic or weather; they must be recessed and protected by an appropriate joint sealing compound.