Laboratory evaluation of a silicone foam sealant bonded to various header materials used in bridge expansion joints

► A silicone foam sealant was developed to provide an easy-to-use and economical joint sealant for small-movement bridge expansion joints. ► Laboratory tests on the sealant were conducted using steel, asphalt, and polymer concrete substrates. ► Mechanical properties of the sealants were evaluated during or after various harsh, but realistic aging exposures. ► Silicone foam sealant was found to bond well to various substrate materials. ► Foam sealant can easily accommodate deformation typical of small-movement expansion joints in bridges. A silicone foam sealant was developed to provide an easy-to-use and economical joint sealant for small-movement bridge expansion joints. In studies reported previously, various laboratory tests were conducted to evaluate the performance of the sealant using concrete as the bonding substrate. In the present study, laboratory tests on the sealant were conducted using other substrates found in practice, including steel, asphalt, and polymer concrete. Some of the tests conducted included a tension test, repair test, oven-aged bonding test, salt water immersion test, and a cure (modulus over time) test that evaluated the mechanical properties of the sealant as it developed its final state of cure. Through the laboratory tests, it has been observed that the silicone foam has the ability to bond to various substrate materials and can easily accommodate deformation typical of small-movement expansion joints in bridges.