“SETTING STANDARDS FOR THE INDUSTRY” PRODUCT CATALOG DENVER FOAM® OPEN CELL POLYURETHANE BACKER ROD TITAN FOAM™ BI-CELLULAR SOFT CELL POLYETHYLENE BACKER ROD MILE HIGH FOAM® CLOSED CELL POLYETHYLENE BACKER ROD MILE HIGH FOAM XL® CROSS-LINKED CLOSED CELL POLYETHYLENE BACKER ROD ULTRA BLOCK® FIRE STOPPING SYSTEMS www.backerrod.com Backer Rod Mfg. Inc. | 4244 N. Broadway | Denver, CO 80216 Toll Free: 800-595-2950 | 303-308-0363 | Fax: 303-308-0393 WHO IS BACKER ROD MFG. INC.? Welcome to Backer Rod Manufacturing Inc. - One of the largest manufacturers of backer rod materials in the world. We are experts in the specialty caulking field, providing backing for elastomeric and other applied sealants to the worldwide construction market. No other company manufactures and supplies backer rod products that are able to withstand temperature variations from -60º F to over 2000º F. We serve customers in the construction industry with specific applications in expansion/ construction joints to include: • Concrete Expansion and Contraction Joints • Curtain Wall Joints • Parking Decks • Bridge and Highway Construction • Pavement Maintenance • Widow Glazing • Log Home Chinking • Joints Requiring Structural Fire Ratings for 2, 3 and 4 hours Backer Rod offers five distinct products for use in construction joints: Denver Foam®, Titan Foam, Mile High Foam®, Mile High Foam XL® and Ultra Block®. The type of backer rod used is governed by the type of sealant used, plus environmental, seismic and temperature requirements. Backer Rod Manufacturing is proud to market our products through authorized distributors and select OEM customers around the world. Backer Rod Mfg. Inc. Reply to: 4244 N. Broadway • Denver, CO 80216 2929 Walker Drive • P.O. Box 8005 • Green Bay, WI 54308-9229 Phone 303-308-0363 • Fax 303-308-0393 Phone 920-406-4000 • Fax 920-406-4040 August 1, 2018 GENERAL CERTIFICATE OF COMPLIANCE DESCRIPTION: BACKER ROD MFG. INC. SEALANT BACKING PRODUCTS Denver foam Titan Foam™ Mile High Foam Mile High Foam XL™ Ultra Block THESE PRODUCTS ARE TESTED TO AND MEET THE REQUIREMENTS OF THE FOLLOWING STANDARDS: DENVER FOAM® TITAN FOAM™ MILE HIGH FOAM® MILE HIGH FOAM XL™ ULTRA BLOCK® ▪ ASTM D 1622 ▪ ASTM D 1622 ▪ ASTM D 1622 ▪ ASTM D 1622 ▪ ANSI/UL 2079 ▪ ASTM D 1623 ▪ ASTM C 1253 ▪ ASTM C 1016 proc B ▪ ASTM D 1623 ▪ ASTM E 84 ▪ ASTM C 1016 ▪ ASTM D 5249 type 3 ▪ ASTM C 1253 ▪ ASTM C 1016 proc B ▪ ASTM E 814 ▪ ASTM D 5249 Type 1 ▪ ASTM D 1623 ▪ ASTM D 5249 type 3 ▪ ASTM D 5249 type 1 ▪ ASTM E 1399 ▪ ASTM D 3574 ▪ ASTM C 1016 proc B ▪ ASTM D 1623 ▪ ASTM C 1253 ▪ ASTM E 119 ▪ ASTM C 1330 Type O ▪ ASTM C 1330 type B ▪ ASTM C 1330 type C ▪ ASTM C 1330 type C ▪ ASTM C 719 ▪ ASTM C 509 ▪ ASTM C 509 ▪ NFPA 251 ▪ NFPA 255 Final Fabrication Points: Backer Rod Mfg Bay Foam Products 4244 N Broadway 2240 W Peoria Ave Denver, CO 80216 Phoenix, AZ 85029 No asbestos, PCB’s, VOC’s or lead are used or contained in these products. All products are proudly manufactured in the USA. Bill Bergel Sales, Marketing and Technical Services Hidden, but essential A technical review of backer rods by J.F. Gibb he majority of construction in At left, the result of outgassing by a closed cell backer rod. The Tcommercial building today is rod has been removed, and the done by use of large building panels panels and sealant bead sawed of various types, connected by a in cross-section to show high performance elastometric seal- cavities caused by the bubbles. This is an unsatisfactory seal. ant material to form a waterproof Below, the sample at left seen seal. These panels consist of either from the side. A cured sealant precast concrete, prestressed con- bead applied above a closed cell backer rod was ruptured when crete, or curtain wall which is pre- trapped gases escaped from the dominately glass and metal. Any rod. combination of these three types also is commonplace in modern construction. It is vitally important that the connecting link, the sealant, joining all these panels be of top quality, capable of performing satisfactorily for a great many years. without this performance, water tightness soon is lost, resulting in long, costly mod- ifications and repairs. Many factors must be considered in designing a commercial building which will give many years of trou- ble free service. These include joint design, selection of sealant, surface preparation of joints just prior to caulking and, finally, selection of the proper backer rod (against which sealant is placed). The right decisions in these important areas, plus proper installation of the prod- ucts, ensures desired results. The backer rod evolves Evolution of the backer rod from the first use of caulking to the present John F. Gibb invented and developed the production equipment used to make open cell backer rods, and holds U.S. and foreign patents on this machinery. He is a member of the ASTM C-24 Joint Sealant Committee, and is General Manager/part owner of Backer Rod Mfg. & Supply Co., Denver. 40 THE CONSTRUCTION SPECIFIER/MARCH ’80 state of the art covers use of many ing even more serious ones. staining. This means they contain different types of materials. They For many years, in limited appli- no materials that would bleed out range from sand in horizontal joints, cations only, polyurethane foam slowly and seep into the sidewalls through wood, fiber board, jute, materials had been used success- (substrate), later to reappear as dis- rope, and twisted paper. About 17 fully. This promoted further de- coloration on the surface (some dis- years ago, a product evolved which velopment of this material, to de- tance away). This is a particularly consisted of an extruded plastic rod. termine its suitability for use in important point, if marble or other This new backer rod was a closed backer rods in the caulking busi- masonry materials are used. cell, flexible foam material. At first, ness. The open cell rod is more flexible it was made from polyethylene plas- Most early applications em- than its counterpart closed cell. The tic. Now it consists of polyethylene ployed a backing material cut into open cell must depend on its chem- and polypropylene, both nearly short strips (square or rectangular in ical and physical make up to attain identical in appearance and per- cross-section). The material exhi- rigidity, while closed cell rigidity is formance. This new rod is manufac- bited a wide range of physical prop- the result of gases trapped in its tured by plastic extrusion: A gas is erties, because much of it had been interior (as explained earlier). injected into the material, creating cut from scrap material used by the Rarely in commercial building plastic foam. The result might be furniture business. The type of construction do expansion joint described best as being somewhat polyurethane used in that industry is widths conform exactly to design. similar to a tube inflated under required to have a very high de- For instance, a one-half inch joint slight pressure as gas is trapped gree of resilency, and to retain this frequently will vary from as little as within its cellular structure. This property through severe usage. This one-quarter inch or less to as much rod proved to be far superior to what same property is necessary in ex- as three-quarter inch (or more). It is had been used previously in the pansion joint backer rod. Therefore, virtually impossible to manufacture trade, but was not without its prob- it proved to be an ideal material for or to erect large building panels lems. backer rod use. economically to such precise di- About six years ago, a round, mensions that joints between such Problems — and solutions open cell, flexible polyurethane panels stay within close tolerances. One of the more serious problems backer rod was introduced. The A backer rod to be packed between was outgassing. When these closed product was made from special these panels must be flexible cells and their outer skin somehow formulations of these flexible enough for easy insertion. become ruptured, trapped gases foams, producing a more uniform Manufacturers of closed cell slowly escape to the atmosphere. If a material. (As noted, uniformity was backer rods recommend that the high proportion of these cells be- lacking in previous urethane backer product not be compressed more come ruptured or deflated (so to rod produced from scrap.) than 25 percent of its diameter. Con- speak), much of the rigidity of the sequently, the applicator must rod is lost. The rod also loses much Open vs. closed cell change sizes frequently, using of its ability to regain its original closed cell in commonplace, vary- round shape once it has been de- There are some interseting (and im- ing width joints, and open cell rod if formed. portant) differences between open he is to exceed the 25 percent max- The problem of outgassing as- and closed cell backer rods. imum compression limit. sociated with these new flexible foam Both open cell and closed cell are Open cell backer rod must be backer rods resulted in sealant inert to all common and more pre- compressed at least 25 percent; it manufacturers insisting on further dominately used sealant materials on does not hurt these rods to be com- research, in the attempt to find a the market today. Both have ex- pressed as much as 75 percent of suitable material that would elimi- cellent chemical resistance. their diameter. This allows the nate this problem — without creat- Both, too, are classified as non- applicator to use fewer sizes in vary- THE CONSTRUCTION SPECIFIER/MARCH ’80 41 ing width joints.