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Learn · Concrete Care

How to Fill Concrete Expansion Joints (Including Old, Rotted Wood Strips)

The short answer

An expansion joint is a full-depth gap between two pieces of concrete, filled with a compressible strip. A control joint is a shallow groove that tells the slab where to crack. When an old wood or fiberboard expansion strip rots out, pull what's left, set closed-cell backer rod, and fill the top with a flexible polyurethane sealant.

By Rob Diederich, owner · Updated
9 min read

If your driveway went in a few decades ago, there's a good chance it's divided by strips of wood or black fiberboard. When the concrete was new, those strips sat flush and tight.

Now you can push a screwdriver through them, dandelions grow out of one, and the slab on one side sits just low enough to catch the snowblower.

You don't need a new driveway, and maybe not even a contractor. You do need to know which joints you have and what goes back in them, because the wrong fill makes things worse.

Two Kinds of Joints, Two Different Jobs

Control joints are straight grooves sawed or tooled partway into a slab, usually about a quarter of its thickness, roughly every 10 to 12 feet on a driveway. Concrete shrinks as it dries and will crack somewhere. The groove makes it crack there, in a straight line, out of sight.

Expansion joints go all the way through. They separate two pieces of concrete, or a slab from something that doesn't move with it, like your foundation, garage floor, or front steps. (Where a slab meets a fixed structure, the industry term is isolation joint, but most people call them all expansion joints.) The gap is usually about 1/2" wide, though old wood dividers can be a full 1-1/2", and it was filled with a compressible strip at the pour: asphalt-impregnated fiberboard, wood, cork, rubber, or foam.

Current guidance says a driveway rarely needs expansion joints between its own panels, but plenty of older driveways around here got wood strips across the slab anyway, sometimes just for looks. More strips means more wood to rot.

Which One Are You Looking At?

Grab a flat screwdriver and walk your driveway, walks, and patio.

ClueControl jointExpansion joint
WidthNarrow saw cut, or a tooled groove with rounded edgesUsually about 1/2" or wider
What's in itNothing, or a hairline crack along the bottomFiberboard, wood, foam, old caulk, or dirt where the strip used to be
Screwdriver testHits solid concrete a short way downSinks into soft filler or goes straight down to soil
Where it isIn a grid across the slabWhere concrete meets the house, garage floor, steps, sidewalk, or street; on older driveways, across the slab too
What it's forDecides where shrinkage cracks formLets two pieces of concrete move independently

Both kinds are worth sealing outdoors. Expansion joints are where the rotted wood lives, so that's most of what follows.

What an Open Joint Does Over a Wisconsin Year

A rotted-out strip is an open channel into the base under two slabs at once. Follow it through the calendar:

  • Winter. Water that ran in during fall freezes in the gap and the soil below. Ice pries at the slab edges, wet soil can heave one slab above its neighbor, and salty slush off your car speeds up the edge damage.
  • Spring melt. Snow piled along the driveway melts at once, and every open joint funnels it to the base. Much of Brown County sits on red, clay-rich glacial soil, which stays soft long after the snow is gone.
  • Summer storms. A downspout or sump line emptying onto the driveway sends a stream down the nearest joint, washing soil out from under both slab edges. That's how one slab ends up lower right at the joint. (More in voids under concrete.)
  • All season long. Sand, grit, and weeds move in. A joint packed with material that won't compress can't close when the concrete expands on a hot day, so the slab edges take the pressure. Keeping debris out is a big reason joints get sealed at all.

Your Options for an Old Wood or Fiberboard Strip

Leave it alone. If the strip is firm, flush or slightly below the surface, and tight to both slabs, it's still working. Check it every spring.

Trim the top and seal over it. If the strip is mostly sound but gaps are opening along its edges, cut out the top half inch to an inch, lay bond-breaker tape on the wood, and fill the pocket with flexible sealant that grips only the concrete sides.

Pull it and seal the joint. The usual answer once the wood is soft, crumbling, or mostly gone. With closed-cell backer rod and a flexible sealant, there's nothing left in the joint to rot.

Replace it with new wood. Doable if you want to keep the look of wide wood dividers: ground-contact treated or rot-resistant lumber, cut for a snug fit. But new boards in old gaps often work loose, and driveway wood here stays wet much of the year. Expect to redo it someday.

Fill it with mortar, grout, or concrete patch. Don't. The joint exists so the concrete can move. A rigid plug can't squeeze when the slabs grow in July or stretch when they shrink in January, so it usually cracks loose and lets water back in. When it does hold, the stress goes elsewhere: chipped edges or a new crack in the panel.

Joint Condition and What to Do About It

What you seeWhat to do
Control joint, tight, slabs levelSeal it if it's about 1/4" wide or more and collecting grit; a thin saw cut can be left alone
Any joint packed with sand, weeds, or cracked old caulk, slabs levelDig it out, backer rod if it's deep, flexible sealant
Wood or fiberboard firm, flush, tight to both sidesLeave it and check each spring, or trim the top and seal over it
Strip soft, crumbling, sunk, sprouting weeds, or gonePull what's left, clean the joint, backer rod, sealant
Strip sticking up above the slabsTrim or pull it, then check whether the slabs around it settled
One slab lower than the other at the jointLift the low slab first, then seal
Slab at the house tipped toward the foundationLift first, then seal (see caulking where concrete meets the house)
Joint edges crumbling or broken offRepair the edges first; sealant needs solid concrete to grip
Old mortar fill cracked looseChip it out carefully, then seal it properly

Pulling Old Wood and Sealing the Joint

The high-level version. Sealant types and backer rod sizing are in our concrete crack caulk guide.

  1. 1Check the slabs first. Lay a straightedge across the joint. If one side is lower, read the next section before you seal.
  2. 2Wait for mild, dry weather. Most joint sealants want at least 40°F, a dry and frost-free joint, and no rain until the sealant skins over. Sealant makers also recommend installing when the joint is near the middle of its movement range, so mild days beat heat waves and cold snaps. Late summer and early fall are the sweet spot here.
  3. 3Get the wood out. Soft rot comes out with a stiff putty knife, a chisel, and a flat bar. For firmer wood, split it down the middle and pry the halves toward the center of the gap, not against the concrete, so you don't chip the edges. Wear eye protection.
  4. 4Clean down to bare concrete. Pull weeds and roots, wire-brush both joint faces, and blow and vacuum out the dust. Let it dry completely.
  5. 5Set backer rod near the top. Closed-cell rod a bit wider than the gap. You don't need to fill the whole depth, just set the rod where it gives the sealant the right shape.
  6. 6Seal it and keep it low. A flexible polyurethane sealant rated for traffic, self-leveling on flat joints, finished slightly below the surface so plow blades skate over it. On a wide gap, check the label's maximum joint width; an old two-by board leaves about 1-1/2", near the top of the range many self-leveling sealants list.
  7. 7Keep off it for as long as the label says.

When to Lift Before You Seal

If the slabs no longer meet flush at the joint, the low one dropped because water got under it, probably through that open joint, and carried soil away. Sealing it where it sits leaves the trip lip and the hollow underneath, and puts a fresh bead right where a snowblower will catch it.

The better order: clean out the joint, lift the low slab, patch the holes, then seal. Pulling the rotted wood first also frees the slab to rise without dragging on its neighbor. We lift with high-density structural polyurethane foam through a few 5/8" holes, about the size of a dime. The foam fills the void and raises the slab in small, controlled increments. See our concrete lifting page.

One limit: foam only raises concrete. If frost or roots pushed a slab up, the fix is lifting its neighbors to meet it, or a different repair entirely.

When You Don't Need Us

Do it yourself if the slabs are level, the old strips come out without a fight, and you can get a dry, mild weekend.

Get help if:

  • A slab has dropped at the joint, or the slab by the house slopes toward the foundation. That's a lift, then a seal.
  • You've got a lot of footage, like a grid of wood strips across a driveway and patio, and you'd rather it get done once.
  • The joint edges are crumbling. That needs a concrete repair contractor first. It's not work we do, and we'll tell you so from your photos.

To see how we handle a sealing job start to finish, read our concrete caulking process.

Questions

Common questions

Does my driveway even need expansion joints?

Between its own panels, often not, because control joints usually handle the movement. Isolation joints still belong where it meets the garage floor, house, steps, or a sidewalk.

What's the black material in my expansion joints?

Most likely asphalt-impregnated fiberboard, a common expansion strip. Over the years it softens and sinks. Once it's soft, treat it like rotted wood: pull it, backer rod, seal.

Can I put new wood strips back in?

Yes, with ground-contact treated or rot-resistant lumber. It keeps the look, but it will eventually rot again. Backer rod and sealant is the lower-maintenance choice.

Is sand or pea gravel OK in an expansion joint?

No. Sand washes out, holds moisture, and grows weeds, and packed grit keeps the joint from closing when the concrete expands.

My wood strip is sticking up above the concrete. What happened?

Usually the slabs around it settled while the strip stayed put, or frost worked the strip up out of the joint. Trim or pull it, then check with a straightedge whether a slab has dropped.

Should control joints get sealed too?

Outdoors, it's a good idea for any control joint wide enough to hold a bead, roughly 1/4" or more. A hairline-thin saw cut with level sides can be left alone.

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Rotted Joints? Send a Photo. No Sales Call.

Send a wide shot of the driveway or patio and a close-up of a few joints with a tape measure across the gap. We'll tell you whether you can handle it yourself, whether anything needs lifting first, and what it costs if you'd like us to do it.

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