Since each rock joint is unique by nature, the utilization of replicas in direct shear testing is required to carry out experimental parameter studies. However, information about the ability of the replicas to simulate the shear mechanical behavior of the rock joint and their dispersion in direct shear testing is lacking. With the aim to facilitate generation of high-quality direct shear test data from replicas, a novel component in the testing procedure is introduced by presenting two parameters for geometric quality assurance. The parameters are derived from surface comparisons of three-dimensional (3D) scanning data of the rock joint and its replicas. The first parameter, σmf, captures morphological deviations between the replica and the rock joint surfaces. σmf is derived as the standard deviation of the deviations between the coordinate points of the replica and the rock joint. Four sources of errors introduced in the replica manufacturing process employed in this study could be identified. These errors could be minimized, yielding replicas with σmf ≤ 0.06 mm. The second parameter is a vector, VHp100, which describes deviations with respect to the shear direction. It is the projection of the 100 mm long normal vector of the best-fit plane of the replica joint surface to the corresponding plane of the rock joint. |VHp100| was found to be less than or equal to 0.36 mm in this study. Application of these two geometric quality assurance parameters demonstrates that it is possible to manufacture replicas with high geometric similarity to the rock joint. In a subsequent paper (part 2), σmf and VHp100 are incorporated in a novel quality assurance method, in which the parameters shall be evaluated prior to direct shear testing. Replicas having parameter values below established thresholds shall have a known and narrow dispersion and imitate the shear mechanical behavior of the rock joint.