Best Practices for Asphalt Pavement Crack Sealing in Commercial Facilities

To keep commercial pavements in top condition, asphalt pavement crack sealing must be done at the right time, with the right materials, and with proper preparation. Following these best practices ensures a long-lasting, durable seal that protects your asphalt investment.

When to Seal

Timing plays a major role in how well crack sealing performs.

• Ideal Season
  Carry out asphalt crack repair and sealing in spring or autumn, when cracks are at a moderate width — not overly expanded from summer heat and not tightly closed from winter cold. This helps the sealant flex with temperature changes throughout the year.
• Temperature Requirements
  Most manufacturers recommend sealing only when pavement temperatures are at least 40°F (4°C) and rising. Colder temperatures reduce adhesion and flexibility.
• Weather Conditions
  Avoid sealing when rain or moisture is present or expected. The pavement must be completely dry, as moisture significantly reduces bond strength.

Crack Preparation

Thorough preparation is the most important step for achieving a long-lasting seal.

Inspection & Classification

Start with a detailed assessment to identify the type and movement of each crack:

• Asphalt pavement crack sealing is best for working cracks — those that expand and contract noticeably (often transverse cracks).
• Crack Filling works better for non-working cracks with minimal movement (typically longitudinal cracks).
• Cracks wider than 1 inch, or areas showing alligator cracking, usually require patching rather than sealing.

Cleaning

Effective bonding requires a clean, dry crack. Use:

• High-pressure compressed air (minimum 90 PSI)
• A hot-air lance to clean, dry, and warm the crack for better adhesion (without overheating or burning the pavement)

Crack Routing (Optional but Recommended)

For working cracks, routing creates a uniform reservoir and improves sealant performance. A typical routed reservoir is:

• About 1/8 inch wider on each side of the original crack
• Deep enough to hold sufficient sealant for long-term movement

Concrete crack routing must be centered over the crack to ensure even bonding.

Material Selection & Proper Application

Choosing the right sealant and applying it correctly ensures maximum durability.

Material Selection

For asphalt driveway or concrete driveway joint sealing, use flexible, polymer‑modified, hot‑pour sealants that meet ASTM or AASHTO standards. Hot‑pour materials generally outperform cold‑applied fillers in commercial settings

Heating

Heat the concrete sealant only within the manufacturer’s recommended temperature range — typically 380°F to 410°F (193°C to 210°C).

• Overheating breaks down the sealant
• Underheating reduces flow and adhesion

Keep the melter agitated to maintain uniform consistency.

Application

• Fill the crack from the bottom up
• Use the correct wand tip for either a flush finish or an overband application
• The overband method is commonly preferred for active cracks
• Do not overfill — sealant should sit no more than ⅛ inch above the pavement surface