Published on June 8, 2025

You don’t need to be a pavement engineer to know that cracks are bad news for your roads. But here’s the good news: you can fight back, and one of the simplest, most cost-effective tools in your arsenal is crack sealing.

Let’s take a quick drive through the why, when, and how of crack sealing, so your roads can last longer and your budget can go further.

Why Cracks Matter

A few cracks here and there might not seem like a big deal, but once water gets in, trouble isn’t far behind. Moisture seeps under the pavement, weakens the base layers, and leads to more cracking, potholes, and eventually major repairs.

Think of crack sealing like weatherproofing your house. It helps keep the bad stuff out.

The Benefits of Crack Sealing

• Extend pavement life
  Properly sealed cracks can add 5 – 10 years to the life of your road surface. That means fewer major repairs down the line.
• Save money
  Crack sealing costs a fraction of what it takes to mill and pave a road. An ounce of prevention here really does pay off.
• Prevent bigger problems
  Sealing blocks water, dirt, and vegetation from turning small cracks into big headaches like potholes and alligator cracking.

When to Seal

The best time to seal is when the road is still in relatively good shape, before the cracks widen or multiply. You want to catch them early, ideally when they are 1/4″ to 3/4″ wide.

Cool, dry weather is ideal, usually spring or fall. That’s when pavement and crack sizes are stable and sealant can bond well.

How It’s Done

Here’s a simple look at the crack sealing process:

1. Clean the cracks
   Use compressed air or a heat lance to remove dirt and moisture so the sealant can adhere properly.
2. Apply the sealant
   Hot-applied rubberized asphalt is poured or injected into the crack. This flexible material expands and contracts with the pavement, keeping the seal intact.
3. Let it cool
   Allow the sealant to set before reopening the road to traffic, typically just a few hours. (Yes, we know it is unrealistic to keep traffic off a road for hours.)

A Little Effort, Big Results

If you’re running a highway department or managing a town’s roads, don’t overlook this simple maintenance tool. A regular blacktop crack sealing program, even on a modest budget, can keep your roads smoother and stronger for years.

Remember: it’s always cheaper to seal a crack than to fill a pothole.

Tagged: Road Maintenance  Highway Department  Highway Superintendent 

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