All About The Daily Texas News

The Role of Crack Fillers in Preventative Pavement Maintenance

Aug 4

Proper pavement maintenance is critical to extending the service life of asphalt and concrete surfaces. One of the most cost-effective and essential strategies in any pavement preservation program is crack sealing or crack filling. These methods prevent water and debris from infiltrating cracks, which can cause structural damage and lead to more costly repairs.

This article explores the role of crack fillers in preventative pavement maintenance, how they work, the types available, and why early intervention makes a difference.

Why Cracks Appear in Pavement

Pavement surfaces are exposed to daily wear from traffic, UV rays, water infiltration, freeze-thaw cycles, and oxidation. Over time, these stresses create cracks in the surface. Left untreated, even small cracks allow moisture to seep beneath the pavement layers. This leads to sub-base erosion, potholes, alligator cracking, and eventually, full-depth pavement failure.

The underlying asphalt mix affects cracking behavior, especially in regions with freeze-thaw cycles or extreme temperature swings.

Poor drainage or subgrade conditions can accelerate pavement deterioration. To understand how proper drainage infrastructure supports pavement health and prevents structural failure, read our article on Effective Sewer & Drainage Systems: Preventing Flooding & Pavement Damage.

Common causes of pavement cracks include:

  • Thermal expansion and contraction

  • Aging and oxidation of asphalt binder

  • Heavy vehicle traffic

  • Poor drainage or subgrade conditions

  • Construction defects

Timely crack filling interrupts this deterioration process and prevents small problems from escalating. Crack fillers are vital for extending pavement life, but they should be chosen with an understanding of complementary paving materials like base layers and sealants.

What Are Crack Fillers?

Crack fillers are flexible sealant materials applied to pavement cracks to block moisture, debris, and chemical infiltration. They are typically used in preventative maintenance programs and are suitable for non-working cracks (less than 1/4-inch movement). Crack filling differs from crack sealing, which is used on more active cracks and involves routing and placing more durable sealants.

While the terms are sometimes used interchangeably, the key distinction is:

  • Crack Filling: Treats less-active cracks with more cost-effective materials.

  • Crack Sealing: Targets cracks with significant movement using rubberized sealants that can expand and contract.

How Crack Filling Supports Pavement Longevity

Filling pavement cracks early prevents water from penetrating the subbase, which is the most significant factor in pavement failure. The benefits of crack filling include:

  • Extended pavement life

  • Delayed need for resurfacing or reconstruction

  • Improved ride quality and appearance

  • Reduced oxidation and raveling

  • Lower life-cycle maintenance costs

Crack filling is especially effective when combined with other maintenance practices such as sealcoating, patching, and surface overlays.

Types of Crack Fillers

The effectiveness of crack filling depends on choosing the right material for the pavement type, traffic conditions, and local climate. Common types of crack fillers include:

1. Cold-Pour Crack Fillers

  • Used for minor, narrow cracks.

  • Easy to apply without heating.

  • Typically used for low-traffic areas or temporary fixes.

  • Less flexible than hot-pour options.

2. Hot-Pour Rubberized Crack Fillers

  • Applied after heating to high temperatures.

  • Flexible and ideal for active cracks.

  • Provides long-term durability.

  • Recommended for highways, parking lots, and commercial areas.

3. Polymeric or Asphalt Emulsion Fillers

  • Modified binders for increased flexibility.

  • Can be used in a variety of climates.

  • Commonly used for residential driveways and light commercial areas.

Choosing the appropriate filler depends on the crack width, climate temperature ranges, and expected traffic loads.

Application Process

A quality crack filling process involves several key steps:

  1. Crack Cleaning

Cracks must be free of dirt, vegetation, and moisture. Compressed air, wire brushing, or heat lances are used to clean the area.

  1. Crack Preparation

For wider or irregular cracks, minor routing may be done to create a reservoir for better filler adhesion.

  1. Filler Application

The chosen filler is poured or injected into the crack. Hot-pour materials require specialized equipment to maintain temperature.

  1. Curing and Finishing

Filler is leveled and allowed to cool or cure. Some jobs may include a dusting of sand or blotter material to prevent tracking.

Regular maintenance checks should be done to monitor filled cracks and address any new damage. To maximize pavement lifespan, experts recommend combining crack fillers with sealants for long-term protection against moisture and surface wear.

When to Use Crack Filling

Crack filling is most effective when used proactively, not reactively. It’s recommended in the following scenarios:

  • Visible transverse or longitudinal cracks 1/8" to 1" wide.

  • Pavement in fair to good condition with isolated cracking.

  • Before applying sealcoat or surface treatments.

  • In climates with freeze-thaw cycles or heavy rainfall.

It’s not ideal for pavements with alligator cracking, severe base failures, or extensive surface distress—those issues require full-depth repair.

Cost-Effectiveness of Crack Filling

Compared to resurfacing or reconstruction, crack filling is extremely cost-effective. According to industry data:

  • Crack filling costs: $0.25 to $1.00 per linear foot.

  • Asphalt overlay costs: $1.50 to $3.50 per square foot.

  • Reconstruction costs: $5.00+ per square foot.

By investing in routine crack filling, municipalities, property managers, and homeowners can save thousands in long-term pavement management.

FAQs

1. What’s the difference between crack sealing and crack filling?

Crack sealing is used for working cracks that move due to temperature changes, using more elastic sealants. Crack filling is used for non-working cracks and uses less flexible, more cost-effective materials.

2. How often should crack filling be done?

Pavement should be inspected annually. Crack filling is typically done every 2–4 years depending on traffic levels, climate, and surface conditions.

3. Can crack fillers be used in cold weather?

Cold-pour crack fillers can be used in cooler conditions, but hot-pour materials require warmer ambient temperatures for proper curing. Most applications are done in spring and fall.

4. Does crack filling eliminate the need for sealcoating?

No. Crack filling and sealcoating serve different purposes. Crack filling addresses structural gaps, while sealcoating protects the surface from oxidation, moisture, and UV damage. Both are recommended for comprehensive maintenance.

5. Will filled cracks reappear over time?

Yes, filled cracks can reopen due to movement, traffic load, or extreme weather. However, routine monitoring and reapplication extend the life of the pavement and delay larger repairs.

Conclusion

Crack fillers play a vital role in preventative pavement maintenance. They are a practical, low-cost way to stop small problems from growing into costly failures. By addressing cracks early with the right materials and techniques, property owners and public works departments can extend pavement life, improve safety, and reduce long-term costs. Regular crack filling should be a foundational component of any pavement maintenance plan.