The Two Terms
‘Crack sealing’ and ‘crack filling’ are often used interchangeably, but they refer to different products with different performance characteristics. Crack sealing uses hot-applied rubberized polymer that flexes with the pavement and bonds tightly. Crack filling uses cold-pour materials that are cheaper but less durable. For commercial work, crack sealing is the right choice.
Crack Sealing: What It Is
Crack sealing uses hot-pour polymer-modified rubberized asphalt heated to 380°F in a kettle and applied through a wand. The hot product flows into the crack, bonds with the pavement, and remains flexible after cooling — meaning it stretches and contracts with thermal cycling without breaking the seal. Service life: 5 to 7 years on average.
Crack Filling: What It Is
Crack filling uses cold-pour material — typically asphalt emulsion-based — that’s poured straight into the crack from a bottle or pail. It dries by water evaporation. It does not bond to the crack walls the way hot-pour seal does, and it’s not flexible enough to handle Chicagoland’s freeze-thaw cycle. Service life: 1 to 2 years.
Why Hot-Pour Wins for Commercial
Bonding. Hot-pour rubberized seal bonds with the asphalt at the crack walls. Cold-pour fillers sit in the crack like caulk in a window. Flexibility. Hot-pour stretches and contracts with thermal cycling. Cold-pour cracks under thermal stress. Durability. Hot-pour lasts 5 to 7 years. Cold-pour lasts 1 to 2 years. Cost-per-year. Hot-pour is more expensive per linear foot upfront but dramatically cheaper per year of service.
When Cold-Pour Filling Makes Sense
DIY residential repairs where the cost of hot-pour equipment isn’t justified. Quick visual fixes for cosmetic appearance. Temporary fixes when hot-pour isn’t available. Cracks too small for hot-pour wands (under 1/8 inch wide). For commercial work, cold-pour is rarely the right choice.
Routing: Important Pre-Treatment
For best results, cracks should be routed before sealing — meaning a routing tool cuts the crack into a clean rectangular reservoir 1/2 inch deep by 1/2 inch wide. Routing creates a deeper bond surface, removes deteriorated edges, and creates a reservoir that holds enough sealant to flex properly. Routed crack seal lasts 7+ years vs. 3 to 5 for un-routed.
Application Process
Clean the crack with high-pressure air to remove debris, dust, and moisture (all of which prevent bonding). Heat the sealant to 380°F in a kettle. Apply sealant through a wand, slightly overfilling the crack. Squeegee flush with the surrounding pavement. Cooling time: 30 minutes to traffic, full cure within 24 hours.
How Many Cracks to Seal
Best practice: seal every visible crack 1/4 inch wide or larger. Smaller cracks (hairline) are too narrow for sealant penetration and are addressed by sealcoating. Larger cracks (1/2 inch or wider) need routing for best results. Alligator cracking can’t be sealed — that requires saw-cut patching.
Annual vs. Multi-Year Cycle
Best practice: annual crack sealing every spring. New cracks form every freeze-thaw cycle, so catching them early prevents pothole formation. Some properties run 2-year cycles, but the math favors annual sealing for high-traffic commercial properties.
Get a Free Commercial Paving Estimate
Need help with a commercial paving project? Every estimate is free, on-site, and itemized. Most on-site estimate within 48 hours, with on-site estimate within 48 hours. Use the form on this page or call (630) 555-PAVE.
Get a Free Commercial Paving Estimate
Need help with a commercial paving project? Every estimate is free, on-site, and itemized. Use the form on this page or call (630) 555-PAVE.