Cracks are one of the earliest indicators of asphalt pavement deterioration. When left untreated, they allow water to penetrate beneath the surface, weakening the pavement base, accelerating deterioration and increasing future maintenance costs.
For contractors and municipalities responsible for maintaining roads, streets, highways and other public infrastructure, addressing cracks early is an important part of an effective pavement preservation program. Selecting the right crack repair method, equipment and materials helps improve efficiency and achieve longer-lasting repairs.
What You’ll Learn
- What is Hot-Pour Crack Sealing?
- Benefits of Hot-Pour Crack Sealants for Asphalt Roads
- Choosing the Right Hot-Pour Crack Sealant
- Choosing the Right Hot-Pour Crack Sealing Equipment
- Oil-Jacketed Melters and Applicators for Hot-Pour Crack Sealing Materials
- CrackPro Double Pump Heated Hose Machine
- Direct Fire Melters for Hot-Pour Crack Sealing
- Learn More About When to Use Mastic for Asphalt Pavement Repairs
- SealMaster Support & Expertise
What Is Hot-Pour Crack Sealing?
Hot-pour crack sealing is a widely used pavement preservation process that uses heated, rubberized crack filler to seal cracks that are wider or deeper than ¼ inch in asphalt pavement.
Before application, the material is heated in specialized equipment to the manufacturer’s recommended temperature. Once properly heated, it flows into cracks where it bonds to the pavement and remains flexible after cooling.
Hot-pour crack sealants are designed to expand and contract with normal pavement movement during seasonal temperature changes. This flexibility helps maintain the seal over time, reducing water intrusion and preserving the pavement against further deterioration.
Hot-pour crack sealing is commonly used as part of roadway maintenance programs for:
- Municipal streets
- County roads
- State highways
- Airport pavements
- Industrial roadways
- Other asphalt surfaces subject to continual traffic and environmental exposure
Benefits of Hot-Pour Crack Sealants for Asphalt Roads
Prevents Water Intrusion
Water is one of the leading causes of pavement deterioration. By sealing cracks, hot-pour crack fillers help keep water from penetrating beneath the pavement surface, reducing the risk of base failure, erosion and freeze-thaw damage.
Remains Flexible as Pavement Moves
Asphalt naturally expands and contracts with changing temperatures. Hot rubberized crack sealants remain flexible after installation, allowing the sealant to move with the pavement while maintaining a durable bond to the crack walls.
Extends and Preserves Pavement Service Life
Sealing cracks before they widen or deteriorate further helps slow pavement aging and supports long-term preservation efforts. As part of a proactive maintenance program, crack sealing can delay more extensive repairs and maximize the life of existing asphalt pavements.
Available for a Wide Range of Applications
Not every roadway has the same maintenance requirements. Hot-pour crack sealants are available in a variety of formulations designed for different climates, traffic conditions and pavement types, making it easier to select the right material for each project.
Choosing the Right Hot-Pour Crack Sealant
Choosing the right hot-pour crack sealant depends on climate, pavement conditions, equipment compatibility and project specifications. Using the appropriate material ensures proper adhesion, flexibility and reliable performance.
CrackMaster Hot-Pour Rubberized Crack Sealants
SealMaster’s CrackMaster® line includes hot-pour crack sealants formulated for different climates, roadway conditions and equipment types, allowing contractors and municipalities to select materials that best match their project requirements.
CrackMaster 3405
Designed for use in oil-jacketed kettles, CrackMaster 3405 meets ASTM D3405 specifications and is ideal for roads and highways in colder climates. Its flexible formulation remains effective in temperatures as low as -20°F, making it well suited for regions that experience frequent freeze-thaw cycles.
CrackMaster 1190
CrackMaster 1190 is formulated for roads and highways in moderate climates and is recommended for use in oil-jacketed kettles. Remaining flexible to 0°F, it provides durable performance while accommodating normal pavement movement.
tack than standard parking lot formulas, lower penetration at elevated temperatures.
CrackMaster Parking Lot Grade
Designed for use in both direct-fired kettles with agitation and oil-jacketed kettles, CrackMaster Parking Lot Grade is a premium hot-applied crack and joint sealing material ideal for large parking lots. Its durable formulation resists tracking at elevated temperatures while remaining flexible in temperatures as low as -10°F.
CrackMaster Parking Lot Grade-LP
CrackMaster Parking Lot Grade-LP is a premium hot-applied crack and joint sealing material formulated for use in direct-fired kettles with agitation and oil-jacketed kettles. Designed for large parking lots, it offers lower surface tack and reduced penetration at elevated temperatures while remaining flexible in temperatures as low as -10°F.
CrackMaster CJA
CrackMaster CJA is a cold-joint adhesive designed for use in oil-jacketed kettles. Ideal for roads and highways, it promotes strong adhesion between asphalt joints while remaining flexible in a wide range of climates.
CrackMaster Supreme DF
For contractors seeking greater flexibility, CrackMaster Supreme DF is compatible with both direct-fire and oil-jacketed kettles. This premium hot-applied crack filler delivers dependable performance while allowing crews to use the same material across multiple equipment types.
Choosing the Right Hot-Pour Crack Sealing Equipment
The performance of a hot-pour crack sealant depends not only on the material itself, but also on the equipment used to heat and apply it. Consistent material temperatures, proper agitation and efficient application all contribute to quality results and improved productivity on the job site.
When evaluating hot-pour crack-sealing equipment, contractors and municipalities should consider factors such as:
- Heating system and temperature consistency
- Material capacity
- Agitation system
- Application method
- Recovery and heat-up times
- Ease of operation and maintenance
- Safety features
- Overall production requirements
Oil-Jacketed Melters and Applicators for Hot-Pour Crack Sealing Materials
Oil-jacketed equipment uses heat-transfer oil to surround the material tank, providing indirect, uniform heating that protects polymer-modified crack fillers while maintaining consistent application temperatures. This heating method is ideal for contractors and municipalities looking for reliable temperature control and high production capabilities.
CrackPro Gravity Flow Melters
CrackPro Gravity Flow Melters provide dependable performance for contractors and municipalities performing hot-pour crack sealing. Available in 125- and 260-gallon capacities, these machines combine consistent material heating with user-friendly operation for a variety of roadway maintenance projects.
Standard features include:
- State-of-the-art burner system with automatic shut-off
- Forward/reverse hydraulic agitation with direct-drive hydraulic motor
- Automatic temperature control
- Anti-splash material loading hatch
- Oil and material temperature gauges
- Low-profile design for improved operator safety
Extended deck models also provide additional storage space for crack preparation equipment, helping crews transport everything needed for the job on a single trailer.
CrackPro Heated Hose Melters and Applicators
When production demands increase, CrackPro Heated Hose Machines help crews maximize efficiency without sacrificing material quality. Available in D, DA and Double Pump models ranging from 125 to 400 gallons, these machines are designed to maintain consistent material temperatures while supporting continuous crack sealing operations.
Standard features include:
- The industry’s fastest heat-up and recovery times
- Heated hose technology that eliminates the need to flush the system
- Automatic temperature controls
- Anti-splash material loading hatch
- Full-sweep hydraulic agitation
- Liquid-cooled Kubota diesel engine
SealMaster also offers an Oil-Jacketed 300-Gallon Mastic Machine for crews performing larger asphalt repair applications requiring hot-applied mastic materials.
CrackPro Double Pump Heated Hose Machine
For larger roadway projects, the CrackPro Double Pump Heated Hose Machine allows two operators to apply hot-pour crack filler simultaneously. Dual-heated hoses and dual-material pumps significantly increase daily production, making them an excellent choice for high-volume municipal and contractor applications.
Direct Fire Melters for Hot-Pour Crack Sealing
Unlike oil-jacketed equipment, direct-fire melters apply heat directly to the bottom of the material tank to melt hot-pour crack filler. Their simple, straightforward design makes them a practical option for contractors and municipalities performing smaller roadway projects, localized repairs or applications where portability and ease of operation are priorities.
SealMaster offers a range of CrackPro direct-fire melters in various capacities, from portable units for small maintenance tasks to trailer-mounted models designed for higher production levels.
SM-125 Direct Fire Melter
The SM-125 is a trailer-mounted, 125-gallon direct-fire melter designed for hot-pour crack sealing operations. Standard features include:
- Automatic fuel shut-off
- Hydraulically driven forward/reverse full-sweep agitation
- Automatic temperature control
- Anti-splash loading hatch
- Storage deck with loading ramp
SM-30 Direct Fire Melter
The SM-30 features a 30-gallon capacity and hand-operated agitation, making it ideal for smaller crack sealing projects. Designed for use with a vapor LP cylinder, it offers a melting time of approximately 30 minutes for efficient jobsite operation.
MA-10 Melter Applicator
The portable MA-10 Melter Applicator features a 10-gallon capacity, hand-operated agitation and a melting time of less than 30 minutes. Its compact size makes it well suited for small repair projects and maintenance work.
SM-10 Melter
The SM-10 is a compact 10-gallon direct-fire melter that includes a burner, hose and regulator for use with a vapor LP cylinder. Its lightweight design makes it an ideal solution for smaller crack sealing applications.
Learn More About When to Use Mastic for Asphalt Pavement Repairs
Every pavement repair starts with selecting the right material for the job. While hot-pour crack fillers are an excellent choice for sealing cracks, mastic materials are often required for larger or more complex pavement distress. Mastic is commonly used for wide cracks, bridge joints, utility cuts, manhole surrounds and other repairs that demand a heavier-bodied material.
Discover when to use mastic, the equipment required and the advantages it offers in our next article.
Read Next: Advantages of Using Mastic for Asphalt Pavement Repairs
SealMaster Support & Expertise
For more than 55 years, SealMaster has helped contractors and municipalities protect and preserve asphalt pavements with professional-grade materials, equipment and technical expertise. Through more than 160 manufacturing and distribution locations worldwide, SealMaster provides expert product recommendations, equipment support and local service to help customers select the right pavement preservation solutions for every project.
To learn more about CrackMaster® hot-pour crack fillers, CrackPro® equipment or to find your nearest SealMaster location, contact your local SealMaster representative or call 800-395-7325.