FHWA Report No. FHWA-RD-99-146

Materials and Procedures for

Repair of Joint Seals in

Portland Cement Concrete Pavements

Manual of Practice

Federal Highway Administration

U.S. Department of Transportation

Strategic Highway Research Program

National Research Council
FOREWORD

This manual (FHWA-RD-99-146) is an update of the Strategic

Highway Research Program (SHRP) manual of practice

(SHRP-H-349) on concrete pavement repair. The Federal

Highway Administration, Long Term Pavement Performance

Program (LTPP) conducted five years of additional research on

concrete pavement repair after the conclusion of SHRP. This

research validated the repair procedures contained in the

original SHRP manual. The manual presents updated

guidelines and recommendations to assist highway maintenance

agencies and other related organizations in planning,

constructing, and monitoring the performance of concrete

pavement joint resealing projects. Included in the manual are

discussions pertaining to when joint resealing is appropriate, the

types of sealant materials and construction methods that should

be used, how each individual step in a joint resealing operation

should be performed, and how the performance and costeffectiveness of joint seals can be evaluated. This report will be

of interest and benefit to various levels of agency maintenance

personnel, from crew supervisors to the chief maintenance

engineer.

NOTICE

This document is disseminated under the sponsorship of the

Department of Transportation in the interest of information

exchange. The United States Government assumes no liability

for its contents or use thereof. This report does not constitute a

standard, specification, or regulation.

The United States Government does not endorse products or

manufacturers. Trade and manufacturers’ names appear in this

report only because they are considered essential to the object

of the document.
Technical Report Documentation Page

 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No.

FHWA-RD-99-146

 4. Title and Subtitle 5. Report Date

 6. Performing Organization Code

 8. Performing Organization Report No.

 7. Author(s)

 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS)

 ERES Consultants

 A Division of Applied Research Associates, Inc. 11. Contract or Grant No.

 505 W. University Avenue DTFH61-93-C-00051

 Champaign, IL 61820-3915 13. Type of Report and Period Covered

 12. Sponsoring Agency Name and Address Updated Manual of Practice

 Federal Highway Administration October 1993 - June 1999

 Pavement Performance Division

 6300 Georgetown Pike 14. Sponsoring Agency Code

 McLean, Virginia 22101

 15. Supplementary Notes

 FHWA Contracting Officer's Technical Representative (COTR): Shahed Rowshan, HRDI

 Project Consultants: Charlie Smyth

 16. Abstract

 17. Key Words 18. Distribution Statement

 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No of Pages 22. Price

Unclassified Unclassified 127

Form DOT F 1700.7 (8-72) Reproduction of completed page authorized

No restrictions. This document is available to the 

public through the National Technical Information 

Service, Springfield, Virginia 22161.

L.D. Evans, K.L. Smith, and A.R. Romine

The Strategic Highway Research Program (SHRP) H-106 maintenance experiment and the Federal Highway Administration

(FHWA) Long-Term Monitoring (LTM) of Pavement Maintenance Materials Test Sites project studied the resealing of joints

in concrete pavements. Many different sealant materials and resealing methods were investigated between 1991 and 1998

through test sites installed at five locations in the United States. The findings of these combined studies have been merged with

standard highway agency procedures to provide the most useful and up-to-date information on the practice of concrete joint

resealing.

This Manual of Practice is an updated version of the 1993 SHRP Joint Seal Repair Manual. It contains the latest information

pertaining to the performance of sealants and resealing methods, the availability and relative costs of sealant materials, and the

proper ways of planning, designing, constructing, and monitoring the performance of joint resealing projects. It also provides

an updated partial listing of material and equipment manufacturers.

This Manual is intended for field and office personnel within highway maintenance agencies and contracted maintenance firms.

It contains valuable information for supervisors and foremen in charge of individual resealing operations, engineers in charge of

planning and overseeing many joint resealing projects, and managers in charge of establishing resealing policies and standards.

Concrete pavement, pavement maintenance, joints, 

joint resealing, joint sealant, joint reservoir, 

performance, effectiveness, cost-effectiveness

Materials and Procedures for Repair of Joint Seals in Portland Cement Concrete 

Pavements---Manual of Practice
 
iii

Preface

This manual is intended for use by highway maintenance

agencies and contracted maintenance firms in the field and in

the office. It is a compendium of good practices for portland

cement concrete (PCC) joint resealing operations, stemming

from the Strategic Highway Research Program (SHRP)

pavement maintenance studies and a follow-up study sponsored

by the Federal Highway Administration (FHWA).

In SHRP project H-105, Innovative Materials and Equipment

for Pavement Surface Repair, the researchers conducted a

massive literature review and a nationwide survey of highway

agencies to identify potentially cost-effective pavement repair

and treatment options (Smith et al., 1991). The information

and findings from that study were then used in the subsequent

field experiments conducted under SHRP project H-106,

Innovative Materials Development and Testing.

In project H-106, many different test sections were installed and

evaluated to determine the cost-effectiveness of maintenance

materials and procedures. Test sections were installed at 22

sites throughout the United States and Canada between March

1991 and February 1992, under the supervision of SHRP

representatives. The researchers collected installation and

productivity information at each site and periodically evaluated

the experimental repairs and treatments through the end of

1992. The first version of this manual was prepared in October

1993 and was based on this work effort.

Following the conclusion of SHRP H-106 in 1993, the FHWA

sponsored a study to continue monitoring the performance of

the experimental repairs and treatments, beginning in October

1993. Under the Long-Term Monitoring (LTM) of Pavement

Maintenance Materials Test Sites project, the repairs and

treatments were evaluated annually through the end of 1997. 
iv

Pertinent long-term performance and cost-effectiveness

information generated by the continued monitoring of the

experimental joint resealing treatments has been included in this

revised manual.

For the reader's convenience, potentially unfamiliar terms are

italicized at their first occurrence in the manual and are defined

in a glossary. Readers who want more information on topics

included in this manual should refer to the reference list

provided at the back. The final report for the H-106/LTM

portland cement concrete (PCC) joint resealing study may be of

particular interest to many readers (Evans et al., 1999). It

details the installation procedures, laboratory testing of the

materials, and field performance of each joint resealing

treatment type investigated.
v

Acknowledgments

The research described herein was supported by the Strategic

Highway Research Program and the Federal Highway

Administration. SHRP was a unit of the National Research

Council that was authorized by section 128 of the Surface

Transportation and Uniform Relocation Assistance Act of

1987.

Special thanks are due the project management teams at SHRP

and the FHWA, and to the following State highway agencies:

! Arizona Department of Transportation

! Colorado Department of Highways

! Iowa Department of Transportation

! Kentucky Transportation Cabinet

! South Carolina Department of Highways and Public

Transportation

The contributions of the following individuals are also

acknowledged: Michael Darter, Sam Carpenter, David

Peshkin, Mike Belangie, Henry Bankie, Charlie Smythe, and

Jim Chehovits.
 
vii

Contents

1.0 Introduction ............................... . 1

1.1 Scope of Manual ...................... . 1

1.2 Overview ............................ . 2

2.0 Need for Joint Resealing ...................... . 3

2.1 Seal Condition ........................ . 3

2.2 Pavement Condition ................... . 9

2.3 Environmental Conditions ............... . 11

2.4 Traffic Conditions ..................... . 12

2.5 Determining the Need to Reseal ........... . 13

3.0 Planning and Design ......................... . 15

3.1 Primary Considerations ................. . 15

3.2 Objective of Resealing .................. . 15

3.3 Accounting for Existing Conditions ........ . 16

3.4 Selecting a Sealant Material Type ......... . 17

3.5 Selecting Backer Materials .............. . 20

3.6 Selecting Primer Materials ............... . 21

3.7 Selecting Joint Reservoir Dimensions ....... . 22

3.8 Selecting Preparation and

Installation Procedures ................. . 26

3.9 Selecting Equipment ................... . 29

3.9.1 Joint Plows .................... . 29

3.9.2 Concrete Saws ................. . 32

3.9.3 Abrasive Blasting Equipment ...... . 33

3.9.4 Airblasting Equipment ........... . 34

3.9.5 Hot Airblasting Equipment ........ . 36

3.9.6 Backer Rod Installation Tools ...... . 36

3.9.7 Hot-Applied Sealant Installation

Equipment .................... . 37

3.9.8 Silicone Sealant Applicators ....... . 38

3.9.9 Other Equipment ............... . 39

3.10 Estimating Material, Labor, 

and Equipment Requirements ............ . 39
viii

3.11 Determining Cost-Effectiveness ........... . 41

3.11.1 Material and Shipping Costs ....... . 41

3.11.2 Labor Costs ................... . 43

3.11.3 Equipment Costs ............... . 43

3.11.4 User Delay Costs ............... . 43

3.11.5 Cost-Effectiveness Comparisons .... . 45

4.0 Construction ............................... . 47

4.1 Traffic Control ....................... . 47

4.2 Safety Precautions ..................... . 47

4.3 Preparing the Joint ..................... . 48

4.3.1 Removing the Old Sealant ........ . 48

4.3.2 Refacing the Joint Sidewalls ....... . 51

4.3.3 Abrasive Blasting the

Joint Sidewalls ................. . 53

4.3.4 Airblasting the Joint Reservoir ..... . 56

4.3.5 Installing Primer ................ . 59

4.4 Material Preparation and Installation ....... . 59

4.4.1 Installing Backer Rod ............ . 60

4.4.2 Sealant Installation .............. . 63

5.0 Evaluation of Joint Seal Performance ............ . 77

Appendix A Material Testing Specifications ........... . 79

Appendix B Sample Cost-Effectiveness Calculations .... . 83

Appendix C Material and Equipment Safety Precautions . . 89

C.1. Materials ........................... . 89

C.1.1. Hot-Applied Sealants ............ . 89

C.1.2. Cold-Applied Sealants ........... . 90
ix

Appendix D Inspection Checklists for Construction ..... . 91

D.1 Preconstruction Plans and Specifications ... . 91

D.2. Equipment Inspection .................. . 93

D.3. Field Installation Inspection ............. . 94

D.3.1. Inspection of Joint Preparation ..... . 94

D.3.2. Inspection of Joint Sealant

Installation .................... . 98

D.4. Final Inspection ..................... . 101

Appendix E Partial List of Material and

 Equipment Sources .................. . 103

E.1. Sealant Material ..................... . 103

E.1.1. Manufacturers of Hot-Applied

Rubberized Asphalt Sealant ...... . 103

E.1.2. Manufacturers of Self-Leveling and

Non-Self-Leveling Silicone Sealant . . 104

E.2. Backer Rod Material ................. . 104

E.2.1. Manufacturers of Expanded ClosedCell Foam Rod ................ . 104

E.3. Sealant Installation Equipment .......... . 105

E.3.1. Manufacturers of Melter–Applicators

For Hot-Applied Sealants ........ . 105

E.3.2. Manufacturers of Pump Applicators

For Cold-Applied Sealants ....... . 105

Glossary ..................................... . 107

References .................................... . 111
 
xi

Figures

Figure 1. Concrete pavement/joint survey form ....... . 4

Figure 2. Sealant adhesion failure ................. . 7

Figure 3. Full-depth cohesion failure ............... . 7

Figure 4. Typical joint cross section ............... . 23

Figure 5. Rear-mounted joint plow ................ . 31

Figure 6. Undercarriage-mounted joint plow ......... . 31

Figure 7. Concrete joint saw ..................... . 32

Figure 8. Abrasive blasting equipment ............. . 34

Figure 9. Airblasting operation ................... . 35

Figure 10. Hand-operated backer rod installation tool ... . 36

Figure 11. Automated backer rod installation tool ..... . 37

Figure 12. Joint plowing operation ................. . 50

Figure 13. Joint resawing operation ................ . 52

Figure 14. Abrasive blasting operation .............. . 55

Figure 15. Airblasting operation ................... . 57

Figure 16. Backer rod installation .................. . 62

Figure 17. Hot-applied sealant installation ........... . 67

Figure 18. Silicone sealant installation .............. . 72

Figure 19. Example joint seal deterioration chart ...... . 78
 
xiii

Tables

Table 1. Decision table for resealing PCC joints ..... . 5

Table 2. Climatic region parameters .............. . 12

Table 3. Traffic-level rating ..................... . 13

Table 4. Relationship between pavement condition

and sealing objectives .................. . 16

Table 5. Factors affecting sealant conditions ........ . 18

Table 6. Summary of sealant materials ............. . 19

Table 7. Backer rod materials ................... . 21

Table 8. Typical recommended shape factors ........ . 23

Table 9. Typical joint design dimensions ........... . 25

Table 10. Joint preparation/installation procedures .... . 27

Table 11. Joint resealing equipment requirements ..... . 30

Table 12. Production rates, costs, and amounts ....... . 40

Table 13. Material and shipping costs .............. . 42

Table 14. Labor costs .......................... . 44

Table 15. Equipment costs ...................... . 44

Table 16. Cost-effectiveness worksheet ............. . 46

Table 17. Troubleshooting procedures for plowing .... . 50

Table 18. Troubleshooting procedures for resawing ... . 53
xiv

Table 19. Troubleshooting procedures for

sandblasting .......................... . 56

Table 20. Troubleshooting procedures for 

airblasting ........................... . 58

Table 21. Troubleshooting procedures for 

backer rod installation .................. . 63

Table 22. Troubleshooting procedures for 

hot-applied sealant installation ............ . 69

Table 23. Troubleshooting procedures for 

cold-applied sealant installation ........... . 74

Table A-1. Rubberized asphalt specifications .......... . 80

Table A-2. ASTM D 5893 silicone sealant specifications . . 81

Table B-1. Example material and shipping costs ....... . 84

Table B-2. Example labor costs .................... . 85

Table B-3. Example equipment costs ............... . 86

Table B-4. Example cost-effectiveness calculations ..... . 87
1

1.0 Introduction

This manual has been prepared for use by maintenance

engineers, maintenance field supervisors, crew persons,

maintenance contractors, and inspectors as an easy reference

for resealing* transverse and longitudinal joints in portland

cement concrete (PCC) pavements. 

1.1 Scope of Manual

Included in this manual are descriptions of procedures and

materials recommended for resealing joints in PCC pavements. 

Guidelines for planning a resealing project and steps for

installing joint seals and inspecting the process are presented. 

The resealing of concrete-asphalt shoulder joints and sealing

cracks in PCC pavements are not addressed.

The information contained in this manual is based on the most

recent research, obtained through reviews of literature and of

current practice, as well as from the field results of a 7-year

study (Smith et al., 1991; Evans et al., 1999). This study

investigated the performance in PCC joints of various hot- and

cold-applied sealants using several methods of installation.

*

Italicized words are defined in the glossary.
2

1.2 Overview

Several steps are required for successful resealing of joints in

PCC pavements. The first is determining the need for resealing. 

Chapter 2 of this manual contains a general procedure that can

be easily modified to meet the needs of any highway agency. 

Once the need for resealing is determined, the next step is

planning the operation. Chapter 3 leads the maintenance

planner through the steps for selecting sealant and accessory

materials, choosing preparation and installation procedures,

specifying equipment, and estimating material and labor

requirements. 

The construction phase of joint resealing is described in chapter

4. Details of each step of the preparation and installation

operations are listed, along with troubleshooting procedures for

each operation. 

The appendixes provide material testing specifications, sample

cost-effectiveness calculations, safety precautions, and

inspection checklists to help ensure good resealing practices

and high-quality results.
3

2.0 Need for Joint Resealing

Excessive delay in replacing a failing sealant system in concrete

pavement joints can result in more rapid deterioration of the

pavement. However, if sealant is replaced too early, precious

maintenance funds may not have been used in the most costeffective manner. How, then, can those responsible for

maintenance determine when is the best time to reseal joints in

concrete pavements? Some States specify that joints be

resealed when a specified amount of sealant material (25 to 50

percent) has failed, allowing moisture or incompressible

materials to progress past the sealant to the underlying layers. 

Other agencies base their decision on pavement type, pavement

and sealant condition, and available funding.

A more complete method for determining whether a pavement

needs to be resealed is to calculate rating numbers based on the

sealant and pavement condition, traffic levels, and climatic

conditions. Figure 1 presents a worksheet that can be used to

estimate these properties, and table 1 gives recommendations

about the need to reseal based on these properties. The

following sections assist in determining the necessary ratings

and conditions.

2.1 Seal Condition

Joint sealant system effectiveness is judged by the sealant's

ability to resist embedment of incompressible materials and the

sealant system's success in preventing entry of water and

incompressible materials into the joint. To evaluate pavement

seal condition, the following steps should be completed and

results recorded on the pavement survey form:
4

Figure 1. Concrete pavement/joint survey form.

Seal Condition Pavement Condition

Low Med High Low Med High

Water entering, % length < 10 10-30 > 30 Expected Pavement Life,

yrs.

> 10 5-10 < 5

Stone intrusion L M H Average faulting, mm <1.5 1.5-

3.0

>3.0

Seal Rating Good Fair Poor Corner breaks, % slabs < 1 1-5 > 5

Environmental Conditions

Pumping, % joints < 1 1-5 > 5

Spalls >25 mm, % slabs < 5 5-10 >10

Avg annual precip., mm Pavement Rating Good Fair Poor

Days < 0oC

Current Joint Design Avg low / high temp, oC

Climatic Region a WF WNF

 DF DNF

Sealant age, yrs

Traffic Conditions

Avg. sealant depth, mm

Avg. joint width, mm

ADT (vpd); % Trucks Avg. joint depth, mm

Traffic Level b Low Med High Max. joint spacing, m

a

 See table 2.

b

 See table 3.
5

Table 1. Decision table for resealing PCC joints.

Sealant

Ratinga

Pvmt.

Rating

Traffic

Rating

Climatic Region

Freeze Nonfreeze

Wet Dry Wet Dry

Fair Good Low Possibly Possibly Possibly Possibly

Fair Good Med Yes Possibly Possibly Possibly

Fair Good High Yes Yes Yes Possibly

Fair Fair Low Yes Possibly Possibly Possibly

Fair Fair Med Yes Yes Yes Possibly

Fair Fair High Yes Yes Yes Possibly

Fair Poor Low Possibly Possibly Possibly Possibly

Fair Poor Med Yes Yes Yes Possibly

Fair Poor High Yes Yes Yes Yes

Poor Good Low Yes Possibly Possibly Possibly

Poor Good Med Yes Yes Yes Possibly

Poor Good High Yes Yes Yes Yes

Poor Fair Low Yes Yes Yes Possibly

Poor Fair Med Yes Yes Yes Yes

Poor Fair High Yes Yes Yes Yes

Poor Poor Low Yes Yes Yes Possibly

Poor Poor Med Yes Yes Yes Yes

Poor Poor High Yes Yes Yes Yes

a

 Sealants rated in "Good" condition do not require replacement.
6

% L '

Lf

Ltot

x 100 Eq. 1

1. Choose 10 or more joints whose sealant condition is

representative of the entire site. If large variations in

condition are evident, subdivide the site into sections

having similar seal condition and evaluate 5 to 10 joints

from each section. 

2. Cut 50-mm samples of sealant from a few joints and

measure the joint width, depth, and sealant thickness. 

3. Determine from the construction records the type and

age of the sealant, the design joint width, and sealant

thickness. 

4. Record the maximum spacing between joints.

Carefully inspect each of the chosen joints, recording the

following items on the pavement survey form:

! Water Resistance— The percentage of overall joint

length where water can bypass the sealant and enter the

joint. 

! Stone Intrusion— The amount of stones, sand, and

debris embedded in the sealant.

Common joint seal distresses include loss of bonding to the

concrete sidewall (figure 2), cohesive failure (figure 3), spalls,

and torn or missing sealant. They reduce water resistance and

allow moisture, sand, and dirt to enter the joint. Bond failure

can be determined by pulling the sealant away from the joint

edge and inspecting for adhesion failure. Full-depth spalls can

be identified by gently inserting a dull knife into the spall and

observing if the knife tip can pass below the sealant. Another

method for locating areas of bond failure is with the Iowa

vacuum (IA-VAC) tester, developed by the Iowa Department

of Transportation (DOT). The percentage of water resistance

loss can be computed using equation 1.
7

Figure 2. Sealant adhesion failure.

Figure 3. Full-depth cohesion failure.
8

SCN ' 1(L) % 2(M) % 3(H) Eq. 2

where: %L = Percent length allowing water to enter joint.

Lf = Total length of joint sections allowing the

entrance of water, m.

Ltot = Total joint section length evaluated, m.

Stone intrusion can be rated using the following criteria, and the

rating should be recorded on the pavement survey form: 

Low = Occasional stones or sand stuck to the top of

the sealant (or material embedded on the

surface of the sealant/channel interface).

Medium = Sand or debris stuck to sealant and some

debris deeply embedded in the sealant.

High = Much sand and debris stuck to and deeply

embedded in the sealant or filling the joint.

Next, determine the sealant rating by calculating the seal

condition number (SCN). This number can be computed using

the following equation:

where:SCN = Seal condition number.

L = The number of low-severity seal conditions

recorded on the pavement survey form.

M = The number of medium-severity seal

conditions.

H = The number of high-severity seal conditions.

Use the SCN and the following rating to determine whether the

existing joint seal is in good, fair, or poor condition, and circle

the correct seal rating on the pavement survey form.
9

Seal Rating SCN

Good 0 - 1

Fair 2 - 3

Poor 4 - 6

Results of a seal condition rating can also be used to monitor

the performance of joint seals and to assist in follow-up

rehabilitation planning.

2.2 Pavement Condition

Pavement condition is the next item to identify. A pavement

will provide several indicators that the joint seal is not

performing adequately and is allowing too much water to reach

the underlying layers. These indicators include the following:

! Surface staining or the accumulation of fine material on

the surface close to joints or cracks indicates pumping

of the base or subbase. This results, in part, from excess

moisture, and it contributes to formation of voids

beneath the pavement, cracks, and corner breaks. 

! Faulting, or drop-off between adjacent slabs, can

indicate that excess moisture is reaching a watersusceptible base or subgrade, and that voids are forming

beneath one side of the pavement as a result of continual

traffic. 

! D-cracking can result from excess moisture beneath a

pavement.

A pavement system can also manifest the effects of the entrance

of stones and other incompressible materials into pavement

joints by the following:
10

PCN ' 1(L) % 2(M) % 3(H) Eq. 3

! Compression-related spalling of the walls of joints that

are filled with sand and stones. 

! Blowups and shattering of slab edges, as well as

permanent increases in joint width causing closure of

nearby expansion joints. 

To evaluate the condition of a pavement considered for

resealing, record the following items in the pavement condition

section of the concrete pavement/joint survey form (figure 1). 

These items should be based on field inspection and the

maintenance schedule.

! The estimated number of years before the pavement

requires major rehabilitation. 

! The average vertical faulting movement.

! The percentage of slabs containing corner breaks.

! The percentage of joints visibly indicating pumping.

! The percentage of slabs containing full-depth spalls

extending greater than 25 mm from the face of the joint. 

To determine a pavement condition number (PCN), use figure 1

and equation 3.

where:PCN = Pavement condition number.

L = The number of low-severity pavement

condition indicators from the pavement

survey form.

M = The number of medium-severity pavement

condition indicators.

H = The number of high-severity pavement

condition indicators.
11

Use the PCN and the following ratings to determine the

condition of the existing pavement and circle the correct

pavement rating on the pavement survey form:

Pavement Rating PCN

Good 0 - 3

Fair 4 - 5

Poor 6 - 15

2.3 Environmental Conditions

The effects of extreme temperatures and precipitation on joint

seal and pavement performance cannot be minimized. In

extremely cold temperatures, sealants are stretched the most as

pavements shrink and joints widen. Extremely hot temperatures

can compress improperly placed sealant, forcing it above the

pavement surface where it may be pulled out by vehicle tires.

Wet climatic regions need highly effective seals (approaching

100 percent effectiveness) to prevent water damage to

susceptible base and pavement structures. Dry climates also

may require highly effective seals to prevent the intrusion of

incompressible material into the joint, which can result in joint

growth, blowups, and structural damage.

When evaluating the climatic conditions that a pavement will

experience, determine the following information and enter it in

the environmental condition section of the concrete

pavement/joint survey form:
12

Table 2. Climatic region parameters

 Climatic 

 Region

Mean annual days 

< 0oC

Average annual

precipitation

Wet-Freeze > 100 > 635 mm

Wet-Nonfreeze < 100 > 635 mm

Dry-Freeze > 100 < 635 mm

Dry-Nonfreeze < 100 < 635 mm

! The normal annual total precipitation for the location.

! The mean number of days in a year with a minimum

temperature of 0oC or below. 

! The highest and lowest recorded temperatures. 

This information is available from the National Climatic Data

Center in Asheville, North Carolina, or from local weather

recording stations. Then, using the information from figure 1

and table 2, identify the climatic region in which the pavement

is located. Circle the correct climatic region on the pavement

survey form.

2.4 Traffic Conditions

To identify traffic conditions, obtain the average daily traffic

(ADT) level and the percent truck traffic. Determine the traffic

level rating from table 3. If the percent trucks is greater than

10 percent or the expected growth rate is greater than 5

percent, use the next higher traffic level rating.
13

Table 3. Traffic-level rating.

Traffic Level ADT, vpd all lanes

Low < 5,000

Medium 5,000 to 35,000

High >35,000

2.5 Determining the Need to Reseal

After completing the pavement evaluation worksheet, use table

1 and the calculated SCN, PCN, the traffic rating, and the

climatic region to evaluate the need for resealing. The basis for

this table is engineering experience; however, it can be adjusted

to the needs and policies of individual State agencies. Choose

the row with the combination of sealant, pavement, and traffic

rating from the three left-hand columns that match the

pavement being evaluated. Then find the intersection of that

row with the appropriate climatic region to obtain the

recommendation on the need for resealing. 

If the recommendation is that sealing is "possibly" needed, then

the case is borderline, and good judgment should be used in

determining the need to reseal. If D-cracking is evident in the

pavement surface, it may be more critical to completely seal the

transverse and longitudinal pavement joints. When an overlay

or rehabilitation is scheduled within 3 to 5 years, sealing could

be delayed unless pavement or base damage would result.

Agencies should use local experience for final determination of

whether and how to reseal.
 
15

3.0 Planning and Design

3.1 Primary Considerations

After determining the need to reseal the joints in a concrete

pavement section, it is important to plan the sealing operation

to ensure that a proper resealing job is completed. Proper

planning should take into account the following factors:

! The long- and short-term objectives for resealing.

! The current sealant and pavement condition and the

place of the resealing effort in an overall maintenance

plan. 

! The applicability and documented performance of the

sealant materials chosen. 

! The effectiveness of the equipment and installation

methods chosen. 

! The level of strain placed on the sealant system as a

result of the dimensions of the joint reservoir.

! The minimization of traffic disruption, increased worker

safety, and efficient installation rates.

3.2 Objective of Resealing

When beginning, it is important to determine the objective of

the resealing project. Possible objectives include the following:

! Temporarily seal the pavement joints for 1 to 2 years

until the pavement is overlaid or replaced.

! Seal and maintain watertight joints for 3 to 5 years.

! Seal and maintain watertight joints for a period

extending more than 5 years. 
16

Table 4. Relationship between pavement condition

and sealing objectives.

 Condition Objective

Pavement to be overlaid in 

1 to 2 years.

Temporarily seal pavement.

Pavement in fair condition. Major

rehabilitation scheduled in 5 years. 

Maintain seal until rehabilitation.

Pavement in good condition and

carries high level of traffic.

Maintain seal as long as possible.

Each of these objectives may be correct for a different situation,

depending primarily on the pavement condition and the traffic

level, as illustrated in table 4.

In dry climates, it is more important to keep sand and dirt out

of the joints to prevent spalling and blowups. A sealant should

then be chosen that does not allow sand to penetrate the sealant

surface. In hot climates, some sealants flow down into the

joint, or track on the surface, or allow stones to become

embedded in the sealant. In some situations, a jet-fuel resistant

(JFR) sealant material is required. In some pavements, only

certain areas of sealant have failed and selective replacement is

needed. Consequently, when choosing sealant materials and

installation methods, the objectives must match the

requirements of the situation. 

3.3 Accounting for Existing Conditions

The condition of a pavement when it is resealed can greatly

affect the performance of the seal. Corner breaks, large spalls,

voids beneath the pavement, faulting, and poor load transfer

can all reduce the effective life of resealed joints. Depending on

existing conditions, some of these pavement distresses should

be repaired before sealant is installed (Collins et al., 1986). 
17

Specifically, prior to resealing, the following repairs should be

considered (Darter et al., 1985):

! Full-depth repair of corner breaks and deep spalls.

! Partial-depth repair of spalls that extend more than 25

mm from the face of the joint.

! Improving subdrainage or roadside drainage. 

! Restoring load transfer at joints and cracks where

poor load transfer exists.

! Undersealing the pavement where voids exist. 

! Grinding the pavement surface to restore a smooth

ride or to improve traction.

Each of these repairs, if needed, should be completed before

resealing begins. The condition of the sealant in longitudinal

joints and transverse cracks should also be evaluated to

determine if resealing is appropriate (Carpenter et al., 1987). 

Studies have shown that extensive pavement damage can occur

due to the large amount of water entering a pavement system

through open transverse cracks and longitudinal joints. 

The condition of the existing joints and sealant can reveal much

about the conditions under which it failed. Several of these

indicators are listed in table 5. When these or other conditions

are evident, care should be taken to address and eliminate them

for the resealing project. 

3.4 Selecting a Sealant Material Type

Sealant materials are subjected to very harsh conditions. 

Selected sealants must have the following capabilities:
18

Table 5. Factors affecting sealant conditions.

Observed Sealant Condition Possibly Indicates That... 

Sealant pulled away from edges

along majority of the site.

Large amount of joint movement. 

Poor sealant or placement

methods.

Sealant pulled away from joint

edges at random positions.

Joint may not have been cleaned

properly.

Sealant tracked on pavement. Sealant overheated,

contaminated, or has too low a

softening point.

! Withstand horizontal movement and vertical shear at

all temperatures to which they are exposed. 

! Withstand environmental effects such as weathering,

extreme temperatures, and excess moisture. 

! Resist penetration by stones and sand at all

temperatures.

! Maintain complete bond to concrete joint sidewalls at

all temperatures. 

There are a wide variety of sealant materials on the market,

each with its own characteristics and costs. However, no one

sealant can meet the demands of every resealing project. 

Sealant selection should be based on the objectives of the

resealing project. 

Table 6 contains a listing of sealant material types commonly

used in resealing joints in PCC pavements. Applicable

specifications are also listed. To help the designer in choosing a

sealant material, the allowable extension and cost range are

included. The allowable extension is the manufacturerrecommended maximum in-place sealant extension.
19

Table 6. Summary of sealant materials.

Sealant Material Applicable Specifications

Design

Extension, % a

Cost Range,

$/L b

PVC Coal Tar ASTM D 3406 10 to 20% $1.75 to 

$2.75

Rubberized

Asphalt

ASTM D 1190,

AASHTO M 173,

ASTM D 3405,

AASHTO M 301

15 to 30% $0.60 to

$1.00

Low Modulus

Rubberized

Asphalt

Modified

ASTM D 3405 30 to 50% $0.70 to 

$1.20

Polysulfide

(1 & 2 Part) Fed SS-S-200E 10 to 20% NotAvailable

Polyurethane Fed SS-S-200E 10 to 20% $5.20 to

$7.20

Silicone

(non-sag) ASTM D 5893 30 to 50% $6.50 to$9.00

Silicone

(self-leveling) ASTM D 5893 30 to 50% $6.50 to$9.50

a

 Consult manufacturers for specific design extensions.

b

 Based on 1998 estimated costs.

Compression seals are not typically used when the pavement

joints are spalled, since the seals tend to twist or move up or

down in the joint at locations where the joint edge is not

vertical and completely smooth.

Many agencies have full-scale testing programs to determine

the performance of potential materials under local conditions. 

Thorough field and laboratory testing is recommended before

any sealant is used on a large-scale project. Commonly used

lab specifications are shown in appendix A.
20

A life-cycle cost analysis (LCCA) should be performed to

determine the material with the least average annual cost over

the expected life of the pavement. Section 3.11 includes a

worksheet to assist in conducting an LCCA.

3.5 Selecting Backer Materials

Backer rod is typically inserted in PCC joints prior to resealing

to keep the sealant from sinking into the reservoir. It also

keeps the sealant from bonding to the bottom of the reservoir

and, if properly selected and installed, it helps maintain the

proper sealant thickness. The rod must be flexible,

compressible, non-shrinking, non-reactive, and non-absorptive. 

Shrinking rod may allow sealant to flow past the rod before the

sealant sets. Backer rod that reacts with certain sealants may

produce bubbles in or staining of the sealant. Finally, backer

rod that absorbs water may shorten the life of the sealant

material.

Several currently available types of backer rod are described in

table 7. Each type has specific properties and intended uses. 

For example, several backer rod types are designed to

withstand the extreme temperatures of hot-applied sealants,

while others are intended only for cold-applied sealants. 

Softer, extruded foam rods have been developed to better seal

joints with irregular edges. Backer tapes that require a more

shallow joint have also been used. 

The manufacturers’ recommendations should be followed when

selecting rod type, since sealant and backer rod must be

compatible. The more commonly used backer rod materials for
21

Table 7. Backer rod materials.

Backer 

Material Type

Applicable 

Standard Properties Compatibility

Extruded closedcell polyethyleneASTM D 5249

Type 3

NMA,

ECI, NS

Most coldapplied sealants

Cross-linked

extruded closedcell polyethylene

ASTM D 5249

Type 1

HR,

NMA,

ECI, NS

Most hot- and

cold-applied

sealants

Extruded

polyolefin

ASTM D 5249

Type 3

NMA, NS,

NG, CI, IJ

Most coldapplied sealants

CI = Chemically inert NG = Non-gassing

ECI = Essentially chemically inert NMA = Non-moisture absorbing

HR = Heat resistant NS = Non-staining

IJ = Fills irregular joints well

hot-applied sealants are cross-linked extruded foam rods. For

cold-applied sealants, extruded closed-cell polyethylene foam or

extruded polyolefin foam rod is typically used. The rod

diameter should be at least 25 percent larger than the joint

width. Backer rod is available in diameters ranging from 10 to

75 mm or more. Since joint widths may vary within a

rehabilitation project, a sufficient range of rod sizes should be

on hand to obtain a tight seal in all joints.

3.6 Selecting Primer Materials 

In areas where high humidity and moisture make it difficult to

obtain a good bond between the sealant and the concrete,

primer may be recommended by the planner or the sealant

manufacturer. The purpose of a primer is to bond to the

concrete surface and provide a surface to which the new sealant

can bond well. Primer may also be used when past experience
22

indicates that it is difficult to obtain a good bond with the

specified sealant. Difficulties in obtaining a good bond with

soft aggregate can also be reduced by use of a primer.

Primers are currently used in only a small percentage of major

PCC resealing operations, with most of the use occurring in wet

or cold climates. Consult sealant manufacturers for primer type

recommendations when the need for priming the joints exists. 

3.7 Selecting Joint Reservoir Dimensions

The width of a joint and the thickness of the sealant in that joint

can significantly affect the performance of the seal (USAF,

1983; ACI, 1990). If a joint is too narrow and temperature

changes cause the joint to widen significantly, the sealant may

be stretched beyond its breaking point or pulled away from the

concrete. In addition, if a thick sealant is stretched, it may tear

or not stick to the concrete, in the same way that a thick rubber

band cannot be stretched as far as a thin one before tearing. 

In designing the dimensions of a joint sealant and the sealant

reservoir, two major items must be determined: the shape factor

and the expected joint movement. Figure 4 shows the

dimensions of a typical sealant reservoir containing sealant

material and backer rod. The shape factor is the ratio of the

sealant width to the thickness (W:T). The sealant recess is

designated as "R," and the joint channel depth is "D."

Manufacturers' recommendations should be followed when

choosing a shape factor. Typical recommended shape factors

are shown in table 8. Silicone manufacturers recommend a

minimum thickness of 6 mm and a maximum of 13 mm.
23

Sealant

Backer Rod

W

D

T

R

Figure 4. Typical joint cross section.

Table 8. Typical recommended shape factors.

Sealant 

Material Type

Typical Shape

 Factor (W:T)

Rubberized Asphalt 1:1

Silicone 2:1

PVC Coal Tar 1:2

Polysulfide and Polyurethane 1:1
24

M ' C L a T Eq. 4

%Emax' 100

Mmax

Winit

Eq. 5

Mmax' 2 M Eq. 6

The maximum joint opening movement for rehabilitated joint

seals can be estimated using equation 4 (Bodocsi et al., 1992).

where: M = Joint opening movement caused by

temperature change of PCC, mm.

C = Subbase/slab friction resistance adjustment

factor (0.65 for stabilized subbase, 0.80 for

granular subbase).

a = Thermal coefficient of contraction for PCC

(9.0 to 10.8 x 10-6/

oC).

L = Joint spacing, mm.

T = Temperature range (temperature at placement

minus lowest mean monthly temperature), oC.

Based on equation 4, the percent elongation that the new

sealant must allow is determined by the following equation:

where: %Emax = Estimated elongation, percent.

Mmax = Joint opening movement caused by

 change of PCC temperature, mm.

Winit = Joint width at the time of sealant

 placement, mm.

Some engineers prefer to determine Mmax using the safer

assumption that a joint between two slabs may be called upon

to take the total movement of both slabs. In this assumption:
25

Table 9. Typical joint design dimensions.

Maximum Joint

Spacing, m

Minimum Joint Width, mm a

Nonfreeze Region b Freeze Region c

< 4.6 6 10

4.7 to 7.6 6 to 10 10 to 13

7.7 to 12.2 10 to 13 13 to 19

12.3 to 18.3 13 to 19 19 to 29

a

 Installation temperature is 27oC, base is stabilized, %Emax < 20%.

b

 Minimum nonfreeze region temperature is -7oC.

c

 Lowest freeze region mean monthly temperature is -26oC.

The joint width, W, should be wide enough to keep the sealant

from being stretched in cold weather more than the design

amount, typically 20 percent. However, joints should not

typically be wider than 19 mm (Collins et al., 1986; USAF,

1983). As a result, there is a tradeoff in the Mmax approach

between reduced sealant fatigue and reduced allowable future

joint widening.

Suggested sealant thicknesses and minimum joint widths for

various joint spacings are listed in table 9 as a check for more

detailed joint design. This table is based on limiting the sealant

stress to less than 20 percent.

The joint reservoir sawcut depth, D, should be the sum of the

selected sealant thickness, the compressed backer rod thickness,

and the depth that the sealant surface is to be recessed. Some

manufacturers recommend that an extra 6 mm be added when

resealing joints to prevent water and material beneath the

sealant from pushing the sealant up and out of the joint. Extra

depth is also needed to account for variability in the sawing

operation. 
26

3.8 Selecting Preparation and Installation

 Procedures

The type of joint cleaning procedures and the final cleanliness

of the concrete joint walls prior to sealant installation can

significantly affect the performance of sealant materials. As a

rule, the cleaner and drier the joint surfaces are, the better a

sealant will adhere, and the more effective it will be. Therefore,

preparation and installation procedures should be chosen as

carefully as sealant materials.

The selection of which combination of preparation and

installation procedures to use should be based on the condition

and requirements of each individual resealing project. Four

combinations are shown in table 10. Each option, if followed

completely, should result in clean joint surfaces and increase the

chances for good performance. 

Option 1 should be considered when:

! The resealing project carries a high volume of traffic.

! A high-quality sealant is being used.

! Joint widths or depths do not meet the minimum design

requirements.

! The existing sealant is hardened and will not melt and

"gum-up" the saw blades.

Option 2 differs from option 1 only by the elimination of water

washing. This option can be used only when it can be

demonstrated that sufficient joint surface cleanliness can be

achieved without water washing.

Option 3 adds a plowing operation to the option 2 procedures. 

It should be used when:
27

Table 10. Joint preparation/installation procedures.

Option Plow Saw Water

Wash

Initial

Airblast

Sand

Blast

Final

Airblast

Backer

Rod

Recessed

Sealant

1 T T T T T T T

2 T T T T T T

3 T T T T T T T

4 T T T T T

! A saw is melting the existing sealant and cannot remove

the sealant efficiently by itself. 

! The joint dimensions are not adequate.

Option 4 replaces the sawing operation with an effective

plowing operation. It can significantly reduce the preparation

time and, since it is a dry operation, it allows immediate

cleaning and resealing. It may only be used if:

! The joint dimensions are adequate.

! The plowing equipment removes more than 95 percent

of the sealant from the joint faces, leaving fresh,

unspalled concrete. 

! The sandblaster is able to efficiently remove any

remaining sealant. 

If compression seals are being replaced with formed-in-place

sealant, sawing is not required when sandblasting can

completely remove the old lubricant from the joint walls

(Collins, 1986).

Several methods of sealant installation have also been used with

varying results (Smith et al., 1991; Evans et al., 1993; Lynch et

al., 1993; Evans et al., 1999). These include:
28

! Recessing the sealant below the pavement surface.

! Keeping the sealant surface level with the pavement

surface.

! Overbanding sealant onto the pavement surface.

Overbanded seals tend to oxidize at a slower rate than recessed

asphalt-based sealants because of the massaging action of traffic

tires. As a result, adhesion failures may occur more quickly in

recessed sealants. A 7-year study of joint seals in five States

indicates that overbanded ASTM D 3405 seals have statistically

outperformed recessed seals even when installed in transverse

joints on heavily trafficked roadways (Evans et al., 1999).

In longitudinal lane-shoulder joints, overbanding may provide

better performance than recessed seals. Therefore, in reduced

traffic areas, such as low-volume roads or lane-shoulder joints,

overbanded sealants may be the most effective choice.

There are two drawbacks of overbanding on PCC pavements. 

First, overbanded sealant material is typically worn away by

traffic within 1 to 3 years. After it is worn, traffic tires tend to

pull the sealant from the joint edge, leading to adhesion failure. 

Second, the scraping action of ice blades on highways in cold

regions tends to pull up overbanded seals from the pavement

surface.

Silicone sealants should never be overbanded or flush with the

pavement surface. Manufacturers recommend a minimum of 7

to 10 mm recess below the pavement surface for all silicone

sealants to avoid the premature adhesion failure noted in the

Long-Term Pavement Performance (LTPP) Specific Pavement

Studies (SPS)-4 test sections in four States (Smith et al., 1999). 
29

3.9 Selecting Equipment

Selection of equipment for the resealing process should be

based on its ability to complete the task. This ability should be

proven prior to beginning the resealing operation by

constructing a test resealing section. 

A contractor or highway maintenance crew should be allowed

to choose the equipment that will effectively clean and reseal

concrete joints in the most efficient manner. However, several

items have been shown to be important to successful use of

each piece of equipment. These requirements are listed in

table 11.

3.9.1 Joint Plows

A joint plow used only to remove sealant prior to sawing must

remove enough sealant to keep the saw blades from gumming

up. A shop-made, rear-mounted plow for this purpose is

shown in figure 5. If the plow is used without resawing, it must

be able to efficiently remove at least 95 percent of the old

sealant from the joint walls and not spall the joint sidewalls. 

Plowing has also been successfully accomplished by attaching a

hydraulically controlled carbide-tipped blade to the underbody

of a small (13.4 to 17.9 kW) tractor, as shown in figure 6. 

Multiple blade sizes should be on hand to keep the blades from

binding in narrow joints. 

Plow blades generally have straight sides, but they may be

tapered. Tapered blades tend to spall the joint edges, especially

at intersections with other joints, at pavement edges, and where

the joint width changes quickly. Straight-sided blades must be

forced against the side of the joints to more thoroughly clean

them, but the risk of spalling is greatly reduced when the blade

width is narrower than the joint width.
30

Table 11. Joint resealing equipment requirements.

Equipment Requirements

Joint Plow Non-tapered, carbide-tipped blades. 

Sufficient blade sizes.

Ability to control blade height.

Ability to force blade against

sidewall.

Concrete Saw

(includes saw, hose, and water

truck)

Self-propelled, water-cooled saw 

> 26 kW. Diamond saw blades

designed to cut hardened PCC to

uniform width. Controllable, does

not pull to one side. 

Sandblast Equipment

(including sandblast unit, air

compressor, hoses, nozzles, and

safety equipment)

Acceptable air compressor.

Recommend Venturi tungsten

nozzles.

Airblast Equipment

(includes air compressor, hose,

wand, and safety equipment)

Functional oil and water removal

filter on compressor.

Min 620 kPa at 0.07 m3/s.

> 19-mm ID hose.

Nozzle with shut-off valve.

Face shield, ear protectors.

Backer Rod Installation Tools Maintains proper recess, + 3 mm.

Does not damage backer rod.

Hot-Applied Sealant Installation

Equipment (includes portable

melter–applicator, hose, wand, and

safety equipment)

Mechanical agitator (recommend

full-sweep agitator).

Separate automatic temperature

controls for oil and melting

chambers. Sealant heating range to

260oC. Sealant recirculation

system.

Silicone Sealant Installation

Equipment (includes pump,

compressor, hose, and wand)

Minimum flow rate 0.025 L/s.

Recommend hose lined with

Teflon, all seals and packing made

with Teflon.
31

Figure 5. Rear-mounted joint plow.

Figure 6. Undercarriage-mounted joint plow.
32

Figure 7. Concrete joint saw.

3.9.2 Concrete Saws

Saws used for refacing the joint should remove the minimum

amount of concrete to achieve the design width and produce

freshly sawn, clean joints of uniform width and depth. Selfpropelled, water-cooled power saws with diamond blades, as

shown in figure 7, are typically used for joint refacing. 

In many cases, blades are ganged side-by-side on the blade

arbor with a solid metal spacer to allow the saw to reface the

joint to a proper, uniform width in one pass (Darter et al.,

1985). The spacer diameter must be sized to prevent sealant

from building up between the blades. Ganged blades can be

exchanged on the arbor to provide more even wear, more

uniform sawing widths, and longer blade life. Single, full-width

blades are also used to resaw joints for resealing. 
33

Blades should be no larger than necessary to achieve the

required depth, since smaller blades are less expensive and

make the saw easier to maneuver. Blades specifically

designed for resawing hardened concrete should be used, and

the body of these blades must be thick enough to resist

warping.

3.9.3 Abrasive Blasting Equipment

Sandblasting equipment must be able to completely remove

dried sawing slurry, dirt, and any old sealant from the joint

faces. To efficiently accomplish this for a medium to large

resealing project, an abrasive blasting unit, as shown in figure 8,

should maintain a minimum nozzle pressure of 620 kPa at 0.07

m

3

/s. The air supply must be clean, dry, and free from oil. 

This may require the installation of an oil and moisture filter on

the air compressor. 

Tungsten carbide nozzles should be used for larger projects,

and ceramic nozzles are more useful for 3- to 4-h projects. 

Tungsten carbide and ceramic nozzles are available in several

diameters, lengths, and shapes. A 5- to 6-mm-diameter Venturi

nozzle has been used successfully for sandblasting joints. A

sandblast chamber that allows continuous sand loading

increases production rates.

Attaching an adjustable guide to the nozzle to keep it 25 to 50

mm from the pavement promotes consistent results and reduces

operator fatigue.

For worker protection and to conform to State and

Occupational Safety and Health Administration (OSHA)

requirements, all necessary safety equipment must be present

and in good working condition. This equipment may include:
34

Figure 8. Abrasive blasting equipment.

! A remote shut-off valve.

! An air-fed protective helmet.

! An air supply purifier.

! Protective clothing for the operator.

! Portable protective barriers between the sandblaster and

adjacent traffic. 

3.9.4 Airblasting Equipment

An air compressor, as shown in figure 9, is used for final

cleaning, and must produce sufficient air quality, pressure, and
35

Figure 9. Airblasting operation.

volume to thoroughly clean the joints. This requires the

following:

! The air supply must be clean, dry, and contain no oil. 

! A compressor with a minimum of 0.07 m3/s at the

nozzle and 690 kPa must be used.

Many modern compressors automatically insert oil into the air

lines to lubricate air-powered tools. For joint cleaning, this

must be disconnected and an effective oil and moisture trap

must be installed. In most cases, the inside of the hose for a

lubricating air compressor is coated with oil. This oil must be

removed or the hose must be replaced to keep oil from reaching

the joints. Attaching a balanced wand with a shut-off control

increases safety and improves worker comfort. Proper eye and

ear protection should also be used.
36

Figure 10. Hand-operated backer rod installation tool.

3.9.5 Hot Airblasting Equipment

A hot compressed air (HCA) lance, or heat lance, used to dry

slightly damp joints must supply heated air at about 1,100oC

with a supply velocity of more than 300 m/s. The temperature

and movement rate must be closely controllable to reduce the

possibility of overheating the pavement, since overheating can

produce chalking and temperature/steam-induced stress

fractures.

Several heat lance options are available, including push-button

ignition, wheels, and balancing straps. Eye, ear, and body

protection devices must be used, due to the heat and noise

produced by this equipment. 

3.9.6 Backer Rod Installation Tools

A backer rod installation tool must be able to push the backer

rod into a joint to the specified depth without tearing,

stretching, or damaging the rod. Many sealant contractors

make their own installation tools, as shown in figure 10.
37

Figure 11. Automated backer rod installation tool.

However, a lightweight, adjustable tool is commercially

available, as is an automated, self-guiding unit like the one

shown in figure 11.

3.9.7 Hot-Applied Sealant Installation Equipment

The equipment used for installing sealant materials that must be

heated should be able to:

! Effectively raise the temperature of the sealant without

overheating portions of the sealant. 

! Allow the operator to maintain exact sealant

temperatures in the range of 160 to 250oC.

! Be large and powerful enough to heat a sufficient

amount of sealant so that installation is not delayed.

Many companies manufacture mobile equipment that will melt

and pump sealant into pavement joints. The sealant capacity of

most melter–applicators ranges from 190 to 1,325 L. 
38

Characteristics of the melter–applicator equipment should

include the following:

! A double-walled heating chamber with heating oil

between the walls as the heat transfer medium.

! A mechanical agitator.

! Accurate thermostats to monitor both the sealant and

the heating oil temperatures (these thermostats should

control the operation of the burners).

! A reversible pump that can feed sealant to the applicator

wand or recirculate the sealant into the melter vat. 

! Nozzle attachments with outside diameters that are

small enough to allow it to be pulled through the

narrowest joint without binding and large enough to

maintain a good installation rate. 

Options that may be helpful include electronic ignition, diesel

heating fuel, wand nozzles that maintain the sealant at a certain

depth, and hoses and wands that are insulated or heated

(Bugler, 1983). 

3.9.8 Silicone Sealant Applicators

Silicone pumps and applicators should provide sealant to the

joint at a rate that does not slow the operator. The applicator

equipment should:

! Not introduce bubbles into the sealant.

! Not allow air to reach the sealant before it enters the

joint, to prevent premature curing.

! Maintain a feed rate of at least 0.025 L/s.

! Have a nozzle designed to fill the joint from the bottom. 

Applicators that have Teflon-lined hoses and Teflon seals are

less likely to allow the sealant to cure in the pump or hose than

those that use neoprene seals and standard hoses.
39

3.9.9 Other Equipment

Under some conditions, a self-propelled vacuum sweeper or

portable air blower may be useful for removing sand and dust

from the pavement surface prior to backer rod installation. 

Rotary wire brushes have been used for joint wall cleaning with

very limited success, due to their tendency to scrape the cement

(which produces dust) and to smear old joint sealant over the

dust (USAF, 1983). They are not generally recommended. 

A long rod with properly sized flexible plastic tubing attached

to the end is useful for forming the surface of non-self-leveling

silicone sealants. Also, for hot-applied sealant installation, a

hand-held infrared thermometer can provide quality control

checks of melter–applicator and nozzle sealant temperature and

the temperature of the pavement joints. 

3.10 Estimating Material, Labor, and

 Equipment Requirements

The information in table 12 is provided to help with estimating

the material, labor, and equipment requirements. This table

contains estimated material amounts and preparation and

installation rates. Costs and rates for two scenarios are shown. 

The first is a self-leveling silicone with a shape factor of 2:1,

and the second is a hot-applied, low-modulus rubberized

asphalt.

The plowing rate can be influenced by the number of passes

required and the difficulty in aligning the blade with the joint.
40

Table 12. Production rates, costs, and amounts.

No. of

Workers

Amounts/Rates (per 300 m)

Silicone Hot-Applied

Average sealant amount a26 to 38 L 49 to 57 L

Average plowing rate 2 2 to 3 h 2 to 3 h

Average sawing rate 1 3.5 to 7.5 h 3.5 to 7.5 h

Average sandblast rate 2 1.5 to 4 h 1.5 to 4 h

Final airblast rate 2 1.5 to 4 h 1.5 to 4 h

Backer-rod installation rate 2 1 to 3 h 1 to 3 h

Sealant installation rate 2 1.5 to 2.5 h 1.5 to 2.5 h

a

 Based on 13-mm joint width.

Sawing rates are influenced by the power of the saw, the blade

speed, the type and width of blade, the cutting depth and

pressure, the hardness of the concrete, and the size of the

aggregate in the concrete. 

Production rates for initial and final airblasting can vary with

the capacity and pressure provided by the air compressor. 

Large amounts of debris in the joint or on the pavement surface

will slow the airblasting operation. The rate of sandblasting is a

function of the equipment, nozzle, and abrasive type used. 

Where old sealant remains on the joint walls, the rate of

sandblasting will decrease. A 270-kg capacity sandblast unit

with a 6-mm nozzle and 25-mm inside diameter sandblast hose

can use about 270 kg of abrasive per hour. 

The rate of primer installation varies greatly with the application

method. Large-volume spray units result in much greater

production rates than brushing the sealant on by hand. The

speed of backer rod installation is dependent upon the

consistency of the joint width. If joint widths vary significantly,

backer rods of different diameters must be used to fill the joints. 
41

This, in turn, requires the installer to carry backer rods of

various sizes, and to sometimes install very short lengths of rod.

The rate of sealant application is controlled by the skill of the

operator, the distance between joints, the dimensions of the

sealant reservoir, and the production rate of the

melter–applicator (hot-applied) or pump (silicone). High

rainfall frequency can significantly reduce the rate of sealant

installation, since time must be allowed for the concrete to dry. 

3.11 Determining Cost-Effectiveness

Steps for determining the cost-effectiveness of methods and

materials for resealing joints in PCC pavements include the

following:

1. Determine the amounts and costs of the materials

needed.

2. Estimate the labor needs and costs.

3. Determine the equipment requirements and costs.

4. Estimate the effective service life of each resealing

option.

5. Calculate the average annual cost for each method

under consideration.

Example calculations are included in appendix B.

3.11.1 Material and Shipping Costs

Material and shipping costs can be determined using table 13. 

Material costs for sealant, backer rod, blasting abrasive, primer,

and other required materials can be obtained from local

suppliers or manufacturers. Coverage rates for sealant can be
42

CR ' 0.001 WF ST W T Eq. 7

Table 13. Material and shipping costs.

Material, unit

Material

 Cost, 

$/unit

Coverage

Rate, 

m/unit

Length

Required,

linear m

Total

Cost, 

$

a b c a x b x c

Sealant, L

Backer Rod, linear m

Blasting Sand, kg

Primer, L

Total Material Cost:

estimated by using equation 7 or by consulting manufacturers’

literature. By multiplying the material cost, the coverage rate,

and the length of the joint to be resealed, the total cost for each

material and the overall material cost can be estimated.

where: CR = Sealant coverage rate, L/m.

WF = Waste factor (WF = 1.2 for 20 percent

waste).

W = Joint width, mm (see figure 4).

T = Thickness of sealant, mm (see figure 4).

ST = Surface type constant (tooled surface: ST =

1.1; non-tooled surface: ST = 1.0).
43

3.11.2 Labor Costs

Labor costs can be determined using table 14. Using the wages

for each worker, the number of workers required for each

operation, and the expected time necessary to complete each

operation, the total labor costs can be estimated. The

production rates and amounts in table 12 should be helpful in

determining labor requirements. In addition to wage rates,

labor costs are greatly influenced by crew productivity and the

need for night work or extra traffic control. 

3.11.3 Equipment Costs

The cost of equipment will be affected by the availability of

adequate equipment and the need for equipment rental. The

amount of time that each piece of equipment is needed also

greatly influences equipment costs. By completing table 15 and

multiplying the daily equipment costs by the number of pieces

of equipment required and the number of days the equipment is

needed, the cost of resealing equipment can be estimated. 

Production rates should be based on local experience, although

the rates shown in table 12 may be used to obtain rough

estimates.

3.11.4 User Delay Costs

Although difficult to determine, there is a cost of delay to

roadway users during the time that joints are cleaned and

resealed. It should be included in cost-effectiveness

calculations if the options being evaluated require significantly

different amounts of lane closure. Experienced traffic engineers

or agency guidelines should be consulted in defining the cost of

user delays.
44

Table 14. Labor costs.

Crew 

Labor

Wages, 

$/day

Number

in Crew

Days 

Required

Total

Cost, $

d e f d x e x f

Supervisor

Traffic Control

Plowing

Sawing

Initial Airblast

Sandblast

Final Airblast

Backer Rod

Sealant Installation

 Total Labor Cost:

Table 15. Equipment costs.

Equipment

Daily

Cost,

$/day

Number

of Units

Number

of Days

Total 

Cost, $

g h i g x h x i

Traffic Control

Joint Plow

Concrete Saw

Air Compressor

Sandblast Equip.

Installation Equip.

Other Trucks

 Total Equipment Cost:
45

3.11.5 Cost-Effectiveness Comparisons

After the material, labor, equipment, and user costs have been

determined, the worksheet in table 16 can be used to determine

the annual cost of each resealing option. The expected rate of

inflation and the estimated lifetime of each material-placement

method option are required inputs for the worksheet. 

By comparing the average annual cost of various materials and

repair procedures, the most cost-effective resealing option can

be determined.
46

Average Annual Cost ' C

E 1%E

D

1%E

D &1

Eq. 8

Table 16. Cost effectiveness worksheet.

Total Material Cost [table 13] $ __________

Total Labor Cost [table 14] $ __________

Total Equipment Cost [table 15] $ __________

Total User Delay Cost [table 16] $ __________

=========== 

 

Total Resealing Cost $ __________ (A)

Project Length (lane-km) __________ (B)

Average Cost ($/lane-km) $ __________ (C)

Estimated Lifetime of Seal, years __________ (D)

Interest Rate (typ. 0.05) __________ (E)

Average Annual Cost 

($/lane-km) $ 
47

4.0 Construction

Once the design and planning stages are completed, joints can

be prepared in the chosen manner and the sealant can be

installed. This construction stage is just as critical as the design

stage, since preparing clean joints and correctly installing the

sealant material in an effective manner will largely determine the

overall performance of the sealant system design. 

This chapter presents the objectives and steps required for

cleaning and resealing joints in concrete pavements. 

Troubleshooting procedures for solving the problems

potentially encountered in each operation are also included.

4.1 Traffic Control

Whenever a joint resealing operation is performed, it is critical

that adequate traffic control be in place to provide a safe

working environment for the installation crew and a safe travel

lane for vehicles. It should also cause the least amount of

disturbance possible to the flow of traffic.

Besides normal signs, arrow boards, cones, and attenuators,

flaggers may be required to accompany the sawing and plowing

operations if the plow or saw is allowed to extend into the lane

carrying traffic.

4.2 Safety Precautions

The equipment and materials used in a joint resealing operation

can present safety hazards to workers if appropriate precautions

are not taken. All guards must be in place, operational worker

protection devices must be used, and appropriate clothing

should be worn. 
48

Material Safety Data Sheets (MSDS’s) should be obtained for

each sealant material to be installed, and proper care should be

taken to protect workers from any potentially harmful materials. 

A more detailed description of safety precautions required for

each step of the sealing operation is included in appendix C. 

4.3 Preparing the Joint

Objective: To provide clean, dry, and properly dimensioned

joints that are free from sawing dust, old sealant, or any other

contamination, and to which sealant material can adequately

bond.

Good joint preparation is essential to good sealant performance. 

No matter what the sealant material quality is, if the joint faces

are not clean and dry, the sealant will pull away from the joint

walls prematurely. Appropriate sealants placed in joints that are

clean and dry should provide effective, long-term performance. 

Successful steps for preparing joints for sealant installation

include removing old sealant, refacing joint sidewalls, abrasive

blasting, airblasting, and installing primer. Hydroblasting has

been used successfully for joint preparation. Care must be

taken with this operation to ensure that oils from the original

oil-based sealant that have penetrated the joint edge are

sufficiently removed.

4.3.1 Removing the Old Sealant

Plows can be used to remove old sealant from concrete joints

prior to or in place of sawing. Preformed compression seals

should be removed by hand or by pulling out longer sections

with a tractor. Plowing involves pulling a thin blade through a

joint to remove old sealant and backer material from the

reservoir and to clean sealant from the sides of the joint. 
49

To effectively remove sealant prior to sawing, the plowing

operation must achieve the following results:

! Sufficient sealant and debris must be removed so that

saw blades are not "gummed-up" during sawing. 

! Joint walls must not be spalled by the plow.

If sawing will not follow the plowing operation, the following

additional results must be achieved:

! At least 95 percent of old sealant must be removed from

the joint sidewalls.

! All sealant remaining on joint sidewalls must be easily

removable by sandblasting. 

Several types of plows have been used, and a few have

functioned successfully. Descriptions of joint plows are given

in section 3.9.1. Successful use of a joint plow typically

requires the following equipment and procedures:

! A rear- or front-mounted, carbide-tipped plow blade for

partial sealant removal (shown in figure 12), or an

undercarriage-mounted carbide blade with hydraulic

controls for complete sealant removal. 

! Multiple passes of a blade that is narrower than the

joint, cleaning each channel face individually.

! Carbide-tipped, steel plow blades of various widths.

! Sufficient tractor weight to maintain blade depth and

remove the old sealant.

! Effective traffic control and equipment guards to protect

workers from flying debris and moving traffic.

Operators must use special care or an alternate procedure if

difficulties with spalling or improper cleaning are encountered. 

Several common plowing problems and possible solutions are

listed in table 17. 
50

Figure 12. Joint plowing operation.

Table 17. Troubleshooting procedures for plowing.

Problems Encountered Possible Solutions

Plow is spalling joint edges. Use an untapered plow bit or a narrower blade.

Plow not completely removing

sealant.

Increase pressure on the joint sidewall.

Undercarriage-mounted plow

places tractor in traffic.

Use rear- or front-mounted blades, hand tools,

or a vertical-spindle router. Redirect traffic.

Guardrail or curb keeps plow

from reaching the entire joint.

Use rear-/front-mounted blades.

Reverse plowing direction.

Use hand tools or a vertical-spindle router.

Trouble lining up plow 

with joint.

Use undercarriage-mounted plow.

Use an assistant. 

Original sawcuts are offset. Use additional care in plowing. Use hand tools

or a vertical-spindle router.
51

Removing old joint material and other debris should be a

continual process during joint preparation. The following

concurrent work is recommended with the plowing operation:

! Blowing sealant and debris from the plowed joints.

! Vacuuming, blowing away, or picking up debris from

the plowing operation.

! Removing the old sealant and properly disposing of it.

Some materials may require hazardous or specialized

waste disposal methods.

4.3.2 Refacing the Joint Sidewalls

Sawing, or refacing, joints in concrete pavements, shown in

figure 13, is done either to increase the joint width and depth to

the design requirements, or to expose clean, fresh concrete to

which new sealant can adhere. Recommendations for watercooled saws and blades are discussed in section 3.9.2. The

following results of sawing must be achieved for the entire

project:

! Uniform width and depth of joint in compliance with the

design dimensions.

! No spalls resulting from resawing.

! Sealant completely removed and concrete freshly

exposed on both sides of each joint.

If the resawing operation is properly completed, the remainder

of the preparation tasks are greatly simplified. Therefore, care

should be taken to ensure accurate and complete sawing, and if
52

Figure 13. Joint resawing operation.

poor results are noticed, they should be corrected promptly. 

Several common problems encountered in resawing are noted in

table 18, along with recommended solutions. Consult saw

manufacturers for solutions to other problems.

Wet-sawing leaves behind old sealant and a slurry of water and

concrete dust in the joint. If this slurry dries on the joint walls,

it is very difficult to remove; if it is not removed, it will keep

new sealant from bonding to the concrete. Therefore, the

sealant and slurry must be removed immediately after sawing by

one of the following methods:
53

Table 18. Troubleshooting procedures for resawing.

Problems Encountered Possible Solutions

Blade pulling to one side. Change the rate of sawing.

Check rear-wheel alignment.

Blade not cleaning both

sides.

Narrow blade— use wider blades.

Poor control— use a more skilled

operator.

Sealant "gumming-up"

blade. Remove (plow) sealant before sawing.

One side of ganged blades

worn.

Switch the inside and outside blades.

Saw cut does not begin in

the center of the joint.

Have the saw operator take more care.

Provide an assistant to the operator.

Sawing is slow.

Use a more powerful saw.

Use a more appropriate blade.

Adjust the water feed.

Increase the cutting rate.

! Flush the joints with low-pressure water, simultaneously

blowing the slurry out with high-pressure air until all

sawing waste is removed (Darter et al., 1985).

! Flush the joints with high-pressure water until all sawing

waste is removed. 

! Clean the joints with high-pressure air until all sawing

waste is removed.

The first and second methods are more effective than the third at

removing concrete dust slurry.

4.3.3 Abrasive Blasting the Joint Sidewalls

An abrasive blasting apparatus is used to direct a mixture of

clean, dry air and abrasive material onto the walls of concrete
54

joints. Results of abrasive blasting include the removal of

sawing dust, old sealant, and other foreign material from the

concrete joint surfaces, as well as the roughening of the concrete

surface in order to create a better bonding surface. To achieve

these results, the abrasive blasting operation must produce the

following effects:

! Joint walls to which sealant must bond must be free from

all sawing dust, old sealant, lubricant adhesive,

discoloration or stain, or any other form of

contamination.

! Joint walls must be completely clean and dry, and have

newly exposed concrete.

The following procedures can provide successful abrasive blastcleaning results:

1. Use approved sandblast units, safety equipment, and

safety procedures, as described in section 3.9.3.

2. Hold the sandblast nozzle no more than 50 mm from the

pavement surface. A long handle attached to the hose

and extending slightly past the nozzle will allow this to

be done from an upright position, as shown in figure 14.

3. Make one complete pass for each joint wall at an angle

from the pavement that directs the blast onto the surface

to which sealant must bond.

4. Remove any old sealant with repeat passes or with a

knife and repeat passes.

5. Protect traffic in nearby lanes from sand and dust, as

necessary, by using a portable shield and low-dust

abrasive.

6. Remove sand and dust from the joint and nearby

pavement to prevent recontamination, using airblasting

or vacuuming equipment.
55

Figure 14. Abrasive blasting operation.

Problems that are encountered in sandblasting must be solved

quickly. Several common sandblasting problems and possible

solutions are listed in table 19.

The sand and dust must be removed from the joints and

pavement surfaces before sealing can begin. If this is not done,

sand and dust can be blown back into the joints, reducing sealant

performance. Self-propelled vacuums and portable blowers can

be used for debris removal.
56

Table 19. Troubleshooting procedures for sandblasting.

Problems Encountered Possible Solutions

Sandblast not removing

sealant.

Ensure that sandblaster is functioning.

Blast joint edges separately.

Cut old sealant away and reblast.

Use a different blaster or abrasive or

larger hoses. 

Improve the accuracy of sawing.

Sandblast quality not

consistent.

Ensure that sandblaster is functioning.

Keep the nozzle height and alignment

consistent.

Use a nozzle guide attachment.

Sandblast progress too slow. Ensure that sandblaster is functioning.

Use a different blaster or abrasive or a

larger hose.

Oil or moisture in sandblast

stream.

Install a functional oil/moisture filter.

Use another compressor that doesn't

add oil or moisture. Use dry abrasive.

Operator fatigue. Use a guide and handle for upright

sandblasting.

Use alternating operators.

4.3.4 Airblasting the Joint Reservoir

After the joints have been sandblasted, and immediately before

sealant installation, the dust, dirt, and sand must be blown from

the joints and pavement surface using a compressed air stream. 

The following results of airblasting are desired over the entire

project:

! Sand, dust, and dirt must be completely removed from

the joint reservoir.
57

Figure 15. Airblasting operation.

! Any sand, dust, and dirt that may recontaminate the

joints must be removed from the surrounding pavement

surface.

In general, joints should be airblasted immediately prior to

backer rod installation. The airblasting, rod placement, and

sealant installation operations must occur on the same day. If

rain or dew recontaminate the joints, they must be sandblasted

and airblasted again after drying. 

Successful airblasting methods for accomplishing the above

results are as follows:

1. Use approved air compressors, safety equipment, and

safety procedures, as described in section 3.9.4.

2. Hold the nozzle no more than 50 mm from the pavement

surface, as shown in figure 15.

3. Blow debris in front of the nozzle. Do not walk

backwards.
58

4. Make slower or repeated passes until the joint reservoir

is completely clean.

5. Elevate and fan the nozzle across the pavement on the

last pass to remove debris from the joint area to a place

where it cannot recontaminate the joints. 

The most common problems encountered in airblasting are

related to contamination of the air stream or lack of air volume

and pressure. Joint seal materials will not adhere well to dirty or

damp joints. Methods for addressing these problems are

described in table 20.

If the joints are slightly damp, a heat lance may be used to dry

the joints prior to installing backer rod (Mildenhall, n.d.). The

extreme temperatures that a heat lance can produce (820 to

1,650oC) can severely spall concrete pavement that is exposed to

the heat for more than a very short length of time. Extreme care

must be taken to keep the heat lance from remaining in one

location for more than 1 to 2 s. Pavement that is saturated must

be allowed to dry before resealing. A heat lance may dry the

surface of such a pavement for a short time, but capillary action

in the concrete will bring the moisture back to the joint very

quickly. 

Table 20. Troubleshooting procedures for airblasting.

Problems Encountered Possible Solutions

Oil in airstream. Ensure oil/moisture filter is functional.

Clean or replace the hose.

Moisture in airstream. Ensure that oil/moisture filter is

functional.

Air not removing dust, dirt,

and sand.

Use a larger compressor.

Use a larger diameter hose.

Reduce the diameter of the nozzle

opening.
59

4.3.5 Installing Primer

To effectively and economically prime joint surfaces, the primer

installation process must achieve the following:

! Primer must very thinly and uniformly coat all joint

surfaces to which sealant must bond.

! Primer should not be wasted by applying thick coats or

covering non-essential concrete surfaces.

Primer can be installed using a brush or spray equipment. Spray

equipment is much more efficient, generally resulting in a thinner

coat, and spray nozzles can be designed to coat only the upper

joint wall surface. It is critical that the primer be allowed to dry,

since as it dries, it gives off gas (ACI, 1990). If hot-applied

sealant is installed before the primer has dried, bubbles will form

in the sealant as the gas tries to escape. 

All required operator safety equipment must be used. This may

include goggles, gloves, protective clothing, and respirators. 

Manufacturers' recommendations for installation methods and

safety procedures must be followed. 

4.4 Material Preparation and Installation

Objective: To properly install backer rod in clean joint

channels and to adequately prepare, install, and shape sealant

material.

The preparation and sealing operations should be scheduled so

that joints are cleaned and left open a minimum amount of time

before resealing. Prepared joints that are left open overnight

must be airblasted again and reinspected for cleanliness and

dryness. Primer, installed before backer rod installation, must be

dry and tack-free. Only a minimum amount of time must be
60

allowed to pass between backer rod installation and sealant

placement. 

No matter how good the joint preparation has been, improper

sealant installation can result in rapid seal failure. Therefore, the

manufacturer's recommendations must be followed regarding

minimum placement temperatures, sealant heating temperatures,

extended sealant heating, and pavement moisture conditions. 

Most sealant manufacturers recommend installing sealant when

the pavement is dry and the air temperature is 4oC and rising. 

Recommended application temperatures for rubberized asphalt

sealants generally range from 185 to 200oC. Hand-held,

calibrated infrared thermometers can be used to easily check

sealant, air, and pavement temperatures. 

Polymers used in some hot-applied sealants are susceptible to

damage from overheating and from extended heating. The

allowable time such sealants may remain at application

temperature ranges from 6 h to 5 days, depending on the sealant

properties. Check with sealant manufacturers for exact heating

time and temperature limits.

4.4.1 Installing Backer Rod

Backer rod should be installed immediately after airblasting and

immediately before placing the sealant. Joint reservoirs and

pavement surfaces must be completely clean before backer rod is

inserted. If unclean joint walls are noted during backer rod

installation, they should be marked for recleaning.

The backer rod serves two purposes. It helps keep the sealant at

its design thickness, and it keeps sealant from bonding to the

bottom of the joint reservoir. Both thicker sealant and bonding

to the reservoir bottom place additional stress on the sealant. To

perform properly and reduce sealant stress, the installed backer

rod must meet the following requirements:
61

! The backer rod must be compatible with and appropriate

for the sealant.

! Backer rod must be at the depth required in the plans.

! No gaps should be evident between the backer rod and

joint walls.

! The rod must be compressed in the joint sufficiently that

the weight of uncured sealant or the tooling operation do

not force it down into the reservoir before curing.

! The rod must be dry and clean.

! The surface of the rod must not be damaged during

installation.

! No gaps should form between backer rods that are

butted together in a joint or at a joint intersection.

Many methods have been used to insert backer rod into joints,

ranging from poking it in with a screwdriver to using automated,

self-guided installation equipment. Using a screwdriver may

damage the surface of the rod and result in bubbles forming in

the sealant. Automated equipment is most effective for

continuous joints where only one size of backer rod is generally

needed. The steps for the most commonly used and successful

method of installing backer rod are as follows:

1. Have enough rod sizes available to fit all of the joint

widths at the project.

2. Use a long-handled installation tool with a largediameter central disk that fits into all joints and does not

cut or damage the backer rod, as shown in figure 16.

3. Insert one end of the proper size of rod into the end of a

joint.

4. Tuck the rod loosely into the joint and push the rod into

the joint by rolling the installation tool along the joint.

5. Roll over the rod a second time with the installation tool

to ensure proper depth.

6. Cut the rod to the proper length, making sure no gaps

exist between segments of backer rod.
62

Figure 16. Backer rod installation.

7. In sections where the rod does not fit tightly to the joint

walls, install larger diameter backer rod.

The depth of the installation tool must be slightly greater than

the required depth of backer rod because the rod compresses

slightly when installed (Blais, 1984). Certain rod materials are

more compressible and require additional tool depth. 

Stretching and twisting of backer rod must be minimized during

installation, since as the material relaxes, gaps may form at joint

intersections and result in sealant failure. When transverse and

longitudinal joints are being sealed in one operation, better

results are obtained if rod is installed in the entire length of the

transverse joints. That rod is then cut at the intersection with

longitudinal joints and the rod is installed in the longitudinal

joints. Possible solutions to common problems encountered

when installing backer rod are described in table 21.
63

Table 21. Troubleshooting procedures

for backer rod installation.

Problems Encountered Possible Solutions

Rod is tearing (slivers formed)

when installed.

Use a smaller diameter backer rod.

Ensure that installation tool is smooth.

Side gaps are evident or rod is

slipping or is easily pushed

down in joints.

Use a larger diameter rod.

Rod depth is inconsistent. Check the installation tool for depth.

Repeat passes with the installation tool.

Rod is shrinking in joint. 

Gaps are forming between rod

ends.

Do not stretch the rod when installing.

Use a larger diameter roller.

If delay occurs before installing the sealant, dirt and sand can be

blown into the cleaned joints, or moisture can enter the joints. 

When dirt has re-entered the joints after the backer rod has been

installed, blow out the dirt using a clean, dry, low-pressure

airstream, taking care not to force the rod deeper into the joint. 

Damp or wet backer rod must be removed from the joints and

replaced with dry rod after the reservoir is completely dry and

has been recleaned.

4.4.2 Sealant Installation

When the joints are clean, the backer rod is installed and, if the

temperatures are within the required limits, sealing can begin. If

rain interrupts the sealing operation, reclean the open joints

before installing the sealant. The sealing operation should

progress quickly and result in a seal with the following

characteristics:
64

! Prevents infiltration of water through the joints.

! Remains resilient and capable of rejecting incompressible

materials at all pavement temperatures.

! Maintains a tight bond with the sidewalls of the joint.

! Has no bubbles or blisters.

! Is not cracked or split.

! Is well bonded to the joint walls.

! Cannot be picked up or spread on adjacent pavement

surfaces by tires or the action of power-vacuum rotarybrush pavement cleaning equipment after the specified

curing period.

! Provides a finished exposed joint surface that is nontacky and will not permit the adherence or embedment of

dust, dirt, small stones, and similar contaminants.

 Hot-Applied Sealant

To install hot-applied sealant that successfully meets the above

requirements, proper heating and installation methods must be

used. Suitable cleanup and safety procedures, as described in

appendix C, must also be followed to ensure worker protection

and properly functioning equipment.

Heating the Sealant 

Hot-applied sealant performance can be significantly changed by

the procedures used to heat and maintain its temperature during

installation. Prior to heating sealant, the melter- applicator

should be checked for the following properties and modified if

necessary:

! Carbon buildup on the sides of the heating chamber

should be removed.

! All temperature gauge sensors should be cleaned and

accurately calibrated.
65

Heating should be scheduled so that the sealant will be at the

recommended temperature when the sealing operation is to

begin. During initial heating, the following guidelines should be

adhered to:

1. Keep the heating oil temperature no more than 24oC

above the safe sealant heating temperature stated on the

sealant packaging. 

2. Keep sealant temperatures between the recommended

pouring temperature and the safe heating temperature

printed on the sealant packaging.

3. Start the agitator as soon as possible.

4. Do not hold the sealant at application temperatures for a

long period before using it.

If sealant is heated above the safe heating temperature, it should

not be used because rubberized sealants break down and become

very thin or very stringy when heated above this temperature. 

The recommended pouring temperature is the temperature of the

sealant that will achieve the best performance. If the sealant is

installed below this temperature, it may cool before it fills the

voids in the concrete, and a poor bond may result. 

Recommended pouring temperatures vary between sealant

manufacturers and types. Therefore, the pouring and safe

heating temperatures of the sealant in use should be obtained

from the sealant packaging, and all sealant operators must be

made aware of it. Supervisors and equipment operators can use

infrared sensors to check pouring temperatures at the nozzle.

The procedures listed below should be followed during

installation. 

1. Check to ensure that the pavement temperature is above

the minimum recommended installation temperature and

above the dew point.
66

2. Check the temperature of the sealant at the nozzle and

adjust the melter controls to obtain the recommended

pouring temperature at the nozzle. 

3. Regularly check the sealant temperatures and adjust as

necessary.

4. Watch for carbon buildup on the sidewalls of the heating

chamber. This is a sign of overheating.

5. Do not use sealant that has been overheated or heated for

an extended period of time, or that remains tacky and

shows signs of breakdown.

Methods of Installation

Trial installation of at least 15 transverse joints should be

completed using the methods scheduled for use in cleaning and

installing sealant on each project. The sealed trial joints should

be inspected after curing and approved or rejected prior to

sealant placement. Hot-applied seals can be cut on three sides

after cooling for a 50-mm length and can be stretched to observe

material and adhesive properties. A similar test can be

conducted on silicone and other chemically cured materials after

curing is complete. 

Upon approval, the remaining joints should be cleaned and

resealed in the same manner as the trial joints. Sealing should

begin only when the air temperature is 8oC and rising and the air

temperature is above the dew point. The following installation

practices are recommended: 

1. Pour the sealant with the nozzle in the joint so that the

joint is filled from the bottom and air is not trapped

beneath the sealant. 

2. Apply the sealant in one continuous motion while moving

the wand in a way that the sealant flows out behind the

wand, as shown in figure 17 (Darter et al., 1985).
67

Figure 17. Hot-applied sealant installation.

3. Apply sealant in one pass, filling the reservoir to the

recommended level. If additional sealant is required in

low sections, it should be added as soon as possible. 

Inform the backer rod installation crew if leaks are

occurring at backer rod joints. 

4. Recirculate sealant through the wand into the melting

chamber when not applying sealant.
68

5. Watch for bubbles, areas of sunken sealant, sealant that

remains tacky, and sealant that has not bonded to the

joint walls, and solve these problems as soon as they are

identified. Several solutions are listed in table 22.

6. Use equipment and installation practices that result in

consistent sealant thickness, little waste, and low

operator fatigue. Support plates on the wand tip may be

useful for this purpose.

7. Do not allow construction equipment or vehicle traffic

onto the pavement until the sealant has set and there is

no danger of tracking or stone intrusion.

Cleanup Requirements

Follow the melter–applicator manufacturers' instructions as to

the frequency of cleaning. If carbon is built up on the heating

chamber walls, remove it completely by scraping and flushing. 

Flush the pump and hose with solvent, if recommended, and

waste the first 10 L of the day to remove any traces of solvent. 

Dispose of the wasted sealant/solvent solution properly.

Safety Precautions

Obtain the MSDS’s for each sealant material and follow the

worker protection and disposal instructions outlined in them. 

Several safety precautions should be followed before, during,

and after installation. These include the following:

1. Be careful when loading blocks of sealant— splashing can

occur.

2. Have operators wear protective gloves and clothing. 

Sealant and oil temperatures can reach 200oC and can

cause serious burns. 
69

Table 22. Troubleshooting procedures for hot-applied

sealant installation.

Problem

Encountered

Possible 

Causes

Possible

 Solutions

Bubbles in

sealant

Reaction with backer

rod.

Use nonreactive backer

rod.

Damaged backer rod. Change the rod

installation method or

rod diameter.

Moisture in joint. Allow the joints to dry. 

Install sealant above

the dew point. 

Bubbles in melter. Add sealant material. 

Reduce the agitator

speed.

Air trapped by

sealant.

Fill joints from the

bottom. 

Sealant is

deeply sunken

in joint

Gap remains between

rod and wall. Rod

slipping into joint.

Use proper diameter

backer rod. 

Gap remains between

backer rod ends.

Do not stretch rod. 

Install rod carefully. 

Sealant recess

is not

consistent

Operator control is

poor. Operator

movement is uneven.

Joint width is

variable. Hoses are

unmanageable.

Use a nozzle with a

depth control plate. 

Use a wand with a

shut-off valve at the

nozzle. Use an

experienced operator. 

Provide a hose support.
70

Table 22. Troubleshooting procedures for hot-applied

sealant installation (continued).

Problem

Encountered

Possible

 Causes

Possible 

Solutions

Sealant is not

sticking to

concrete walls

Joint walls are not

clean.

Remove all old sealant,

oil, dust, dirt, sawing

slurry, and other

contaminants. 

There is moisture on

the walls from rain,

dew, or condensate. 

Wait for concrete to

dry. Install above the

dew point temperature. 

Sealant temperature is

too low. 

Maintain recommended

sealant temperature. 

Insulate and heat

hoses. 

Pavement temperature

is too low. 

Wait for warmer

conditions. Insulate

and heat hoses. 

Sealant

remains tacky

after

installation

Kettle contaminated

with asphalt, heat

transfer oil, solvent,

or other sealant.

Remove sealant. Clean

and flush kettle. 

Replace with

uncontaminated

sealant.

Sealant has been

overheated or heated

too long. 

Remove and replace

with fresh sealant. 

Check melter

temperatures.
71

3. Do not overheat the sealant— it is flammable.

4. Make sure the appropriate hoses (manufacturer

recommended) are used.

5. Follow manufacturers' safety instructions when using

coal tar compounds. Excessive breathing of fumes or

skin contact with coal tar compounds may cause

irritation (ACI, 1990).

6. Follow disposal instructions for cleaning solvent and

wasted sealant.

Cold-Applied Sealant

Several types of sealant are installed without heating. These

include polysulfides, polyurethanes, and silicones. Consult

manufacturers' literature for installation recommendations for

each sealant type. The discussion in this manual is limited to the

installation of one-part, cold-applied sealants. 

Loading Sealant in Pumping Apparatus

Typically, silicone sealant is pumped from storage containers

through compressed-air-powered pumping equipment to a wand

with an application nozzle, as shown in figure 18. The sealant is

pumped from 19-L buckets or 208-L drums. Two important

precautions should be observed when loading silicone into an

approved pumping apparatus.

! Load the sealant in the apparatus in a manner that keeps

bubbles from becoming trapped in the sealant. 

! Limit the exposure of the sealant to air and moisture. 

Premature curing can result from such exposure.

Methods for Installation

The following practices have been used successfully and are

recommended for installing silicone sealants:
72

Figure 18. Silicone sealant installation.

1. Pour the sealant with the nozzle in the joint, so that the

joint is filled from the bottom and air is not trapped

beneath the sealant.

2. Use a nozzle that applies sealant at a 45o angle, and push

the bead along the joint rather than draw it with the gun

leading. 

3. Apply the sealant in one continuous motion, moving

steadily along the joint, so that a uniform bead is applied

without dragging, tearing, or leaving unfilled joint space

(USAF, 1983). 

4. Adjust the pump rate, nozzle type, and nozzle diameter

to control the speed of application.

5. Tool (i.e., form a concave surface in) the non-selfleveling sealant using a piece of oversized backer rod,

plastic tubing on a fiberglass rod, a dowel, or other

suitable instrument.
73

6. When tooling is required, press the sealant around the

backer rod, forming a uniform concave surface with no

wasted sealant on the pavement surface. The bottom of

the concave tooled surface should be at least 7 mm

below the pavement surface.

7. The surface of the self-leveling silicone sealant must be

recessed 7 to 10 mm below the pavement surface and

should never be exposed to traffic wear.

8. Watch for bubbles, sunken sealant, a non-uniform

surface, and other installation deficiencies, and solve

these problems as soon as they are identified. Several

solutions are listed in table 23.

9. Allow non-self-leveling sealant to become tack free and

self-leveling sealant to skin over before opening the

pavement to traffic. If large pavement deflections are

expected, allow a longer cure time.

Non-self-leveling silicone sealant is generally tack free within 90

minutes at temperatures above 4oC, and it cures within 7 days. 

Self-leveling silicone sealant typically skins over within 60

minutes and cures in about 21 days.

Cleanup Requirements

Cleaning of the applicator equipment apparatus will be required

if the sealant begins to cure in the pump or hose. Follow the

sealant pump manufacturer’s instructions for cleaning frequency

and required solvents.
74

Table 23. Troubleshooting procedures for cold-applied

sealant installation.

Problem

Encountered

 Possible 

Causes

Possible 

Solutions

Sealant is not

sticking to

concrete walls

Joint walls are not

clean.

Remove all old sealant,

oil, dust, dirt, sawing

slurry, and other

contaminants.

Moisture remains on

the walls from rain,

condensate, or dew. 

Wait for concrete to

dry. Install above the

pavement dew point

temperature.

Tooling was

inadequate. 

Use more tooling care. 

Use another strike-off

tool. 

Sealant is

deeply sunken

in joint

Gap between rod and

wall. Rod is slipping

into joint.

Use larger diameter

backer rod. 

Gap between backer

rod ends.

Do not stretch rod. 

Install rod carefully.

Installed

sealant

contains

bubbles

Reaction with backer

rod.

Use nonreactive backer

rod. 

Damaged backer rod. Change rod installation

method, tool, or rod

diameter. 

Bubbles in pump

lines.

Set the pump

diaphragm into sealant

better.

Air was trapped by

the sealant.

Fill the joint from the

bottom.
75

Table 23. Troubleshooting procedures for cold-applied

sealant installation (continued).

Problem

Encountered

 Possible 

Causes

Possible 

Solutions

Sealant recess

is not

consistent

Operator control is

poor. Operator

movement is uneven. 

Joint width is

variable.

Use a more

experienced operator. 

Use a “dog leg”

applicator.

Nozzle tip is wrong

size.

Reduce nozzle tip size

to easily insert to top of

backer rod.

Surface tooling is

poor. 

User more tooling care. 

Use another strike-off

tool (large backer rod,

plastic or rubber tubing

on flexible handle).
 
77

%Leff ' 100 & %Lfail Eq. 9

5.0 Evaluation of Joint Seal

 Performance

Monitoring the performance of joint seal treatments is good

practice, and it can be done rather quickly (in 1 or 2 h) with fair

accuracy. At least one inspection should be made after the first

winter, and subsequent evaluations should be conducted at

regular intervals to chart the rate of failure and plan for

subsequent maintenance. A mid-winter evaluation is highly

recommended, since at that time, joints will be near their

maximum opening and, as a result, adhesion loss can be seen

more easily. Visual evaluation, alone or in conjunction with the

IA-VAC joint seal tester, can provide seal performance

information. The IA-VAC system can easily determine joint seal

effectiveness in a consistent manner any time of the year until

failure rates become moderate or greater (Steffes, 1993). Visual

evaluation methods will become more necessary as failure rates

increase.

As discussed in section 2.1, a small representative sample of the

pavement section should be selected for the evaluation. 

Resistance to the entrance of water and debris to the joint should

be measured by noting the percentage of water resistance loss

using equation 1 provided earlier. The joint seal effectiveness

can then be calculated using the following equation:

where: %Leff = Percent joint seal effectiveness.

%Lfail = Percent length allowing water to enter

 joints.

After a few inspections, a graph of seal effectiveness versus time

can be constructed, such as the one in figure 19.
78

A minimum allowable effectiveness level, commonly 50 percent,

will help to indicate when additional joint seal treatment is

required. For example, a resealing plan using figure 19 could

include immediate resealing of sites G, H, and I. A budget for

resealing in the next 2 years could be prepared for sites E and F. 

Moreover, estimates of the time to 50 percent effectiveness

could be obtained for planning the resealing of the remaining

sites.

Figure 19. Example joint seal deterioration chart

(See next page)
0

10

20

30

40

50

60

70

80

90

100

0 10 20 30 40 50 60 70 80

Times, months

Seal effectiveness, % joint length

Site A

Site B

Site C

Site D

Site E

Site F

Site G

Site H

Site I
79

Appendix A

Material Testing Specifications

Material testing specifications are listed in tables A-1 and A-2. 

These specifications are based on specifications prepared by the

American Society for Testing and Materials (ASTM), the

American Association of State Highway Transportation

Officials (AASHTO), and by States having significant joint

resealing experience. Specifications are revised frequently, and

the sponsoring society should be contacted to obtain the latest

edition. Information regarding the availability of specifications

can be obtained from the agencies listed below.

ASTM Specifications

American Society for Testing and Materials

100 Barr Harbor Drive

West Conshohoken, PA 19428

610-832-9500

www.astm.org

AASHTO Specifications

American Association of State Highway and Transportation

Officials

444 North Capitol Street, NW, Suite 249

Washington, DC 20001

202-624-5800

www.aashto.org

U.S. Federal Specifications

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22161

800-553-6847

www.ntis.gov

www.fhwa.dot.gov
80

Table A-1. Rubberized asphalt specifications.

Test 

Description a

Test Criteria

Other Standard Low Modulus

ASTM

D 1190

AASHTO

M 173

ASTM 

D 3405

AASHTO

M 301

Federal

SS-S-1401

State

Specification 

Cone penetration (25oC,

dmm)

< 90 < 90 < 90 < 90 < 90 110 to 150

Flow (60oC, mm) < 5 < 5 < 3 < 3 < 3 < 3

Resilience (25oC, %

recovery)

> 60 > 60 > 60 > 60

Bond (-18oC, 50% ext.) Pass 

5 cycles

Pass

5 cycles

Bond (-18oC, 100% ext.)

or

(-29oC, 50% ext.)

Pass

3 cycles

Bond (-29oC, 100% ext.)

or (-29oC, 200% ext.)

Pass

3 cycles

Pass 

3 cycles

Pass

3 cycles

Asphalt compatibility Pass

Cone penetration (-18oC,

dmm)

> 40

a

 1 dmm = 0.1 mm
81

Table A-2. ASTM D 5893 silicone sealant specifications.

Test Description

Test

 Method

Silicone Type a

Non-Sag Self-Leveling

Rheological properties ASTM 

D 2202

<7.6 mm

slump

Type 1,

smooth

Extrusion rate, mL/min ASTM 

C 1183

> 50 > 50

Tack-free time, h ASTM 

C 679

< 5 < 5

Bond (-29oC, 100% ext.,

immersed, nonimmersed, oven-aged)

ASTM 

D 5893

Pass Pass

Hardness (-29oC, type

A2)

ASTM 

C 661

< 25 < 25

Hardness (23oC, type

A2)

 ASTM 

C 661

> 30 > 30

Flow ASTM 

D 5893

No flow No flow

Ultimate Elongation, % ASTM

D 412(C)

> 600 > 600

Tensile stress at 150%

strain (23oC), kPa

ASTM

 D 412(C)

< 310 < 310

Accelerated weathering

(500 h)

ASTM

 C 793

Pass Pass

Resilience, % ASTM 

D 5893

> 75 > 75

a

 21-day cure time.
 
83

Appendix B

Sample Cost-Effectiveness Calculations

Sample worksheets for cost-effectiveness calculations are

presented in this section. The forms included in section 3.11

are used to illustrate the method discussed in that section. Data

used for calculation of cost-effectiveness are listed below and in

tables B-1 through B-3.

Sealant Type = Self-leveling silicone sealant

Shape Factor = 2:1

Joint Width = 13 mm

Joint Length to Seal = 6.0 km

Project Length = 4.0 km

Primer = None required

Estimated Lifetime = 8 years

Plow Rate = 160 m/h

Saw Rate = 84 m/h

Airblast Rate = 152 m/h

Sandblast Rate = 114 m/h

Backer Rod Install Rate = 165 m/h

Sealant Installation Rate = 165 m/h

Labor Rates = $150/day

Supervisor Rates = $200/day
84

CR ' 0.001 1.2 1.0 12.7 6.4 ' 0.0975

The sealant coverage rate is calculated in the following

equation:

where: CR = Coverage rate, L/m

WF = Wastage factor = 1.2

W = Joint width, mm = 12.7

T = Thickness of sealant = 6.4

ST = Surface type constant = 1.0

 Table B-1. Example material and shipping costs.

Material, unit

Material

 Cost, 

$/unit

Coverage

rate,

unit/m

Length

required,

m

Total

cost

$/material

a b c a x b x c

 Sealant, L 7.40 0.0975 6,100 4,401

 Backer rod, m 0.011 1.05 6,100 211

 Blasting slag, kg 0.11 0.30 6,100 201

 Primer, L -0- -0- -0- -0-

 Total material cost: 4,813
85

Table B-2. Example labor costs.

Crew 

Labor

Wages,

$/day

Number

in Crew

Days 

Required

Total

Cost, $

d e f d x e x f

 Supervisor 200 1 14 2,800

 Traffic control 150 1 14 2,100

 Plowing 150 2 5 1,500

 Sawing 150 1 3.5 525

 Initial airblast 150 2 3.5 1,050

 Sandblast 150 2 6 1,800

 Final airblast 150 2 3.5 1,050

 Backer rod 150 2 4.6 1,380

 Sealant installation 150 2 4.6 1,380

 Total labor cost: 13,585
86

Table B-3. Example equipment costs.

Equipment

Daily Cost,

$/day

Number

of Units

Number

of Days

Total 

Cost, $

g h i g x h x i

 Traffic control 450 1 14.0 6,300

 Joint plow 150 1 5.0 750

 Concrete saw 225 2 3.5 1,575

 Air compressor 175 1 7.5 1,125

 Sandblast equip.

 (including

compressor)

200 1 6.0 1,200

 Installation equip. 200 1 4.6 920

 Other trucks 100 2 14.0 2,800

 Total equipment cost: 14,670
87

Avg. Annual Cost ' C

E 1%E

D

1%E

D &1

Avg. Annual Cost ' 8,834 0.05 1%0.05 8

1%0.05 8&1

' $1,367

Avg. Annual Cost ' 8,510 0.05 1%0.05 5

1%0.05 5&1

' $1,966

Table B-4. Example cost-effectiveness calculations.

Total material cost [table B-1] $ 4,831 

Total labor cost [table B-2] $ 13,585 

Total equipment cost [table B-3] $ 14,670 

User delay cost $ 2,250 

==========

Total resealing cost $ 35,336 (A)

Project length, lane-km 6.1 (B)

Avg. resealing cost, $/lane-km $ 5,793 (C)

Estimated lifetime of seal, years $ 8 (D)

Interest rate (typically 0.05) $ 0.05 (E)

Average Annual Cost, $/lane-km $ 1,367 

Using an ASTM D 3405 sealant that costs $1.10/L and lasts 5

years, together with the same preparation methods listed above

and a shape factor of 1:1, the computed average annual cost is:
 
89

Appendix C

Material and Equipment Safety Precautions

Mandated highway safety attire, such as vests and hard hats,

should always be worn by crews and supervisors during sealing

operations. In addition, individual crews should be made aware

of all safety precautions associated with the materials and

equipment with which they are working.

C.1 Materials

In order to protect the health and well-being of maintenance

workers who handle the various sealant materials, MSDS’s

should be obtained from the manufacturers of all materials to be

installed, and these sheets should be reviewed by those handling

the materials. These sheets provide important information

about health hazards, fire and explosion data, reactivity data,

and safe usage and disposal. Every effort should also be made

to determine the type of sealant material to be removed and to

address any safety hazards that it may present.

C.1.1 Hot-Applied Sealants

Hot-applied sealants require that several safety precautions be

followed:

1. Be careful when loading blocks of sealant— splashing

may occur.

2. Have operators wear protective gloves and clothing. 

Sealant and oil temperatures can reach 200oC and can

cause serious burns.

3. Do not overheat the sealant— it is flammable.
90

4. Follow manufacturers' safety instructions when using

coal tar compounds. Excessive breathing of fumes or

skin contact with coal tar compounds may cause

irritation or possibly more serious health problems.

5. Use care with any solvents required for cleanup. 

6. Dispose of diluted or wasted sealant as specified in the

MSDS.

C.1.2 Cold-Applied Sealants

When working with cold-applied sealants, care should be taken

to protect workers from skin, eye, or internal contact with

sealant materials. MSDS and the manufacturer's

recommendations should be consulted to determine specific

safety requirements for each sealant material.
91

Appendix D

Inspection Checklists for Construction

This section is intended for use by inspectors of resealing

processes, as well as by supervisors and contractors. It

contains discussions of planning, equipment, and procedures

critical to the successful completion of a resealing project. 

Checklists pertaining to each step of the process, including

planning, equipment, material preparation, joint preparation,

sealant installation, final inspection, and safety precautions, are

included.

Field experience has shown that each step in the resealing

process requires careful supervision and inspection. An

inspector must continually observe the various operations to

ensure that proper procedures are being performed. In most

cases, it is the contractor's responsibility to effectively clean and

reseal the joints, and it is the inspector's responsibility to

continually monitor the work and ensure that corrections are

made if requirements are not met. 

D.1 Preconstruction Plans and Specifications

Plans must be prepared and distributed to the inspectors and the

supervisors of the installation crew. It is recommended that the

inspectors and the construction supervisors meet before work

begins to discuss the plans and specifications. Information that

must be contained in the plans includes the following:

G 1. Project layout, including stationing and slab

lengths.
92

G 2. Original joint reservoir dimensions, including

existing variability.

G 3. Original sealant material type.

G 4. Location and type of required pre-resealing

repairs.

G 5. Required reservoir dimensions.

G 6. Required sealant thickness.

G 7. Required sealant recess below pavement surface.

Specifications may be based on adherence to designated

procedures, on achieving a quality end product, or a

combination of the two. Information that must be contained in

procedure-based specifications includes the following:

G 1. Lot testing requirements.

G 2. Delivery and storage requirements.

G 3. Repair methods and materials for pre-resealing 

repairs.

G 4. Equipment requirements.

G 5. Material requirements.

G 6. Preparation procedure requirements.

G 7. Installation procedure requirements.

G 8. Weather condition limitations.

G 9. Traffic shutdown requirements.

G 10. Safety requirements.

G 11. Material disposal requirements.

If end-result specifications are used, the following information

must be included: 

G 1. Lot testing requirements.

G 2. Delivery and storage requirements.

G 3. Repair methods and materials for pre-resealing

repairs.

G 4. Required results of each preparation procedure

and acceptance/rejection criteria.
93

G 5. Required results of the installation process and

acceptance/rejection criteria.

G 6. Weather condition limitations.

G 7. Limitations of traffic shutdown.

G 8. Safety requirements.

G 9. Material disposal requirements.

An example of installation acceptance criteria is included in

section D.4. In most cases, a combination of procedure-based

and end-result specifications is used, and the following

inspection process is based on a combination of the two.

D.2 Equipment Inspection

All equipment must be inspected and approved before the

project begins, as well as during joint preparation and sealant

installation. A list of proposed equipment should be submitted

for approval before installation. During pre-installation

inspection, the inspector should check all equipment to be used

on the project, making sure that each piece meets the

requirements of the project specifications or the suggested

requirements listed previously in table 11. If questions arise

about the suitability of the equipment, a statement from the

sealant manufacturer should be supplied, indicating that the

equipment is acceptable for installing the sealant.

The condition and effectiveness of each piece of equipment

should be checked during trial installation and at the beginning

of each day of preparation and installation. Criteria for

equipment effectiveness are listed in the sections below.
94

D.3 Field Installation Inspection

After all required spall repair, load transfer restoration, slab

stabilization, grinding, and other rehabilitation have been

completed and approved, the resealing process can begin. It is

recommended that the inspectors and supervisors meet before

work begins to discuss the following subjects:

1. Exact locations and number of joints to be

resealed (boundaries should be clearly marked).

2. Traffic control requirements and lane closure time

limitations.

3. Methods required for cleaning and resealing joints

(if procedure-based specification).

4. Criteria for approval of all cleaning and installation

equipment and processes.

5. Final criteria for approval of resealing work,

including procedures and penalties for rejection.

6. Any localized variations from the specified

methods.

7. Safety requirements for all equipment and

procedures (including material disposal

requirements).

8. Procedures in the event of wet or cold weather.

9. Procedures in the event that seal quality

requirements are not met.

D.3.1 Inspection of Joint Preparation 

Joint preparation, as discussed in this manual, refers to sealant

removal, joint refacing, final cleaning, primer installation, and

backer rod insertion. Sealant manufacturers' instructions should

be followed when preparing joints unless noted otherwise in the

plans and specifications. The following inspection checklist can

be used to ensure that joint preparation is completed properly
95

(USAF, 1983), although not all of these cleaning processes are

used, in many cases.

G 1. Joint plowing:

G Plow is removing the required amount of

sealant.

G Plow is not spalling the joint edges. 

G Worker and driver safety are not

compromised.

G 2. Concrete sawing:

G Saw is removing the required amount of

concrete and sealant. 

G Saw is uniformly cutting to the proper width

and depth (depth and width can be checked

quickly using a metal template).

G Saw is refacing both sides of the joint. 

G All guards and safety mechanisms are

functioning properly.

G All sawing slurry is immediately removed

from the joints.

G 3. Waterwashing:

G Equipment is removing all sawing slurry and

old sealant from the joints. 

G No standing water remains in the joints.

G 4. Abrasive blasting:

G The nozzle is being held 25 to 50 mm from

the pavement.

G Two passes are made for each joint,

directing the nozzle toward one side of the

joint for each pass. 

G No old sealant, oil, or dried sawing slurry

remains on the joint walls. 
96

G The blaster does not introduce oil or

moisture to the joint. 

G The operator is using all OSHA- or Staterequired protective devices. 

G Following sandblasting, all joint walls exhibit

freshly exposed concrete.

G 5. Airblasting:

G Equipment is removing all dirt, dust, and

sand from the dry joint reservoir. 

G The airblaster does not introduce oil or

moisture to the joint (check for oil by

directing the airstream onto a tire or a piece

of paper and noting any discoloration).

G The operator is wearing required eye and ear

protection. 

G Following airblasting, the joint is clean and

dry. 

G 6. Vacuum or compressed-air cleaning:

G Cleaning equipment is removing all old

sealant, sand, dirt, and dust from the

pavement surface.

G Debris has no potential for re-entering the

joints, especially on windy days or when

traffic is moving next to the cleaned joints.

G 7. Primer application:

G Primer applicator is applying a thin layer of

sealant uniformly over joint faces to receive

sealant. 

G All required safety protection equipment is in

use and is operational. 

G Primer is allowed to dry before backer rod is

inserted.
97

G 8. Backer rod installation:

G The rod is inserted into the joint uniformly to

the required depth without stretching or

tearing it. Depth can be checked using a

template (slivers of rod in the joint indicate

that the rod is too large). 

G The rod remains tight in the joint without

gaps along the sides, at joint intersections, or

between rod segments. 

G The rod is compressed in the joint enough

that the weight of the uncured sealant or 

installation equipment or tooling equipment

will not force it down into the joint. 

G A larger diameter rod is used in wide joint

sections.

G 9. Low-pressure air cleaning :

G When needed, all dust or dirt that has reentered clean joints that contain backer rod

is blown out. 

G The backer rod is not pushed into the joint

by the airstream.

Water on the joint walls during sealing will severely reduce the

ability of the sealant to bond to the walls and can result in

bubbles in some sealants. Check frequently for dew that may

collect in the joints and remain after the surface is dry,

particularly if temperatures and humidity levels have been at or

near the dew point. If cleaned joints are recontaminated by

rain, dew, dirt, or oil, they should be recleaned in a manner that

restores cleanliness. This may require sandblasting and

airblasting or merely airblasting. Cleaned joints that are left

overnight should, at a minimum, be airblasted again. Moist

backer rod should be replaced after drying and joint recleaning. 
98

One method that an inspector can use to communicate the need

for additional preparation at a particular joint is to mark near it

with a particular color of paint (USAF, 1983). A possible

pattern that could be used is the following. 

1. Yellow— Repairs must be made to joint before

sealing.

2. Orange— Joint is not the proper size.

3. Red— Joint is not properly cleaned.

4. Blue— Backer rod is not tight or is not at proper depth.

5. Brown— Improper sealing technique (too full, too low,

tacky sealant, not tooled correctly, bubbles in sealant,

sealant not bonded, etc.).

The contractor or supervisor can use green spray paint to

indicate that the problem is repaired and the inspector should

re-examine the joint for approval.

D.3.2 Inspection of Joint Sealant Installation

The inspector should watch for several items prior to and

during installation of the sealant material. The following

section is a checklist for inspection of joint sealant installation.

D.3.2.1 Hot-Applied Sealant Installation Inspection

When inspecting the installation of hot-applied sealant

materials, the information listed below must be determined

before heating begins. This information can be obtained from

sealant manufacturers and from the project plans and

specifications: 

G 1. The recommended sealant application

temperature.

G 2. The safe sealant heating temperature.
99

G 3. The length of time that a sealant can be heated

before it begins to break down.

G 4. The required thickness of sealant.

G 5. The required sealant recess below the pavement

surface.

G 6. The air temperatures allowable for sealing.

G 7. The average sealant curing time and the time

before traffic can be allowed on the pavement

after resealing.

G 8. The MSDS’s.

G 9. The criteria for acceptance/rejection of resealing

work, and the penalties associated with rejection.

G 10. Acceptable test results for all materials to be

installed.

G 11. The production date and shelf life of all materials.

During installation of hot-applied sealants, the following items

should be regularly checked to ensure that they meet the

requirements: 

G 1. All joints remain clean and dry.

G 2. All backer rods remain tight in the joint at the

correct height with no gaps.

G 3. The melter–applicator maintains the sealant at the

required temperature without overheating. 

G 4. Sealant leaving the nozzle is at the application

temperature. 

G 5. The agitator is functioning properly. 

G 6. No carbon is built up on the melting chamber

walls. 

G 7. All thermometers and temperature controls are

monitored and functioning properly.

G 8. The operator is not trapping bubbles in the sealant

or overfilling or underfilling the joints.

G 9. Spilled sealant is removed from the pavement

surface.
100

G 10. Areas of low sealant are not present or are quickly

filled. Steps are taken to eliminate the cause of

the low sealant.

G 11. All required operator safety equipment is in use. 

This applies especially to D 3406 materials. 

Warning: If white smoke is seen rising from the kettle, stop

the operation immediately and check the sealant temperature. 

If the sealant remains tacky in the joint long after placement, or

the sealant becomes stringy inside the melting chamber, the

sealant has been overheated and should be completely removed

from the chamber and wasted.

D.3.2.2 Silicone Sealant Installation Inspection 

Prior to installation of silicone sealants, the following

information should be obtained by the inspector:

G 1. The expiration date of the sealant material.

G 2. The air temperatures allowable for sealing.

G 3. The required thickness of sealant.

G 4. The required sealant recess below the pavement

surface.

G 5. The need for tooling the surface of the sealant.

G 6. The average sealant curing time and the time

before traffic can be allowed on the pavement

after resealing.

G 7. Safety data from the MSDS.

G 8. The criteria for acceptance/rejection of resealing

work and penalties for rejection.

G 9. The acceptable results of lot tests for all materials.

G 10. The production dates and shelf life of all materials.

As sealant installation continues, the following items should be

regularly checked for compliance with the plans and

specifications:
101

G 1. All joints remain clean and dry.

G 2. Backer rods remain tight in the joint at the correct

height with no gaps.

G 3. The silicone applicator system is not introducing

bubbles to the sealant. 

G 4. The applicator, wand, and controls allow the

operator to fill the joint uniformly to the correct

level.

G 5. The operator is not trapping bubbles in the sealant.

G 6. The operator is not overfilling or underfilling the

joints (sealant thickness and recess can be checked

by inserting a thin ruler through the uncured

sealant to the top of the backer rod).

G 7. Non-self-leveling silicone sealant is tooled

immediately, forcing sealant against the joint walls

and creating a smooth concave surface. 

G 8. Any sealant that remains on the pavement surface

is removed.

G 9. Areas of low sealant are not present or are quickly

filled. Steps are taken to eliminate the cause of the

low sealant.

G 10. All required operator safety equipment is in use.

G 11. Traffic is not allowed on the pavement until the

sealant is skinned over and cannot be damaged.

D.4 Final Inspection 

During installation and prior to approval, the resealed joints

should be individually inspected, ensuring that the sealant meets

the following criteria, and noting the presence and severity of

any distresses (Darter et al., 1985; USAF, 1983):
102

G 1. Sealant is bonded firmly to the joint sidewalls 

(cured sealant material should not separate from

the sidewalls when pulled lightly with the

fingertips across the joint).

G 2. Sealant is not tacky after curing and will not

permit adherence of dust, dirt, or small stones.

G 3. Sealant material contains no cracks, bubbles, or

blisters.

G 4. Sealant cannot be picked up or spread on adjacent

pavement surfaces by tires, rubber-tired vehicle

traffic, or the action of power-vacuum rotarybrush pavement-cleaning equipment after the

specified curing period. 

G 5. Sealant is resilient and capable of rejecting stones

at high pavement temperatures.

G 6. Sealant is recessed to the correct depth below the

pavement surface (this is critical for silicone

sealants, as they are not resistant to traffic wear).

G 7. Sealant spilled on the pavement surface has been

removed.

G 8. No debris remains on the pavement surface.
103

Appendix E

Partial List of Material and 

Equipment Sources

This section contains information for contacting several

manufacturers of sealant materials, backer rod, and installation

equipment. Addresses and phone numbers are given for

manufacturers and suppliers who can provide the inquirer with

information regarding material properties, recommended

installation practices, safety procedures, and local suppliers. 

MSDS’s that describe the material components, any hazardous

properties, and any required protective equipment, should be

available from all sealant manufacturers.

E.1. Sealant Material

E.1.1. Manufacturers of Hot-Applied Rubberized Asphalt

 Sealant

Crafco Incorporated W.R. Meadows, Inc.

6975 W. Crafco Way 300 Industrial Drive, Box 338

Chandler, AZ 85226 Hampshire, IL 60140-0338

(602) 276-0406 (847) 683-4500

(800) 528-8242 (800) 342-5976

www.crafco.com www.wrmeadows.com

Koch Materials Company

4111 East 37th Street North

P.O. Box 2338

Wichita, KS 67220

(316) 828-8399

(800) 654-9182

www.kochmaterials.com
104

E.1.2. Manufacturers of Self-Leveling and Non-Self-

 Leveling Silicone Sealant

Crafco Incorporated Dow Corning Corporation

6975 W. Crafco Way P.O. Box 994

Chandler, AZ 85226 Midland, MI 48686-0994

(602) 276-0406 (517) 496-4000

(800) 528-8242 www.dowcorning.com

www.crafco.com

E.2. Backer Rod Material

E.2.1. Manufacturers of Expanded Closed-Cell Foam Rod

Nomaco, Inc.

501 NMC Drive

Zebulon, NC 27597

(919) 269-6500

(800) 345-7279

www.nomaco.com

Industrial Thermo Polymers Limited

153 Van Kirk Drive

Brampton, ON, Canada L7A 1A4

(905) 846-3666

(800) 387-3847
105

E.3. Sealant Installation Equipment

E.3.1. Manufacturers of Melter–Applicators for Hot-

 Applied Sealants

Cimline, Inc.

2601 Niagra Lane

Minneapolis, MN 55447

(800) 328-3874

www.cimline.com

Crafco Incorporated

6975 W. Crafco Way

Chandler, AZ 85226

(602) 276-0406

(800) 528-8242

www.crafco.com

Stepp Manufacturing Company, Inc.

12325 River Road

North Branch, MN 55056

(612) 674-4491

(800) 359-8167

www.steppmfg.com

E.3.2. Manufacturers of Pump Applicators for Cold-

 Applied Sealants

Graco, Inc.

P.O. Box 1441

Minneapolis, MN 55440-1441

(612) 623-6000

(800) 367-4023

www.graco.com
 
107

Glossary

Adhesion failure–Complete loss of bond between a sealant

material and the concrete joint wall.

Allowable extension–The amount of stretching of a sealant

material under which performance is estimated to be

adequate.

Average daily traffic (ADT)–The total traffic volume

carried by a pavement during a given period (in whole

days), greater than 1 day and less than 1 year, divided

by the number of days in that period.

Blowups–The result of localized upward movement or

shattering of a slab along a transverse joint or crack.

Channel face–The vertical concrete sidewall of a sawed

joint sealant reservoir.

Compression seals–Preformed seals, generally made from

neoprene, that can be compressed and inserted into

concrete joints for sealing purposes.

Corner break–A diagonal crack forming between transverse

and longitudinal joints that extends through the slab,

allowing the corner to move independently from the rest

of the slab.

D-cracking–The breakup of concrete due to freeze-thaw

expansive pressures within certain susceptible

aggregates (also called durability cracking). 
108

Embedment–To become fixed firmly in a surrounding

mass, as stones sink into and become fixed in soft

sealant material.

Extruded–Forced through a die to give the material a

certain shape.

Flow–The sinking of unstable sealant into a sealant

reservoir.

Horizontal movement–Opening and closing of joints

resulting from pavement expansion and contraction.

Incompressible material–Material that resists compression,

such as stones, sand, and dirt in a crack or joint

reservoir that is closing.

Joint growth–The gradual increase in joint width resulting

from the filling of joints with incompressible materials

during cold cycles.

Joint sidewalls–The vertical concrete edges of a sawed

joint reservoir.

Life-cycle cost analysis (LCCA)–An investigation of the

present and future costs of each repair alternative,

taking into account the effects of both inflation and

interest rates on expenses over the life of the project.

Load transfer–The transfer of load across a joint or crack

in concrete pavement resulting from aggregate

interlock, dowels, or other load-carrying devices.
109

Overbanding–Spreading a thin layer of sealant (about 38 mm 

wide) onto a pavement surface centered over a joint or 

crack at the same time that the sealant reservoir is 

filled.

Pumping–The ejection of water and fine materials from

beneath a concrete pavement through cracks or joints

under pressure from moving loads.

Refacing–Removing about 1 to 2 mm of concrete

from each wall of a sealant reservoir using diamond saw

blades.

Resealing–Replacing sealant in joints or cracks, preferably

using good-quality methods and materials.

Sealant/channel interface–The vertical edge of a sealed

joint where sealant material and concrete joint face

meet.

Sealant reservoir–The channel along a joint or crack that

has been widened by sawing to allow sealant to be

placed in it.

Sealant system–All components that function to seal joints

(i.e., sealant material, surrounding concrete, and

sealant/concrete interface).

Slurry–The mixture of water, concrete dust, old sealant,

and dirt that results from resawing a joint in concrete

pavement.

Subdrainage–Drainage of moisture from beneath a

pavement by means of a porous subbase material

connected to outlet drain lines.
110

Track–The spreading of unstable sealant material along the

pavement surface by traffic tires.

Undersealing–Filling voids beneath a concrete pavement

using a pressurized slurry or hot asphalt material.

Vertical shear–Vertical stress along the sealant/concrete

interface resulting from traffic loading, curling, or

pavement faulting.

Weathering–Breakdown of sealant material resulting from

the effects of moisture, ultraviolet rays, and time.
111

References

American Concrete Institute (ACI). 1990. Guide to Sealing

Joints in Concrete Structures, American Concrete Institute

Report ACI 504R-90.

Blais, E.J. 1984. Value Engineering Study of Crack and Joint

Sealing, Federal Highway Administration Report FHWA-TS84-221.

Bodocsi, A., I.A. Minkara, and R.S. Arudi. 1993. “Analysis of

Horizontal Movements of Joints and Cracks in Portland Cement

Concrete Pavements,” Transportation Research Record 1392.

Bugler, J.W. 1983. "Problems and Solutions in Rigid Pavement

Joint Sealing," Public Works.

Carpenter, S.H., M.R. Tirado, E.H. Rmeili, and G.L. Perry.

1987. Methods for Shoulder Joint Sealing, Vol. 1:

Serviceability Requirements, Federal Highway Administration,

Washington, D.C.

Collins, A.M., W.D. Mangum, D.W. Fowler, and A.H. Meyer.

1986. Improved Methods for Sealing Joints in Portland Cement

Concrete Pavements, Center for Transportation Research,

University of Texas at Austin, Research Report 385-1,

FHWA/TX-87-385-1.

Darter, M.I., E.J. Barenberg, and W.A. Yrandson. 1985. Joint

Repair Methods for Portland Cement Concrete Pavements,

NCHRP Research Report 1-21.

Evans, L.D. et al. 1993. Innovative Materials Development

and Testing. Volume 1: Project Overview (SHRP-H-352);

Volume 2: Pothole Repair (SHRP-H-353); Volume 3: Treatment

of Cracks in Asphalt Concrete-Surfaced Pavements (SHRP-H-
112

354); Volume 4: Joint Seal Repair (SHRP-H-355); Volume 5:

Partial-Depth Spall Repair (SHRP-H-356), Strategic Highway

Research Program (SHRP), National Research Council,

Washington, D.C.

Evans, L.D., M.A. Pozsgay, Smith, K.L., and A.R. Romine. 

1999. Long-Term Monitoring of SHRP H-106 Pavement

Maintenance Materials Test Sites, PCC Joint Reseal

Experiment Final Report, Federal Highway Administration,

Washington, D.C.

Mildenhall, H.S., and G.D.S. Northcott. (no date). A Manual

for Maintenance and Repair of Concrete Roads, Department of

Transportation, Cement and Concrete Association. 

Smith, K.L. et al. 1991. Innovative Materials and Equipment

for Pavement Surface Repairs. Volume I: Summary of Material

Performance and Experimental Plans (SHRP M/UFR-91-504);

Volume II: Synthesis of Operational Deficiencies of Equipment

Used for Pavement Surface Repairs (SHRP M/UFR-91-505),

Strategic Highway Research Program (SHRP), National

Research Council, Washington, D.C.

Smith, K.L., M.A. Pozsgay, L.D. Evans, and A.R. Romine. 

1999. Long-Term Monitoring of SHRP SPS-4 Pavement

Maintenance Materials Test Sites, SPS-4 Supplemental Joint

Seal Experiment Final Report, Federal Highway Administration,

Washington, D.C.

Steffes, R.F. 1993. “Innovative Leak Test for Pavement Joint

Seals,” Transportation Research Record 1392.

United States Air Force (USAF). 1983. Rigid Pavement Design

for Airports, Chapter 7–Standard Practices for Sealing Joints

and Cracks in Airfield Pavements, Air Force Manual 88-6.