Summer is the peak season for asphalt paving, sealcoating, striping, and crack repair operations. When temperatures rise and project deadlines tighten, equipment reliability becomes the single biggest factor separating a profitable season from a costly one. As Larry Spring, Northeast product support manager for Ingersoll-Rand, puts it: “Contractors need to see the value of preventive maintenance, or they won’t do it. It is cheaper to maintain your equipment than to repair or replace it.” Well-maintained equipment not only saves money on repairs but also delivers higher productivity and a better finished mat. This article covers practical maintenance strategies for four critical categories of pavement equipment, drawing on insights from experienced manufacturers and contractors across the industry.
Daily and Preventive Maintenance for Asphalt Pavers
Asphalt pavers operate under extreme conditions: high material temperatures, abrasive aggregates, and long operating hours. Without consistent care, minor issues escalate into major breakdowns that halt production and degrade mat quality. Mark Bolick, LeeBoy product support manager, notes that a paver that runs without proper servicing may still function but will produce a poor-quality mat, potentially costing more in fines and rework than the price of routine maintenance.
Daily Startup Checks
Every operating day should begin with a structured walk-around inspection. This routine takes only a few minutes but catches issues before they become costly failures. Follow this sequence at machine startup:
- Check all fluid levels: engine oil, hydraulic oil, transmission fluid, and engine coolant.
- Verify the battery is filled to the proper level.
- Grease all designated points according to the manufacturer’s schedule.
- Inspect cables, torque hubs, and hydraulic functions.
- Record engine hours for service interval tracking.
Conveyor and Auger Systems
Conveyor chains are the most expensive wear item on a paver. Hours of use and tonnage generally dictate replacement timing. Look for wear patterns on sprockets and chains, and ensure conveyor bars are not bent. All chains must be adjusted to manufacturer specifications. Conveyor chains that are too loose may cause drive sprockets to wear prematurely or unevenly. Auger conveyor drive chains that are out of adjustment can jam inside the auger box, locking the conveyors with asphalt. Spring advises that operators can usually hear chains jumping or snapping during operation if they are loose. “When auger drive chains come loose, you can hear them slap the inside of the box after the conveyors are turned on,” he says.
Clutch, Screed, and Wear Components
Several components require scheduled attention beyond the daily check:
- Clutch or drive plates: Inspect every 500 hours to ensure all plates are tight and properly adjusted. A slipping clutch can fail completely, cutting hydraulic flow to the traction system and requiring a tow.
- Wear plates on augers: As these plates wear down, material movement becomes less efficient. Perform visual inspections regularly.
- Auger and conveyor drive chain tension: With the paver shut off, grab the outer end of the auger and twist. There should be no more than 1 inch of play. Also inspect auger sections for visible wear.
- Screed plate: Monitor thickness visually. If the plate becomes too thin, holes will appear and mat quality will suffer.
- End gates: These wear just like a screed plate. Replace before thinning affects the finished mat.
- Track rails and rollers: Inspect for cracks and other signs of wear.
Hydraulics, Lubrication, and Daily Cleaning
A loose hydraulic hose pulls air into the system, causing damage to pumps and the entire circuit. Increased noise or foamy oil indicates a loose hose. Follow the manufacturer’s lubrication schedule and lubricate at the end of the day while the machine is warm to ensure lubricant reaches all critical points.
Daily cleanup extends the life of components in material handling areas and reduces many mat problems. Manufacturers recommend cleaning the paver after every shift. Keith Hofer, service manager at Gehl Power Products, notes that “cleaning a machine each day is easier than cleaning asphalt off after it has hardened.” Abrasive materials accumulate in sprocket, bearing, auger, and conveyor areas, accelerating wear on all components. Apply a release agent wherever asphalt touches the machine, especially on the bottom of the screed and in the hopper.
For additional context on asphalt pavement types and their material properties, see asphalt pavement types and classification.
Sealcoating Equipment: Preventing Buildup and Maintaining Flow
Sealcoating rigs face unique maintenance challenges because of the nature of the materials they handle. Sealer can build up inside tanks, plug intake lines, and damage pumps if not managed properly. Steve Rapp, manager of the equipment division at SealMaster, offers practical guidance for keeping these rigs productive throughout the summer.
Tank and Agitation System Care
Heat from the sun can cause sealer buildup of half an inch to an inch or more inside the tank. If the buildup becomes too thick, dried sealer can fall off and plug the intake. Rapp recommends opening the lid and spraying down the walls with a garden hose once or twice a year to remove buildup. The agitation shaft is another critical area. Any leakage where the shaft passes through the bearings should be addressed immediately. Sometimes tightening the bolts is sufficient; other times, bearings and shaft seals must be replaced. Keep tank lids properly vented, as plugged vents prevent the pump from working efficiently and disrupt gravity flow.
Spare Parts and Proactive Replacement
Experienced sealcoating contractors carry critical spare parts to minimize downtime. Bill Grauer of Bluegrass Sealing and Striping in Louisville, Kentucky, stocks two sets of parts for his diaphragm pumps, including two diaphragms, four balls, and four seats. With these on hand, he can tear down a pump and have it back in service within 90 minutes. He runs 30,000 to 60,000 gallons of sealer through each truck with 2.5 percent additive and 4 pounds of sand per gallon in the mix.
David Lewis of Moore Seal Inc. in Kirkwood, Delaware, keeps extra ball valves on hand because sand in the sealer accelerates valve wear. He recommends buying higher-quality ball valves, which can last three to four times longer than cheaper alternatives. Lewis advises replacing ball valves periodically, even on rainy days when crews have downtime. A telltale sign that a ball valve needs replacement is when the wand leaks after being laid down. He also recommends cleaning filter baskets at least twice a week to prevent pump starvation on the job site.
Striping Machine Maintenance for Continuous Operation
Striping equipment handles paint rather than asphalt or sealer. The guiding principle, according to Craig Treon of Kelly-Creswell, is simple: “Clean, clean, clean. A striping machine is just like an expensive paint brush. If you want to use it again, you have to clean it.” Rob Krommendyk of EZ-Liner adds that neglecting maintenance can cost a striping crew hundreds in downtime alone.
Daily and Weekly Maintenance Tasks
A consistent maintenance routine keeps striping equipment running reliably:
- Clean tips and nozzles daily, using techniques appropriate for the specific paint type. Use clean, strained paint.
- Change air and engine filters frequently. Paint overspray clogs filters quickly because the spray gun operates near the engine or compressor.
- Spray components with oil to prevent overspray from sticking, allowing thorough cleaning at the end of each day with a simple wipe.
- Tape over the gun exhaust hole on automatic striping guns overnight or during storage on rainy or humid days to prevent moisture from entering the chamber, which can cause rust and corrosion around the diaphragm.
- Avoid partial flushing of paint lines. Adding water to latex-based paints can accelerate drying inside the lines, causing plugs and buildup.
Experienced Operator Insights
Jim Lunay of JCL Equipment Inc. offers a pragmatic perspective. For rookie operators, he recommends cleaning the machine every day without fail. For experienced stripers, he suggests a less aggressive approach: fill the tank with paint and leave it sit overnight. “People familiar with striping equipment do not often have maintenance problems,” Lunay says. “An experienced striper will know where to look for that clog.” However, even experienced operators should check oil, engine, and compressor every morning. Weekly tasks include draining moisture from the main air tube and blowing out the intake filter on the compressor. Shoot wheel grease into the wheel bearings every three to four months.
Crack Repair Equipment: Heat Transfer Fluid and Pump Packing
Crack filling machines endure long hours, dirty conditions, and extreme temperatures. Following the manufacturer’s maintenance schedule is the most reliable way to prevent breakdowns. Marty Drinkwine, Cimline technical advisor, advises keeping track of machine hours to know what requires attention at any given time.
Heat Transfer Fluid Management
The heat transfer fluid is a critical component in crack filling equipment. As the fluid heats up and cools down repeatedly, it picks up dirt and loses its ability to transfer heat efficiently. Drinkwine explains that the oil itself breaks down over time. “It will still get up to the right temperature but the process will be slowed. It will not be as efficient as when the transfer oil was new.” Crafco recommends checking heat transfer oil and hydraulic oil every 8 hours and changing them at least every 500 hours. Cimline recommends changing heat transfer oil about once a year, or between 750 and 1,000 hours of use. Hydraulic filters should be changed every 250 hours according to Crafco specifications.
Daily and Weekly Maintenance Schedule
Establish a consistent inspection rhythm for crack repair equipment:
| Frequency | Maintenance Task |
|---|---|
| Daily (every 8 hours) | Check all fluids; inspect exhaust, fuel filters, air cleaners, hoses and covers, hose connections; clean material system |
| Weekly | Check all fluids including heat transfer oil and hydraulic fluid |
| Every 250 hours | Replace hydraulic filters |
| Every 500 hours | Change heat transfer oil and hydraulic oil |
| Every 750-1,000 hours | Change heat transfer oil (Cimline recommendation) |
Material Pump Packing
The packing gland on the material pump requires careful attention. Crafco notes that the packing needs to be snug but not too tight. Some drippage, several drops per minute, is necessary for the pump to function effectively. If material is dripping more than that, tighten the packing. If the packing is too tight, it causes premature wear, slows the pump, and reduces efficiency. If it is too loose, material leaks out. This balance is one of the most commonly overlooked adjustments on crack filling equipment, yet it directly affects both material waste and pump longevity.
Understanding how asphalt durability and service life relate to proper construction and maintenance practices helps contractors justify the time invested in equipment care. For those looking to deepen their knowledge of road construction and asphalt paving equipment, understanding the full machinery ecosystem contributes to more informed purchasing and maintenance decisions. A broader perspective on asphalt pavement management systems also helps contractors see how equipment reliability fits into the larger picture of asset stewardship and project profitability.
The summer paving season demands maximum uptime from every machine on site. Following manufacturer maintenance schedules, performing daily inspections, cleaning after every shift, and stocking spare parts minimizes downtime and delivers consistent results. Preventive maintenance pays for itself through reduced repairs, higher productivity, and fewer penalties. As the experts agree, the best money a contractor can spend all day is time spent on preventive maintenance.