Pavement maintenance is one of the most cost-effective investments property owners and contractors can make to protect asphalt surfaces from premature deterioration. In regions where freeze-thaw cycles, heavy traffic, and seasonal weather take a toll on parking lots and roadways, a proactive maintenance approach can double or even triple the lifespan of pavement. Industry professionals like Dan Biehl, owner of Dun-Rite in Marinette, Wisconsin, have built successful companies around the principle that quality pavement maintenance, executed consistently, delivers long-term value for customers. For contractors looking to deepen their expertise, Leed Certification for Pavement Maintenance Contractors What You provides valuable guidance on integrating sustainable practices into maintenance operations. Understanding the fundamentals of crack management, sealcoating, equipment upkeep, and crew development is essential for anyone serious about pavement preservation.
The Critical Role of Crack Management in Pavement Preservation
Crack management is the single most important element of any pavement maintenance program. Water infiltration through cracks is the primary cause of pavement failure. When water seeps into the base layers and freezes, it expands and forces the pavement upward, creating potholes and alligator cracking that require expensive repairs or full reconstruction. Addressing cracks early and correctly prevents this chain of deterioration.
Why Crackfilling Takes Priority Over Sealcoating
A common misconception among property owners is that sealcoating alone provides sufficient protection. Experienced contractors know the opposite is true. Biehl emphasizes that when customers request a sealcoat, he first advises them to pull weeds and fill cracks. Sealcoating applied over unsealed cracks traps moisture inside the pavement, accelerating the very damage the owner hopes to prevent. Crackfilling must always precede sealcoating for the treatment to be effective.
The results of this approach speak for themselves. One grocery store parking lot that Dun-Rite has maintained for 18 years demonstrates the value of consistent crack management. By filling every crack every spring, the lot remains in better condition than many lots only five or ten years old. This real-world example illustrates that regular, disciplined crack maintenance is the most cost-effective pavement preservation strategy available.
Hot Rubber Crackfilling: Materials and Methods
Hot rubber crackfilling is the industry standard for durable crack repair. The process involves heating a rubberized asphalt material to approximately 375 degrees Fahrenheit and applying it into clean, dry cracks. The material bonds with the pavement walls and remains flexible enough to expand and contract with temperature changes without breaking the seal.
Key equipment for professional crackfilling includes:
- Melter applicators such as the Crafco E-Z Pour 200, which heats and dispenses the rubberized material
- Air compressors and heat lances for cleaning and drying cracks before filling
- Crack routers for widening and shaping cracks to create a proper reservoir for the filler
- Supershot 125 applicators for precise, controlled material placement
Proper surface preparation is essential. Cracks must be clean, dry, and free of vegetation before material is applied. Routing creates a uniform channel that allows the filler to bond securely and accommodate thermal movement. Skipping preparation steps leads to premature adhesive failure and wasted material.
Cracksealing Versus Crackfilling: Understanding the Difference
Industry terminology distinguishes between cracksealing and crackfilling, though the terms are sometimes used interchangeably. Crackfilling uses materials that do not bond to the crack walls and are designed for non-working cracks with minimal movement. Cracksealing uses higher-performance materials that bond to the sidewalls and accommodate significant thermal expansion, making them suitable for working cracks. For most parking lot applications, hot rubber crackfilling provides adequate performance when applied correctly to properly prepared cracks.
Sealcoating Best Practices for Maximum Pavement Protection
Sealcoating serves as a protective layer that shields asphalt from the damaging effects of UV radiation, vehicle fluids, and oxidation. When applied as part of a comprehensive maintenance program that includes crack management first, sealcoating significantly extends pavement life and improves appearance.
Application Timing and Conditions
Successful sealcoating depends heavily on weather conditions and surface preparation. The following factors must be considered before application:
- Ambient temperature should be above 50 degrees Fahrenheit and rising
- Surface must be clean, dry, and free of oil spots, vegetation, and debris
- No rain should be forecast within 24 hours of application
- New asphalt should cure for a minimum of 90 days before sealcoating
- All cracks must be filled and cured before sealcoating begins
Applying sealcoat in marginal conditions leads to poor adhesion, premature wear, and customer dissatisfaction. Professional contractors schedule work carefully and communicate weather-related delays to customers rather than compromising on quality.
Selecting the Right Sealcoating Material
Coal tar emulsion and asphalt emulsion are the two primary sealcoating material types available to contractors. Each has distinct performance characteristics:
| Property | Coal Tar Emulsion | Asphalt Emulsion |
|---|---|---|
| Oil and fuel resistance | Excellent | Moderate |
| UV resistance | Excellent | Good |
| Flexibility | Moderate | Excellent |
| Environmental considerations | Restricted in some regions | Widely accepted |
| Typical lifespan | 3 to 5 years | 2 to 4 years |
| Cost per square foot | Higher | Lower |
Contractors should select materials based on site conditions, client preferences, and local regulatory requirements. Some municipalities have restricted coal tar products due to concerns about polycyclic aromatic hydrocarbons, making asphalt emulsion the preferred choice in those markets.
Equipment Maintenance Strategies for Remote Operations
For contractors operating in rural or remote areas, equipment reliability is not just a convenience it is an operational necessity. When equipment fails on a jobsite hours away from the nearest parts supplier, the cost of downtime far exceeds the cost of preventive maintenance. For more detailed guidance on fleet upkeep, Construction Equipment Maintenance Programs a Complete Guide to offers comprehensive strategies for preventive maintenance programs.
Winter Maintenance Programs
Winter months provide an ideal window for comprehensive equipment overhauls. Biehl and his team at Dun-Rite spend the winter repairing and servicing every piece of equipment in their fleet, ensuring that their backup machines are as reliable as the primary units. This winter maintenance program includes:
- Complete engine servicing including oil changes, filter replacements, and belt inspections
- Hydraulic system checks and fluid replacement
- Applicator wand and nozzle refurbishment for sealcoating and crackfilling equipment
- Compressor and melter unit overhauls
- Tire replacement and wheel bearing maintenance on towable units
By dedicating the off-season to equipment maintenance, contractors enter the busy summer months with a fully prepared fleet. This approach eliminates the scramble for repairs during peak season and ensures that every machine is ready when called upon.
Rainy Day Maintenance Protocols
Even during the busy summer season, equipment maintenance cannot be neglected. Smart contractors use rainy days productively by performing scheduled maintenance tasks on machines that are due for service. Rather than losing revenue to weather, they convert downtime into maintenance time. Rotating machines through a maintenance schedule during inclement weather keeps the fleet in top condition without sacrificing productive working days.
This disciplined approach has a compounding benefit. When primary equipment is serviced regularly, backup equipment is used less frequently and remains in better condition. The result is a fleet where every machine, primary or backup, is capable of performing at a professional level. As Biehl notes, backup equipment that is as good as everyday equipment provides peace of mind and operational flexibility, especially when replacement parts are two hours away.
Building a Quality Crew and Growing a Pavement Maintenance Business
Equipment and materials are essential tools, but the quality of the crew ultimately determines the quality of the work. Successful pavement maintenance contractors invest heavily in their teams, recognizing that skilled, motivated employees are the foundation of customer satisfaction and business growth. For insights on industry events and networking, Maximizing Value At Pavement Maintenance Trade Shows Lessons provides useful strategies for connecting with peers and suppliers.
Hiring and Retaining Skilled Workers
Building a reliable crew starts with hiring the right people and creating conditions that encourage them to stay. Contractors who retain their best employees year after year benefit from crews that understand company standards, anticipate job requirements, and deliver consistent results without constant supervision. Key retention strategies include:
- Offering year-round employment where possible, even if winter work is lighter
- Investing in training and certification opportunities
- Providing quality equipment that makes the job easier and safer
- Creating clear career progression paths within the company
- Recognizing and rewarding quality workmanship
Dun-Rite operates with eight full-time employees supplemented by part-time workers during peak months. Biehl credits his business success directly to his crew, emphasizing that independent, trustworthy employees who can manage jobs without constant oversight are invaluable. When a crew is given clear instructions and trusted to execute, the business scales naturally without requiring the owner to be present on every job site.
Diversifying Services for Steady Growth
Dun-Rite offers a comprehensive range of pavement maintenance services including sealcoating, striping, hot rubber crackfilling, parking lot signs, patching, and sweeping. This diversity serves two purposes. First, it allows the company to serve customers as a single point of contact for all their pavement maintenance needs. Second, it provides revenue stability by offering services that can be performed across different seasons and market conditions.
The company serves an equal mix of residential and commercial clients, with job sizes ranging from small residential driveways at thirty dollars to large commercial projects exceeding fifty thousand dollars. This willingness to take on work of any size has helped the company build a broad customer base and steady referral network. Since 1976, the company has grown consistently without a single year of decline, expanding its service radius from 30 miles to 50 miles and beyond into Michigan’s Upper Peninsula. For contractors interested in the technical side of pavement work, Asphalt Pavement Engineering Mix Design Construction Methods Rehabilitation offers a thorough overview of asphalt pavement engineering principles.
The Economic Case for Pavement Maintenance
Every year, more asphalt is laid as development continues. As the inventory of paved surfaces grows, so does the opportunity for maintenance contractors. Biehl observes that when the economy is tight, maintenance activity actually increases as property owners seek to protect their existing assets rather than invest in new construction. This counter-cyclical dynamic makes pavement maintenance a resilient business sector.
The financial argument for preventive maintenance is compelling. Spending one dollar on crack sealing and sealcoating can prevent six to ten dollars in future repair and reconstruction costs. The 18-year-old grocery store parking lot maintained by Dun-Rite illustrates this principle dramatically a surface preserved through consistent maintenance outperforms newer lots that received minimal attention. Property owners who understand this cost calculus are willing to invest in annual maintenance programs that protect their pavement assets over the long term.
For contractors building a pavement maintenance business, the formula for success is straightforward but demanding: prioritize crack management as the foundation of every maintenance program, apply sealcoating only after proper crack preparation, maintain equipment rigorously to prevent costly downtime, and invest in a skilled crew that can deliver quality work independently. Following these principles consistently, year after year, builds the kind of reputation that sustains a business across decades.