PENSWASTAAN PENYENGGARAAN

JALAN PERSEKUTUAN
SEMENANJUNG MALAYSIA

PROJECT QUALITY PLAN

CRACK SEALING

Lokasi : …………………………………………………

LOGO
SYARIKAT
KONSESI

CAWANGAN SENGGARA FASILITI JALAN

IBU PEJABAT JKR ALAYSIA ALAMAT SYARIKAT
KUALA LUMPUR
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

1.0 OBJECTIVE

To outline the procedure by which crack sealing works are carried out as per JKR standard
specifications.

2.0 SCOPE

This procedure shall be applicable for all crack sealing works.

3.0 DEFINITION

Cracking in pavement occurs when a stress is built up in a surface layer that exceeds the
tensile or shear strength of the pavement causing a crack to open. Crack types include
fatigue cracks, longitudinal cracks, transverse cracks, block cracks, reflective cracks, edge
cracks, slippage cracks, and joints in PCC pavements. Cracks can be divided into working
and non-working cracks.

Working cracks are active cracks, usually transverse in orientation, which still exhibit
movement due to traffic loading and/or temperature changes. Non-working cracks typically
include diagonal cracks, most longitudinal cracks, and some block cracks, with relatively
little horizontal and/or vertical movements as a result of temperature changes and/or traffic
loading. Because of the relatively close spacing or free edges between non-working cracks,
little movement occurs.

Crack sealing is defined as the method which can be used to repair both working and non-
working cracks in pavement surfaces, by preventing the intrusion of water and
incompressible materials into cracks.

The cause and type of the crack play a dominant role in determining the success of crack
sealing operation.

Normally, working cracks with limited edge deterioration should be sealed, whereas non-
working cracks with moderate to no edge deterioration should be filled. Materials placed in

1
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

working cracks must adhere to the crack sidewalls and flex as the crack opens and closes.
Minimal movement in non-working cracks permits the use of less specialized crack-filler
materials.

Ideally crack sealing is conducted shortly after working cracks have developed to an
adequate extent. When newly developed cracks are sealed, deteriorated crack segments
which adversely affect seal performance, are minimized.

In order to determine whether to seal or fill a crack, it must be established whether the
crack is working or non-working and whether the crack undergoes horizontal or vertical
movement. The criteria for working crack is > 6mm of horizontal movement annually, with
the crack width exceeds 6mm.

Placement methods vary according to the nature of the distress. When selecting the
placement method, one should consider the method’s applicability to;

i) the type of distress

ii) the dimensions of the crack channel
iii) the type of crack channel (cut or uncut)
iv) the finish requirements

For working cracks, crack sealing is recommended with a reservoir is cut and routed in the
pavement and filled with an elastomeric sealant.

4.0 PROCEDURES

4.1 Upon receiving of Work Order from the S.O., the Project Manager shall prepare
and submit Project Quality Plan (PQP) which consist of the following items for
approval by the S.O.;

a) Work Program.
b) Traffic Management Plan.
b) Crack sealing Layout Plan/ Types.

2
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

c) Certificate of Product Conformance.

e) Inspection and Test Plan.
f) Method Statement.
g) Bills of Quantities.

4.2 Upon approval of the PQP, the Project Manager shall proceed with site
possession, mobilization of plant and machineries, site demarcation and crack
sealing operations.

4.3 Traffic control and safety shall be in accordance to the Traffic Management Plan
(TMP) as approved by the S.O.

4.4 The crack sealing methods (isolated cracks treatment) outlined are Flush Fill,
Reservoir, Overband, and Combination. The cracks shall be sealed using;

a) Cold-applied thermoplastic bituminous materials (sealants);

• Bitumen emulsion
• Polymer modified bitumen emulsion

b) Hot-applied thermoplastic bituminous materials (sealants);

• Penetration grade bitumen
• Polymer modified bitumen

c) Chemically cured thermosetting materials;

• Self-leveling silicone

4.4.1 For Flush Fill method, the following procedures shall be used :-

a) Clean the area

The crack must be clean and dry by blowing or brooming.

b) Heat the binder (when using hot-applied sealant)

Do not overheat. Use the thermometer to check the temperature.

3
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

c) Placing of sealant
Crack sealing material shall be simply placed into the existing, uncut
crack and excess material is struck off.

Desirable for non-working cracks (less than 2.5mm horizontal crack

movement) and low to moderate traffic levels, where cracks are still narrow
to be economical.

Figure 1.1: Flush Fill Method

4.4.2 For Reservoir method, the following procedures shall be used:-

a) Clean the area

The crack must be clean and dry by blowing or brooming.

b) Cut the cracks

Crack cutting shall follow cracks well, and produces minimum spalls,
using crack saw with 150 – 200mm diameter diamond blades.

c) Heat the binder (when using hot-applied sealant)

Do not overheat and use the thermometer to check the temperature.

d) Placing of sealant
Crack sealing material shall be placed only within the confines of a cut
crack. The material shall be placed either flush or slightly below the
surface.

4
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

Figure 1.2: Standard Reservoir Method

4.4.3 For Overband method, the following procedure shall be used:-

a) Clean the area

The crack must be clean and dry by blowing and brooming.

b) Heat the binder (when using hot-applied sealant)

Do not overheat and use the thermometer to check the temperature.

c) Placing of sealant
Crack sealing material shall be placed into and over an uncut crack,
shaped into a band over the crack by squeegee that flattens the
material over the crack.

Overband configuration is most appropriate for cracks having a

considerable amount of edge deterioration (more than 10% of crack length)
because the overband simultaneously fills and covers the deteriorated
segments in the same pass.

5
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

Figure 1.3: Standard Overband Method

4.4.4 For Combination (Reservoir/Overband) method, the procedures are :

a) Clean the area

The crack must be clean and dry following the sweeping.

b) Cut the cracks

Crack cutting shall follow cracks well, and produces minimum
spalls, using crack saw with 150 – 200mm diameter diamond blades.

c) Heat the binder (when using hot-applied sealant)

Do not overheat and use the thermometer to check the temperature.

d) Placing of sealant
Crack sealing material shall be placed into and over a cut crack,
shaped into a band over a cut crack by a squeegee, to place the band
centered over the crack reservoir.

For long term crack sealing performance, configurations of Overband and

Combination shall be considered.

6
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

Figure 1.4: Standard Combination Method

4.5 Traffic shall not be allowed on the crack sealing material until it has cured and the
possibility of tracking no longer exists. However, if the S.O. so decides that it is
necessary to allow traffic to pass over the material before adequate curing, clean
sand, quarry dust or other approved materials shall be spread using shovels over
the sealed cracks.

4.6 These materials shall be applied immediately after finishing and shaping so that
they can stick to the sealing material and serve as temporary covers. They shall be
applied in a thin layer and shall fully cover the exposed sealing material.

4.7 Upon completion of work, final inspection/measurement shall be carried out jointly
with the S.O. representatives.

4.8 Refer to Flow Chart on page 8.

5.0 REFERENCES

i. Arahan Teknik (Jalan) 2C/85 – Manual on Traffic Control Devices; Temporary

Signs and Work Zones Control.

ii. Standard Specifications for Road Works (JKR/SPJ/2008), Section 4.14 – Crack
Sealing.

7
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

iii. JKR Guide 1997 – For District Engineers Staff On Pavement Maintenance.

iv. JKR Privatization Agreement in relation to the maintenance of Federal Roads in

Peninsular Malaysia.

8
 PROJECT QUALITY PLAN Reference No.:

WORK INSTRUCTION MANUAL

Revision No.:
CRACK SEALING

ACTIVITY RESPONSIBILITY REFERENCE

Start

Project Manager Work Order

Receive Work Order from S.O.

Prepare PQP and submit to S.O. for approval Project Manager Project Quality Plan
which consist of:
1. Work Program
2. Traffic Managemant Plan
3. Crack Sealing Layout Plan/Types
4. Certificate of Product Conformance
5. Inspection & Test Plan
6. Method Statement
7. Bills of Quantities

NO
Approved Project Manager
by S.O. S.O.

YES
Prepare and mobilize relevant resources to Project Manager
identify work area

Project Manager
Set up Traffic Management Plan

Project Manager
Flush
Overband Reservoir Combination
Fill

Uncut the cracks Cut the cracks Project Manager

Project Manager
Clean the area from debris by using air blower or broom

Apply crack sealant bituminous compound to the Project Manager

affected areas

Inspection and testing Project Manager Inspection and Test Plan

S.O.

Approved NO Project Manager

by S.O. S.O.

YES

End

9
 PROJECT QUALITY PLAN Reference No.:

INSPECTION AND TEST PLAN

Revision No.:
CRACK SEALING
LEGEND
W WITNESSED
A APPROVED
C CONFIRMED
V VERIFIED
P PREPARED
TECHNICAL
FREQUENCY LAB TECHNICIAN / PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
OF TEST SUPERVISOR MANAGER
ENGINEER
1.0 TRAFFIC MANAGEMENT
1.1 Traffic control at worksite Arahan Teknik (Jalan) 2C/85 Visual Approved TMP P P/V C W

2.0 DEMARCATION
Setting out and
2.1 Approved layout plan P P/V C W
demarcation

3.0 EQUIPMENTS
1. Manufacturer's certificates
conforming to the followings :
JKR/SPJ/2008-S4 Table 4.14.5
3.1 Air Compressor a. Min air pressure (690kPa) Once per project P P/V C W
Manufacture's Certificates
b. Min flow (0.07 m3/s)
c. Blast velocity (990 m/s)
1. Manufacturer's certificates
conforming to the followings :-
a. Cutting machine -vertical
Visual &
3.2 Crack Cutting Machine JKR/SPJ/2008-S4 Clause 4.14.3.3a spindle router, rotary-impact Once per project P P/V C W
Measurement
router, random crack saw.
b. Random crack saw:
150-200 mm diameter.
3.3 Wire Brush JKR/SPJ/2008-S4 Table 4.14.5 Type 1. Do not use with worn brushes Once per project
1. Manufacturer's certificates
conforming to the followings :-
Visual & a. Capable of withstanding
3.4 Squegee JKR/SPJ/2008-S4 Clause 4.14.3 Temperature Once per project P P/V C W
Measurement temperature > 230°C.
b. Type: flexible rubber,
Type
moulded into a 'U' or 'V' shape.
1. Manufacturer's certificates
conforming to the followings :-
a. Heating to application
temperature : up to 230 C,
and mobile.
JKR Guide 1997, 2.4.2 c b. Heating duration:within 3hrs.
3.5 Binder Heating Equipment Visual Once per project P P/V C W
JKR/SPJ/2008-S4 c. Equipped with 50mm
recirculating pump &
discharge line.
d. 380L (max) capacity for
melting kettle for small job.

10
 PROJECT QUALITY PLAN Reference No.:

INSPECTION AND TEST PLAN

Revision No.:
CRACK SEALING
LEGEND
W WITNESSED
A APPROVED
C CONFIRMED
V VERIFIED
P PREPARED
TECHNICAL
FREQUENCY LAB TECHNICIAN / PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
OF TEST SUPERVISOR MANAGER
ENGINEER
1. Manufacturer's certificates
conforming to the followings :-
JKR Guide 1997, 2.4.2 c a. Temperature measurement:
3.6 Thermometer at every 30 min. Once per project P P/V C W
JKR/SPJ/2008-S4
b. Calibration : within 6 months
prior to usage.

1. Manufacturer's certificates
3.7 Silicone Pump JKR/SPJ/2008-S4 Clause 4.14.3.4c conforming to the followings :- Once per project P P/V C W
a. Flow rate : 0.03 L/sec

4.0 MATERIALS
4.1 Crack Sealants
a) Polymer Modified M.S 161 Manufacturer's certificates
Emulsion (PME) conforming to the followings :-
JKR/SPJ/2008-S4 Clause 4.14.2.1 1. Mixture of bitumen emulsion
& polymer additive
ASTM D 244 2. Physical properties
(Table 4.14.2):-
ASTM D 244 (random test as a) Grading : max 10%
Once per project P P/V C W
required by S.O.) retained on 850 um sieve.
ASTM D 244 & ASTM D5 b) Saybolt Furol viscosity
@ 50°C : 100 - 400.
ASTM D 244 & ASTM D36 c) Penetration on residue
@ 25°C, 100g, 5s : 45 - 70
d) Ring & ball softening point
on residue : 45 - 60°C.
b) Polymer Modified M.S 124 Manufacturer's certificates
Bitumen (PMB) conforming to the followings :-
JKR/SPJ/2008-S4 Clause 4.14.2.2 1. Mixture of penetration grade
bitumen & polymer additive.
2. Polymer shall be
non-carsinogenic.
ASTM D 4402 Manufacture's 3. Physical properties
Once per project P P/V C W
Certificate (Table 4.14.3): Prior to RTFOT
(rolling thin flim oven test)
AASHTO T315 a) Viscosity, max 3 Pa, test
temperature °C : 135
ASTM D 5 b) Dynamic shear , G/sin min,
1.0 kPa, 10 rad/s,
test temprature °C : 70

11
 PROJECT QUALITY PLAN Reference No.:

INSPECTION AND TEST PLAN

Revision No.:
CRACK SEALING
LEGEND
W WITNESSED
A APPROVED
C CONFIRMED
V VERIFIED
P PREPARED
TECHNICAL
FREQUENCY LAB TECHNICIAN / PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
OF TEST SUPERVISOR MANAGER
ENGINEER
ASTM D36 c) Penetration , 100g, 5s,
25 C, 0.1mm : for
consistency check
AASHTO T48 d) Ring & ball softening point,
min °C : 55
AASHTO T283 e) Flash point, min °C : 230
f) Moisture sensitivity test,
min % : 80
g) Emission of toxic gases,
max mg/m3 : 15
AASHTO T240 or ASTM D2872 4. Physical properties
(Table 4.14.3):- After RTFOT
AASHTO T315 a) Mass loss, max % : 1.0
b) Dynamic shear , G/sin min,
2.2 kPa, 10 rad/s,
test tempr °C : 70

c) Self-Leveling Silicone JKR/SPJ/2008-S4 Clause 4.14.2.3 1. Manufacturer's certificates

conforming to the followings :-
ASTM C1183 2. Physical properties
(Table 4.13.4) :- Based on 21d
cure time.
ASTM D412 (C ) a) Extrusion rate , ml/min : 50
ASTM D2202 b) Tensile stress @ 150%
strain (23 °C), kPa : 310
ASTM C679 c) Rhelogical properties :
Type 1, smooth
ASTM D5893 Physical prop d) Tack - free time, hr : 5 Once per project P P/V C W
ASTM C661 e) Bond (-29 C, 100% ext, imm,
non-immersed, oven-aged) :
Pass
ASTM C661 f) Hardness (-29 C, type A2) : 25
ASTM D5893 g) Hardness (23 C, type A2) : 30
ASTM D412 (C ) h) Flow : No flow
ASTM C793 i) Ultimate elongation, % : 600
ASTM D5893 j) Accelerated, weathering:Pass
Manufacturer's Certificates k) Resilience, % : 75

12
 PROJECT QUALITY PLAN Reference No.:

INSPECTION AND TEST PLAN

Revision No.:
CRACK SEALING
LEGEND
W WITNESSED
A APPROVED
C CONFIRMED
V VERIFIED
P PREPARED
TECHNICAL
FREQUENCY LAB TECHNICIAN / PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
OF TEST SUPERVISOR MANAGER
ENGINEER
4.2 Sand JKR/SPJ/1988 Clause 2.2.3.5 Tbl 2.1 Grading / 1. Grading Limits (Table 2.1)
Sieve Analys 10.0mm : 100% passing
5.0mm : 90 - 100%
1.18mm : 45 - 80%
Once per project P P/V C W
300um : 10 - 30%
150 um : 2 - 10%
Physical prop. 2. Non-plastic fine materials,
free from clay & organic matter.

5.0 APPLICATION OF CRACK SEALING

5.1 Flush Fill Method
5.1.1 Cleaning/ Airblasting JKR/SPJ/2008-S4 Clause 4.14.3.3a 1. Distance : >50mm , the air-
blasting wand away from cracks
Measurement Size 2. Immediately apply sealent after Once per project P P/V C W
blow.

5.1.2 Preparation of Sealant JKR/SPJ/2008-S4 Clause 4.14.3.1a Temperature 1. Temperature : 188 - 200°C
(for hot-applied sealant)
Manufacturer's Certificates Time 2. Time : >4hrs of overheated /
Once per project P P/V C W
remained sealant , to be
wasted (ref : us dept).

5.1.3 Application of Sealant JKR/SPJ/2008-S4 Clause 4.14.3.1a Visual 1. Application temperature

(cold-applied) : at ambient
temperature.
Temperature 2. Application temperature
Once per project P P/V C W
(hot-applied) : 188 - 200C
Time 3. Immediately apply after
cleaning.

13
 PROJECT QUALITY PLAN Reference No.:

INSPECTION AND TEST PLAN

Revision No.:
CRACK SEALING
LEGEND
W WITNESSED
A APPROVED
C CONFIRMED
V VERIFIED
P PREPARED
TECHNICAL
FREQUENCY LAB TECHNICIAN / PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
OF TEST SUPERVISOR MANAGER
ENGINEER
5.2 Reservoir Method
5.2.1 Crack Cutting JKR/SPJ/2008-S4 Clause 4.14.3.3a Visual 1. Cracks cut or routed forming
a reservoir of sizes :-
Once per project P P/V C W
Size a) Width : range from 12 - 19mm
b) Depth : range from 12 - 25mm
5.2.2 Cleaning/Airblasting As per 6.1 (A)
5.2.3 Preparation of Sealant As per 6.2 (A)
5.2.4 Application of Sealant JKR/SPJ/2008-S4 Clause 4.14.3.3b Visual 1. Sealant shall be placed only
within the confines of a cut crack
2.The material shall be shaped
either flush with or slightly
Once per project P P/V C W
below surface
a. Width : 12 - 19mm
b. Depth : 12 - 25mm

5.3 Overband Method

5.3.1 Cleaning/ Airblasting As per 6.1 (A)
5.3.2 Preparation of Sealant As per 6.2 (A)
5.3.3 Application of Sealant JKR/SPJ/2008-S4 Clause 4.14.3.3c Visual 1. Sealant shall be placed into
and over an uncut crack.
Manufacturer's Certificates 2. Overband size : 75 - 125mm
width.
Once per project P P/V C W

5.4 Combination (Reservoir/Overband)

5.4.1 Crack Cutting 1. Reservoir formation :
a) Width : 12 - 19 mm
b) Depth : 12 - 19 mm Once per project P P/V C W
2. Overband formation :
75 - 125mm width,
5.4.2 Cleaning/Airblasting As per 6.1 (A)
5.4.3 Preparation of Sealant As per 6.2 (A)

14
 PROJECT QUALITY PLAN Reference No.:

INSPECTION AND TEST PLAN

Revision No.:
CRACK SEALING
LEGEND
W WITNESSED
A APPROVED
C CONFIRMED
V VERIFIED
P PREPARED
TECHNICAL
FREQUENCY LAB TECHNICIAN / PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
OF TEST SUPERVISOR MANAGER
ENGINEER
5.4.4 Application of Sealant JKR/SPJ/2008-S4 Clause 4.14.3.3d Visual 1. The crack sealant shall be
placed into and over a cut crack
Manufacturer's Certificates 2.The material shall be shaped
into a band by squeegee, that is
centred over the crack reservoir. Once per project P P/V C W
Drawings 3. Placing of sealant :-
a) 12- 19mm (Reservoir width
& depth) b) 75-125mm
(Overband).

6.0 OPENING TO TRAFFIC

6.1 Opening To Traffic JKR/SPJ/2008-S4 Time - manufactures recommendation
TMP Checklist - immediate opening -sand P P/V C W
blinding, quarry dust

15