Asphalt and Concrete Expansion Joint Repair Asphalt and Concrete Expansion Joint Repair

What You'll Need
Screwdriver
Putty knife
Hammer
Mortar and patch repair
Pipe insulation
Masking tape
Joint sealer
Garden hose
1-inch Board

Because expansion joints are an important factor in maintaining the integrity of concrete and asphalt surfaces such as roads, sidewalks and driveways, expansion joint repair is a key factor in keeping these surfaces from cracking and breaking up. Expansion joints, like other construction materials, eventually need to be repaired or replaced. If you have driveways or other pavement surfaces with these expansion joints, you will no doubt want to know how to repair these joints to keep your pavement surfaces from breaking up. Here are 7 steps you can use to accomplish this maintenance.

Step 1 – Clean Out Joints

Before applying sealers in your expansion joints, use a putty knife or flathead screwdriver to clean out all debris, including dirt, caulking compounds, or old joint expansion materials. For removal of stubborn debris or old joint material, use a pry bar or  hammer and cold chisel. Flush loose dirt, sand, or debris from the joint with forced air water sprayed from a garden hose.

Step 2 – Repair Cracks, Chipping and Gouges

Use mortar and patch repair to seal crack and other defects in the joints. This repair material should harden overnight before completing repair of the joint. If cracks are wider than ¼", flush out loose dirt or debris with a garden hose.

Step 3 – Fill Joint with Insulation

Into the expansion joint, place closed cell pipe insulation, using a putty knife to force the insulation into the joint and leaving space for joint sealer to be added on top. Be sure to leave enough space between insulation and surface top, so the concrete or asphalt surface will be level with top surface of the sealer when it has been compacted. This will keep moisture from penetrating the insulation and running between it and the sides of the joint.

Step 4 - Create an Edge in the Joint

Mask joint edges with masking tape to create edges for your joint sealer.

Step 6 – Apply Joint Sealer

Cover joint insulation with joint sealer, bringing the surface of the sealer level, or slightly above level, with the concrete or asphalt surface. Compacting the sealer will lower its top level. Use a hammer and the edge of a 1-inch board to compact the sealer into the joint crease. Lay the edge of the board into the crease, with the sealer under the board edge, then strike the top edge of the board, compacting the sealer into the crease. If the crease is too narrow to insert the board, chip some of the sides of the crease away before attempting to compact the sealer. Be sure all dirt or debris has been flushed out of the crease before compacting the sealer.

Step 7 – Allow Sealer to Harden

Check application instructions by the sealer manufacturer for sealer curing time. When the sealer has cured, remove the tape.

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