Why Skipping Crack Sealing on Asphalt with PetroMat® Geotextile Fabric Can Lead to Bigger Problems

PetroMat® geotextile paving fabric is a popular choice for extending the life of asphalt overlays. It helps create a moisture barrier and stress-absorbing interlayer between the existing pavement and the new asphalt layer. However, while PetroMat® can enhance pavement performance when used correctly, it can also contribute to accelerated surface cracking if proper maintenance—especially crack sealing—is neglected.

An issue is where PetroMat is sold by contractors in two different ways that is not truthful:

1.) PetroMat adds a tensile strength equivalent to 1/2" of asphalt: What contractors sell this as is the property owner/manager can now reduce the asphalt thickness by 1/2". They will tell the property owner/manager to reduce the final compacted thickness of the asphalt overlay from 2" to 1 1/2" to reduce cost and offset the cost of the PetroMat.  THIS IS NOT ADVISABLE!  PetroMat is an option to "reinforce" an asphalt overlay- not reduce its thickness, which does the opposite.

2.) PetroMat is a "One & Done":  Contractors will tell the property owner/manager once they invest the $0.50-$0.60 per square foot into PetroMat that the asphalt will be free from cracks or maintenance for the life of the overlay. THIS IS FALSE!  PetroMat is designed to DELAY reflective cracking- not eliminate it.  

This blog will discuss why this is one of the biggest fallacies when using PetroMat for your asphalt overlay.  

Failed asphalt over PetroMat where only a 1/5" asphalt overlay was installed.

How PetroMat® Geotextile Fabric Works

PetroMat® is designed to absorb and distribute stress from underlying pavement cracks, helping to delay reflective cracking in the new asphalt overlay. It also acts as a moisture barrier, preventing water from seeping into the subbase or groundwater from seeping up. This function helps minimize damage from freeze-thaw cycles, which is a major cause of pavement deterioration.

However, PetroMat® does not eliminate reflective cracking—it only delays it. Over time, if cracks are not properly maintained, they can still propagate to the surface, sometimes even faster and more severely than expected.

What Happens If You Skip Crack Sealing?

Many property owners assume that once they install an overlay with PetroMat®, they won’t have to worry about cracks for years. This is a big mistake. If cracks do appear and are not sealed, here’s what happens:

1. Moisture Infiltration Becomes a Bigger Problem

   • Once cracks form in the overlay, water can seep through the asphalt and saturate the PetroMat® fabric. Because the fabric is designed to hold some level of asphalt binder, it can also trap moisture within its fibers.
   • This trapped moisture can soften the asphalt binder and weaken the pavement structure over time.
   • Water trapped in the fabric layer can freeze and expand during winter, causing the overlay to crack even more aggressively.

2. Accelerated Crack Reflection

   • Without routine crack sealing, small surface cracks quickly allow moisture to penetrate deeper, reactivating the movement of cracks in the underlying pavement.
   • The PetroMat® layer, which was initially placed to slow down cracking, now serves as a stress point where cracks can propagate more quickly to the surface.
   • The fabric layer can also debond from the asphalt overlay, causing cracks to widen and creating an uneven, deteriorating surface.

3. Cracks Tend to Widen and Become More Severe

   • As cracks worsen, they no longer just reflect from the old pavement below; they start spreading laterally within the asphalt overlay.
   • Because the PetroMat® acts as a flexible membrane, once cracks form, they tend to widen faster than in a standard asphalt overlay without fabric.

4. Surface Raveling and Premature Pavement Failure

   • If cracks are left unsealed, water penetration leads to oxidation and raveling, where the top layer of asphalt starts breaking apart.
   • Over time, the surface may become rough and deteriorated, requiring costly repairs or even a full repaving project much sooner than expected.

The Solution: Routine Crack Sealing and Sealcoating

To maximize the benefits of PetroMat® geotextile fabric and prevent it from accelerating pavement deterioration, property managers and facility owners must follow a routine maintenance plan:

✅ Crack Sealing: Any cracks that develop in the overlay should be sealed as soon as possible with a high-quality, hot-applied rubberized crack sealant. This prevents moisture from infiltrating and undermining the PetroMat® layer.

✅ Sealcoating: A scheduled sealcoating program (every 2-3 years) helps protect the asphalt binder from oxidation, preventing premature cracking and extending the pavement’s life.

✅ Regular Inspections: Conducting biannual pavement inspections allows for early detection of cracks, ensuring they are addressed before they become major structural issues.

CASE STUDY: When PetroMat Fails To Perform As Intended

In 2011, we were contracted to mill and pave a parking lot in Northern New Jersey, a region known for its challenging soil conditions, particularly due to the high clay content found in Middlesex County. This clay, combined with the existing issues of asphalt cracking, posed a significant challenge for the longevity and durability of the pavement. To address these concerns, I recommended the installation of PetroMat before paving, a strategy I frequently employ for many projects situated north of the Raritan River, specifically between Interstates 287 and Route 21 in New Jersey. The decision to use PetroMat was based on its proven ability to enhance the performance of asphalt overlays by acting as a moisture barrier and stress-absorbing interlayer, which is crucial in areas prone to reflective cracking.

The project was executed flawlessly, with meticulous attention to detail at every stage, from milling to the final paving. The client was impressed with my recommendation and extremely satisfied with the quality and appearance of the finished product. This success reinforced the importance of using PetroMat in similar projects, especially in regions with challenging soil conditions.

Over the past 20 years, my experience working with National Accounts for paving has taught me invaluable lessons in helping clients maintain and preserve their second most expensive capital assets—their parking lots. However, challenges often arise with leased properties, where the responsibilities for parking lot maintenance can shift between the landlord and the tenant as leases are renewed. These transitional periods often lead to confusion and neglect, resulting in maintenance being overlooked.

For this particular property, which was under a lease agreement, the responsibility for maintaining the parking lot oscillated between the landlord and the tenant. Unfortunately, this back-and-forth led to a lack of consistent maintenance, and as a result, no crack sealing was performed for over a decade after we initially paved the lot. This neglect led to the very issues we aim to prevent with PetroMat, as the absence of routine crack sealing allowed moisture infiltration and accelerated deterioration.

By 2024, the parking lot was finally crack-sealed and seal coated, but by then, the damage had already been done, and the opportunity to maximize the benefits of PetroMat had been missed. This case is a stark reminder of the critical importance of regular maintenance and timely interventions to protect and extend the life of asphalt overlays.

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Left Picture (2011 After Paving)                                                                                                               Right Picture (February 2025 After Seal Coating)

Cracks visible after milling and sweeping prior to asphalt resurfacing.                             PetroMat fabric being installed prior to paving.

PetroMat installation ready for asphalt resurfacing.

The current condition is in February 2025, after some crack sealing and seal coating was completed in 2024.

CASE STUDY:

The video below provides a detailed visual account of a parking lot where paving fabric was utilized as part of the asphalt overlay process. However, it highlights a critical oversight: the failure to perform timely crack sealing. This omission led to the fabric not being able to fully perform its intended function of delaying reflective cracking. As a result, the video illustrates the subsequent deterioration of the pavement, showcasing how the lack of maintenance allowed cracks to form and propagate more rapidly than anticipated. This serves as a cautionary example of the importance of adhering to a regular maintenance schedule to preserve the integrity and longevity of asphalt surfaces.

Final Thoughts

PetroMat® geotextile paving fabric is a great tool for extending asphalt life, but it’s not a cure-all for pavement issues. Without proper maintenance—especially crack sealing—it can actually contribute to faster deterioration of the asphalt overlay. A proactive maintenance strategy ensures that the benefits of PetroMat® last as long as possible, protecting your investment and avoiding premature pavement failure.

If your property has an overlay with PetroMat® and you’re noticing cracks forming, don’t wait—get them sealed before they turn into a much bigger (and more expensive) problem.