United States Department of Transportation
i
Development of the Sealzall Machine : Upgrade to the TTLS (Pavement Crack Sealer)
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2009-10-31
[PDF-1.20 MB]
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Edition:Final report; Sept. 2006-June 2009.
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Abstract:The AHMCT Research Center, together with Caltrans, has been leading a multi-year research effort to develop
innovative high production crack sealing equipment, which improves safety while reducing costs. The Sealzall
Machine development project is the latest version of a line of successful longitudinal crack sealing machine prototypes
developed and deployed with Caltrans on California highways. The program’s key technical element has been the
application of automation technologies and custom engineering solutions to achieve increased sealing efficiencies and
to eliminate the workers’ exposure to highway traffic. The preceding Transfer Tank Longitudinal Sealer (TTLS)
development project produced a prototype high production longitudinal sealing application vehicle and a large
capacity transfer kettle trailer designed to efficiently resupply and support high production highway sealing operations.
Defective commercial sealant melting equipment had rendered the TTLS equipment effectively unusable for general
deployment. In addition to replacing deficient components, Caltrans requested inclusion of additional features to
further enhance functionality. The most significant upgrade was to add in-lane sealing capabilities. An electrically
heated sealant hose and application wand assembly was developed on the front of the application machine to support
manual in-lane crack sealing capabilities. The rebuilt TTLS application vehicle was then renamed Sealzall to reflect
the expanded sealing capabilities. The Sealzall machine retains the continuous 2-5 mph moving lane closure
longitudinal sealing functionally first developed for the TTLS with the additional features of compressed air blast
crack cleaning and hot sealant recirculation. The Sealzall will ultimately be turned over to Caltrans for full highway
operational deployment.
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