Asphalt Paving & Overlays
Asphalt overlays are a great way to renew the service life of your pavement surface without the cost of rebuilding from scratch, which should only be done in extreme cases.
Asphalt overlay is a paving approach of applying a fresh layer of asphalt to an old surface. Instead of tearing up the deteriorating asphalt surface altogether, an asphalt overlay uses the current layers as a base for the new and improved asphalt pavement.
Some existing surfaces with heavy damage like large cracks, potholes, root damage, and/or expansions will need to be milled before a new asphalt overlay is applied.
Asphalt Paving & Overlay Process
Asphalt Observation and Assessment
Every existing asphalt surface is not suitable for an asphalt overlay. If it has severe structural damage such as large potholes, rooting, or ruts in the surface, it will need to be ripped up entirely. Asphalt surfaces that do not drain water properly are also likely not fit for an asphalt overlay because the it would need to be regraded to handle water correctly.
Conduct Asphalt Milling
After the site is assessed and deemed appropriate for overlay, it's time to get to work. The next step is an asphalt milling process which removes the top layer of the existing asphalt surface to remove the cracks, raveling, and other damage. The previous layer that has been damaged must be completely removed to make sure there is an even bond when the new asphalt is applied, and to ensure a level surface. We use an asphalt milling machine to grind down 1″ to 3″ (depending on the extent of the wear and tear on the existing surface). The removed surface material will be hauled off to a nearby asphalt recycling plant, where it will be recycled and used for new asphalt mix projects. We are proud to be 100% environmentally friendly!
Determine Needed Base Repair
The base of an asphalt surface may need to be completely removed and replaced in where potholes, rutting, and sinking have occurred. We will take no shortcuts here, to make sure a significant problem will not form again. The base of the affected asphalt surface area must be rebuilt using multiple lifts of asphalt and aggregate materials.
Begin Paving the Surface
Once the pre-existing asphalt surface has been properly prepared, the asphalt overlay can begin to be applied! The amount of asphalt overlay applied to the surface will usually be between 1.5″ to 2″ thick, but this can change depending on the thickness of the existing surface.
Can you overlay asphalt on concrete?
Sometimes, asphalt overlay can be applied to a concrete paved surface. When such a concrete surface experiences severe deterioration, there is not an simple option to repave the surface with new concrete without completely tearing up the existing surface. Asphalt overlay is a possible option for some of these concrete surfaces, but there are considerations.
Unlike asphalt, concrete paved surfaces are not compacted and compressed. Instead, the concrete sticks to and fills holes and irregularities with the subgrade and soil underneath it. Since concrete is a harder surface which will not have as much flexibility as asphalt, several expansion joints are usually cut into it to avoid cracking from seasonal contraction and expansion. If you were to simply pave over concrete with asphalt, these expansion joints will cause the asphalt surface to move over time, which can bring about bumps and cracks. The asphalt cracks along expansion joints will not cause the surface to fail, but it will need to be continuously sealed over time to keep water resistance.