The Ultimate Renovation For An Existing Road

An asphalt overlay is a cost effective way to turn your old, beaten and tattered roadway into a new and beautiful asphalt surface that will truly last.

The Overlay Process – Preparation is CRUCIAL

An asphalt overlay consists of either cold milling your old asphalt surface and repairing your existing asphalt, or just repairing your asphalt surface and then installing an asphalt overlay to create a brand-new asphalt surface.

Depending on how damaged the existing asphalt is, a mill may be needed to reclaim a solid surface in a worst case scenario. This is done by grinding down the original asphalt to remove the damaged pieces and reclaim the area. In most cases, you can make repairs to any damaged areas and thoroughly clean the remaining areas. After this is done, an asphalt based tack coat adhesive will be applied. When this sets, a new layer of asphalt will be paved directly over the old asphalt giving you a new and sturdy asphalt surface.

These procedures can be accomplished in so many different applications. Parking lots, roads, bike paths and residential driveways can all benefit from new coats of asphalt. Overlaying your existing asphalt as opposed to completely removing and repaving the area can protect your investment from becoming a major expense.

To Remove or To Overlay?

Depending on your Asphalt’s strength and integrity, in the worst case scenario, you may have to remove and replace. This is costlier than an overlay and may involve base and sub base work to improve the strength and integrity of your asphalt’s foundation.

In most cases, however, your old asphalt can be overlaid by strengthening the existing asphalt’s failed areas with a solid repair, then installing an asphalt overlay with new asphalt. The depth of the asphalt depends on the application and the type of material used. Some overlay asphalts are called structure course materials and others are called friction course materials.

There are also surface materials called a wear course. Each one is specifically designed for different applications, such as structural course SP 12.5, which is designed for strength and durability and is only to be installed in depths between 1.5” and 2” lifts. These specifications must be so to achieve maximum density, or compaction.

Friction Course

Friction course materials are specifically designed for traction in areas that are dangerous in wet conditions, such as highways, where traction is greatly needed. Most friction course materials are manufactured and engineered to achieve traction by using a liquid rubber polymer in the asphalt mix, and designed with different aggregate sizes to match the depth required and friction needed specifically for each application. They are usually installed in depths ranging from 0.75” to 1.25” depending on application.

Friction courses are very expensive to install, due to materials involved, such as the rubber polymer, and the aggregate size which is usually made from Granite rock (a material not mined here in Florida). Granite rock must be shipped in either by trains or barges, making the cost as high as $165.00 to $195.00. This material is widely used for DOT projects such as state roads and interstates, exit ramps, and turn lanes.

Wearing Course

Wearing course asphalts are widely used for the average parking lot application. The material comes in different aggregate sizes to accommodate different depths in order to achieve maximum density, or compaction. Standard overlays are installed from 1.25” in depth to 2” in depth, depending on the application.

The two most common mix designs for overlays are the S-1 and the S-3. Both are made for strength and beauty, if installed correctly with a team that takes the ultimate pride in their work – like we do here at Pavemaster.

The result is an asphalt surface that not only will be gorgeous, but will also have unmatched strength and durability, the end result being an asphalt parking lot roadway or driveway that is beautiful with long lasting stability.