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Originally Posted On: https://rstanleypaving.com/asphalt-overlay-how-to-revitalize-worn-paved-surfaces/

Asphalt Overlay: How to Revitalize Worn Paved Surfaces

We ask a lot of our asphalt surfaces—cars constantly traverse them, the sun beats down relentlessly, and water can flood in from below, weakening the binding that holds the asphalt particles together. In short, given enough time and even with proactive maintenance, asphalt can start to deteriorate.

Rather than completely reconstructing these surfaces, asphalt overlay provides an efficient solution that revitalizes performance. Opting for an overlay rather than a complete reconstruction can minimize disruptions to your routine or business while enhancing surface appearance and traction.

In this blog, the professionals at R. Stanley Paving LLC discuss this convenient revitalization method, including the benefits of restoring your worn surfaces, how the process works, and how to decide if an overlay is the right choice to address surface damage.

The Benefits of Overlay for Asphalt Repair

What makes overlay ideal for surface renewal is the addition of a new layer that seals cracks and prevents water infiltration, eliminating the need for a full replacement.

Here are the key benefits of this surface renewal method for asphalt repair:

• Strengthens/protects: Asphalt can become brittle and lose its flexibility over time. An overlay adds a fresh layer that reinforces the existing pavement, protecting it from further damage caused by traffic, weather, etc.
• Seals and extends lifespan: Asphalt cracks act as entry points for water. An overlay fills cracks and seals the surface, preventing further water penetration.
• Improves drainage: Proper drainage is important for asphalt health. An overlay can be used to address minor drainage issues by creating a slight slope that encourages water runoff.
• Faster installation: Asphalt overlay projects can typically be completed in a shorter timeframe compared to complete replacements.

What’s the Asphalt Overlay Process?

Though it isn’t a complete overhaul, the asphalt overlay process requires a specific strategy. In some cases, this strategy can involve shaving off damage on the top layer and patching deep cracks before paving a new layer.

Here are the main steps that follow surface preparation:

1. Milling (optional): In some cases, the top layer of the old asphalt may be milled or removed to achieve a level surface and proper bonding with the new overlay.
2. Tack coat application: A bituminous emulsion tack coat is applied to promote adhesion between the existing surface and the new overlay.
3. Paving: Hot-mix asphalt is carefully laid over the prepared surface using paving equipment according to a specific thickness and density.
4. Compaction: The newly laid asphalt is compacted using heavy rollers to achieve the desired density and smoothness.
5. Finishing touches: This step can involve line striping and installing reflective markers to enhance safety and visibility. It largely depends on the surface’s usage and specific application.

Applying Overlay to an Asphalt Driveway: Key Considerations

Your existing asphalt’s condition dictates the extent of the work required. The overlay project is primarily determined by a thorough surface evaluation, the results of which are then used to calculate overlay thickness and material choices.

Here’s a breakdown of what this involves:

Surface Evaluation

A surface evaluation’s primary function is to pinpoint the extent and severity of existing damage (cracks, potholes, rutting, fatigue) via visual inspection. This information factors into the overlay thickness and whether additional repairs are needed.

Asphalt Overlay Thickness

A thin overlay (one to one and a half inches) might suffice for minor surface wear, but extensive cracking or weak subsoils might require a thicker layer (two to three inches) to provide a strong foundation and prevent cracks from reflecting through the new overlay.

Overlay Materials

After determining thickness, the next question is what materials to use to pave over the old surface. The condition of the existing pavement plays a major role in this decision.

Here’s a look at the relevant factors:

• Heavily cracked surfaces: Consider a more flexible mix for better crack bridging.
• Weaker subsoils: A stronger mix might be needed for better support.
• High-traffic areas: A stronger, coarser mix is ideal to handle wear and tear.

Low-traffic areas: A more economical option might suffice.

Asphalt Maintenance for Overlay

Overlay isn’t a “set it and forget it” solution—proper maintenance goes a long way in preserving its lifespan. Even tasks as simple as sweeping away debris and applying a sealcoat every few years can protect your asphalt from the harsh effects of sun, water, and wear.

Overlay maintenance generally follows the same principles as regular asphalt maintenance but with a few additional considerations:

• Newer surface: Overlays are a fresh layer of asphalt, so they might be slightly less susceptible to cracking initially compared to older asphalt.
• Sealcoat timing: Sealcoating is typically recommended for regular asphalt every three to five years. With a new overlay, the initial sealcoat might be applied after a longer period, around five to seven years, depending mostly on traffic patterns.

Regular maintenance tasks for overlaid asphalt still include:

• Sealing cracks and joints with sealants as needed
• Patching or filling potholes
• Sealcoating
• Surface cleaning (sweeping and pressure washing)
• Drainage maintenance (clearing catch basins, ditches, and culverts)
• Conducting periodic inspections

Overlay vs. Asphalt Replacement: Making the Right Choice

You’re faced with the option of an overlay or a complete reconstruction: While both approaches restore your pavement’s quality and appearance, the decision should be based mainly on the level of disruption you’re willing to endure and long-term performance requirements.

Here are three key factors that can help you choose:

Severity of the Damage

• Overlay for moderate cracking, minor potholes, and general wear and tear.
• Reconstruction for extensive cracking, severe raveling (loss of surface stones), base failure, or significant depressions.

Asphalt Thickness

• Overlay works well if there’s enough existing asphalt remaining to create a stable base for the new layer.
• Reconstruction is needed if the existing asphalt is too thin or weak to support and overlay effectively.

Drainage Issues

• Overlay may not be sufficient to address severe underlying drainage problems that contribute to the asphalt’s deterioration.
• Reconstruction allows for correcting drainage issues (edge cracking or standing water) by addressing the subbase and installing proper drainage systems.

Explore Our Asphalt Overlay Solutions

At R. Stanley Paving LLC, we offer asphalt overlay solutions for a wide range of applications, ensuring a hard, long-lasting surface for cracked driveways, weathered parking lots, splitting roads or pathways, and more.

Contact us today at (845) 831-1616 to discuss whether you need an overlay or a full replacement.