Asphalt overlay is a cost effective paving method of applying a new layer of asphalt to a deteriorating surface. Rather than tearing up an old asphalt surface entirely, an asphalt overlay project will use the existing layers as a base for the new asphalt pavement. Some asphalt surfaces with severe damage like rutting, potholes, large cracks, and expansions will need to be milled before an overlay is applied.
Asphalt milling will remove the top layer of an asphalt surface that has taken on cracks, raveling, or other damage. The old layer that has sustained damage must be removed to ensure an even bond when the new asphalt is applied, and to maintain a level surface. An asphalt milling machine will grind down 1″ to 3″ depending on the wear of the asphalt surface. The ground surface material will be hauled to an asphalt recycling plant where it can be integrated into new asphalt mix designs.
The base of an asphalt surface may need to be replaced in areas where potholes, rutting, and sinking have formed. In order to make sure a severe problem will not form again the base of the asphalt surface will be rebuilt using multiple lifts of aggregate and asphalt.
Once the existing asphalt surface has been prepared, the asphalt overlay can be paved on top of the surface. The amount of asphalt overlay applied to the surface will vary depending on the thickness of the existing surface, but typically will be within 1.5″ to 2″ thick.