Asphalt pavements have to deal with a lot of foot traffic, and regular maintenance is key to making them last longer. Being able to recognize problems early and getting them fixed right away can save a considerable amount of money.
We recently helped one of our clients save thousands of dollars with our recommendation. Let us walk you through the project we did at Pike Delta York High Schools – we promise there are lessons you can learn for your own project from this.
An Overview of the Problem
The school had an uneven, fatigued pavement that was at the end of its lifecycle. They were looking for a cost-effective solution to solve this problem.
We kickstarted the project with proper surface inspection to analyse current deficiencies of the pavement. We then prepared a structured layout to execute our actionable solutions in the best possible way. By considering all factors, we decided on asphalt overlay. Asphalt is the most recycled, reused and versatile pavement material. Of the 2.6 million miles of paved roads in the U.S., over 94 percent are surfaced with asphalt – and a lot of the durability can be attributed to it.
On-Site Asphalt Overlay Work
We did an asphalt resurface along with some other concrete and seal coat work. 950 Tons of asphalt was used to complete the 7 step process for the asphalt pavement installation project.
This is how the project went:
Step 1: Demolition and Removal
Demolition and removal were completed using heavy machinery, including small bobcats and forklifts and when necessary, front loaders and large dump trucks.Next, debris was removed. We recycled the old asphalt and concrete in our asphalt plants, turning deteriorating waste into strong, usable new asphalt.
Because we are committed to reducing impact on the environment, we recycle nearly 100% of the materials removed from a job site.
Step 2: Grading and Sloping
With a clean slate, we prepared the surface for appropriate water drainage. Using cutting edge technology like laser-guided transits and automatic motor graders, we graded the surface to be paved to ensure that water will run off appropriately. Proper water drainage is vital to your asphalt because water is a major cause of damage — including potholes, cracks, and heaving.
Step 3: Prepare the Sub Base
As the most important part of your new asphalt surface, the sub-base provides a stable surface to support new pavement. It acts as a frost barrier to help reduce winter damage due to freezing and thawing. During the installation, base thickness, base stability, and compaction were taken into consideration. If the sub-base is not appropriately compacted, the asphalt surface on top will not provide years of durability.
Step 4: Proof Roll, Undercutting and Sub Base Repair
Once the sub base was fully graded and compacted, an extra step was followed, called a proof roll, to ensure the underlying surface was strong and ready to support new asphalt. We made the necessary repairs in compromised areas to ensure the entire sub base is supportive. Undercutting was done to repair soft spots. This process involves digging down below the surface 2 or 3 feet and replacing the underlying soft clay or soil with a stronger aggregate material.
Step 5: Binder and Surface Course
Once the sub base was laid and soft areas were identified and repaired, we added the binder. The binder layer can be thought of as the strength of any new asphalt surface.
Step 6: Install New Asphalt Surface
Once the supportive structures of a new asphalt surface were installed, the top layer of fresh asphalt was added to provide a clean, smooth finish. Surface asphalt is made up of small aggregate, sand, and oil. This combination of materials creates jet-black asphalt that, when installed appropriately, provides a smooth ride and a shiny, attractive finished surface.
Step 7: Butt Joints and Transitions
It is very rare to install an asphalt surface that does not connect to existing driveways, roadways or parking lots. As asphalt paving contractors, we found a way to smooth the transition from old surface to new. Butt joints are areas where old asphalt or concrete meets new asphalt pavement. These transitional areas require special attention to ensure that the grading and water run-off are appropriate.
Once the asphalt and butt joints were laid, the new asphalt pavement surface was compacted and smoothed over using a roller truck. This step ensured that no small bumps of aggregate or stone were left poking through the smooth new surface.
What Were the Challenges We Had to Overcome?
One challenge that comes with resurfacing jobs is that we have to mill out sections of asphalt in front of the concrete walkways to meet the existing grade.
Milling is the process of removing the top layer of asphalt without disturbing the underlying subbase. This is an excellent option if your subbase is perfectly functional and only the top layer of your asphalt needs repair work. After milling, we leveled the parking lot to have a smooth paving surface. The entire process was completed in a relatively short period.
Next, we sprayed a layer of liquid asphalt (tar) so that the new asphalt sticks to the old pavement underneath. Then, we overlaid 2 inches of asphalt and ensured that there is adequate drainage to all drains so that there is no standing water after rain.
How We Dealt with Cracks and Potholes?
1. Crack filling: In the area that was not that badly damaged, we went with a crack fill and seal-coat repair instead of asphalt overlay.
We filled the cracks in the pavement using hot sealant to prevent water from doing any more damage. The sealant adheres to the asphalt, keeping water and other natural elements from penetrating and exploiting the weakness in the pavement.
While others make the mistake of waiting too long to get the pavement cracks filled, we were mindful of not letting the cracks grow bigger and compromise the integrity of the entire pavement surface.
2. Sealcoating: We did seal coating to extend the life of the pavement, reduce long term repair costs and enhance the appearance of the property. Sealcoating left the pavement looking sleek and dark.
This is the perfect solution we offer to our clients to improve the appearance of their asphalt and protect it from the elements.
Why We Chose Asphalt?
- Safety: Asphalt pavements increase road safety as they are skid-resistant with better traction. This reduces the chances of accidents.
- Cost-Effective and ROI : Asphalt roads can be built cost-effectively and have a better ROI than any other pavement material.
- Quiet: Asphalt roads can reduce noise by as much as seven decibels.
- Traveller friendly: They can be paved just a lane at a time, minimizing disruption to people and reducing congestion through speedy construction processes.
- Environmentally friendly: Asphalt is 100% recyclable as it requires 20% less energy to produce and construct than other pavement materials.
- Durable: All asphalt pavements have a bridging action and are flexible, which means they can withstand occasional overloads without serious damage. Asphalt only needs periodic maintenance to remain in good shape indefinitely.
How Much Time Did Our Asphalt Overlay Project Take?
It took us two complete days to finish the asphalt work. The rain lumped the odds against us on the second day, but we still managed to get the project done on time.
The End Result
Doesn’t it look great?
At Buckbros, we handle large-scale commercial asphalt work projects from all over Toledo. If you are looking for a reliable asphalt contractor, let’s talk!