Overlays

Probably the least understood of all maintenance options, an overlay can be your best friend or worst enemy. An overlay, as its name implies, is simply a new pavement section, generally 1.5”-2” thick placed over the top of an existing pavement section, often with a fabric interlayer (Petromat is a name brand often used for paving fabrics, much like Kleenex is for tissue).  With the proper application, an overlay can build on what you already have invested in your road or parking lot, eliminating the need for removal and replacement.  Sounds like the perfect solution, right?  Well, yes and no – remember that “worst enemy” bit?  If a section has already failed to a certain point, the overlay on top of it will fail, too.  If drainage is an issue, raising the height of some areas with an overlay and lowering others (transitions to concrete, etc, must remain flush by grinding down, then raising back up again with new asphalt) may cause puddles or flooding.  If you have carports, all that big equipment needed for overlays (oil/fabric truck, etc) isn’t going to fit.  A proper overlay should include wedge cutting of all flush transitions to concrete gutters, pads, etc and any asphalt that will not be overlaid.  All utilities (manholes, utility lids, etc) should be raised to the new height.  Most importantly, areas should be replaced first if they are failed to the point that the overlay will not bridge across them.  If an overlay is a viable option, we’ll check all these little details for you, perhaps even survey the existing grades and drainage patterns with a laser, to make sure everything will work as planned.

Sometimes an overlay can provide for a longer life than a new section can and at half to two-thirds of the cost.

Typical unit cost range -

1.5” overlay with fabric – $0.70 - $1.60 per square foot.

2” overlay with fabric – $0.85 – $1.75 per square foot.