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New Asphalt Works

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7 Step Process for New Asphalt Pavement:

Attention to details on all steps is our assurance to quality workmanship. 

Step 1: Demolition and removal

  • The existing asphalt, concrete or paver is  removed by smaller skid steerer for tight areas and front loaders for larger areas and transfered to awaiting dump trucks. 

  • Old asphalt is transported to an asphalt plant for recycling.

Step 2: Grading and Sloping

  • Using laser transit, area to be paved is graded to favourable water flow pattern.

  • Proper water drainage is vital to the longevity of the new pavement. 

Step 3: Sub Base Preparation

This is the most important step as the surface asphalt is only as good as the solid subbase which it is built on.

  • Sub base is a sublayer of roadbase material to structurally support new asphalt surface and a frost barrier to reduce contraction and expansion damage due to temperature.

  • Sufficient base thickness, stability and compaction are important attributes to ensure the longevity of the new asphalt surface. 

Step 4: Sub Base testing for softspots

After grading and compaction, compaction test is performed to ensure the sub base is stable to support new asphalt.

  • Proof rolling test involves driving a quad-axle dumb truck, loaded with 72,000 pounds over the entire surface.

  • Ground flex more than an inch under the weight of the truck is indicative the ground is not sufficiently stable to support top asphalt layer.

To repair detected "soft spots", there are two methods:

  • Undercutting method - digging down below the surface 2 or 3 feet and replacing the underlying soft clay or soil with stronger aggregate material can be applied. 

  • Or, where applicable, structural geofabric grid installation at about 16" below surface to bridge base materials is effective to create a solid support structure and more economical than undercutting method. 

Step 5: Binder and Surface Course  (multi-lift application)

  • The base layer (binder) of asphalt is larger aggregate & oil mixture is first laid and compacted. Multi layer application allows for more effective compaction. 

Step 6: Surface asphalt layer application

  • Surface asphalt consists of finer aggregate, sand and oil to provide smoother ride and appearance. 

Step 7: Butt Joints and Transitions (areas where old and new asphalt pavement join)

  • Attention to proper grading at the joints and transition area are essential for proper water run-off and for prevention of pedestrian tripping hazards. 

Final Rolling and Inspection for proper water flow pattern and smoothness. 

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