Asphalt Overlays – Why and How?

As a property manager or business owner, maintaining curb appeal, safety, and infrastructure integrity is part of your everyday responsibilities. Asphalt surfaces wear down over time due to weather, traffic, and everyday use. When your parking lot or streets start to show signs of wear like cracks, raveling, or uneven areas, it doesn’t necessarily mean you need to tear everything out and start over. In many cases, an asphalt overlay can provide a cost-effective way to restore your pavement’s appearance and performance, extending its life without the expense of committing to a major capital improvement like a full replacement.

What Is It?

An asphalt overlay is a resurfacing technique that applies a new layer of asphalt over an existing paved surface. It’s ideal when the underlying base is still stable, but the surface has deteriorated.

For those looking to maximize budgets, overlays offer a valuable middle ground between patching and full replacement.

There are two main types of overlays:

• Standard Overlay: The existing asphalt is milled down 1½” to 2” using a grinder, and a fresh layer of asphalt is applied over the top. This can be enhanced in strength with blended fiber additives (like Forta-Fi asphalt fiber) if needed.
• Fabric/Mat Overlay: No longer a standard practice, this method included applying a layer of special fabric or mat (such as Petromat or TruPave) between the milled surface and the new asphalt. It was thought to reduce reflective cracking and provide a moisture barrier, however, it has been found to cause issues during removal as it cannot be milled in place and is not recyclable. If Petromat or other fabric materials are discovered during the overlay process, the project will incur additional processing and dump fees.

Why Might You Need It?

Here are some common signs that an overlay could be the right choice:

• Cracking: When cracks spread across your asphalt, water can seep through and damage the base layer. An overlay helps seal the surface and reduce further deterioration. However, any deep cracks that extend beneath the milled layer will eventually reflect to the top as the underlying issue is not being addressed.
• Raveling: This is when the surface begins to break apart into loose gravel. It’s a sign the top layer is breaking down. As only the top layer is affected, an overlay could be a cost-effective way to remedy this issue. Although, unless the cause of the raveling is remedied (likely irrigation leaks, spraying, or runoff; areas where water on the asphalt surface is constant), the raveling process will start again on the new overlay.
• Uneven Areas or Potholes: These are not only safety hazards but also symptoms of deeper issues that overlays can help address, if caught in time. Potholes can potentially be removed completely with an overlay and uneven areas can be leveled.

The key is timing: an overlay is ideal when your asphalt is damaged but not beyond repair. If the underlying base has failed or the asphalt has reached the end of its lifespan, full removal and replacement is the better long-term solution.

Why Does It Matter?

Whether you’re managing a retail center, apartment complex, HOA, or office park, pavement condition impacts both perception and performance. Here’s why overlays should be on your radar:

• Preserve Property Value: A smooth, well-maintained lot gives a strong first impression to prospective homeowners, tenants, customers, and visitors.
• Avoid Safety Hazards: Cracks and potholes can lead to trip-and-fall claims or vehicle damage, opening the door to injury and costly liability issues.
• Save on Long-Term Costs: An overlay can add 10-12 years of life to your asphalt, delaying the need for a full replacement

How Does the Process Work?

1. Site Assessment: We assess the existing pavement condition to determine if an overlay is viable.
2. Milling: We grind (sometimes called “cold planing”) down 1½”–2” of the existing asphalt, especially in transition areas (flowlines, gutter edges, etc.) to create a level surface for the new layer and assist with proper flow and drainage.
3. Tack Coat Application: We apply a thin layer of asphalt emulsion or hot oil binder to act as a bonding agent. This facilitates a strong adhesion between the old asphalt and new layer, preventing slippage and improving performance.
4. New Asphalt Installation: A new asphalt layer (typically 1½” to 2″ thick) is installed and compacted.
5. Finishing Touches: This includes line striping (if contracted) and cleanup.

What Are the Pros and Cons?

Pros:

• Cost-effective compared to full replacement
• Faster project turnaround
• Improves surface appearance and performance
• Extends pavement lifespan by 10-12 years

Cons:

• Not a permanent fix; underlying cracks will eventually reflect through over time, depending on the depth and severity of the cracks and other factors on the surface (traffic load, frequency of use, etc.)
• Less durable than full replacement (which lasts 20–25 years with maintenance)
• Not suitable for pavement with base failure or extensive structural damage
• Some fabric overlays (like traditional Petromat) are non-recyclable and more expensive to remove later

Conclusion

If your property’s asphalt surface is visibly deteriorating but structurally sound, an asphalt overlay can be a smart investment that extends pavement life and enhances curb appeal. It’s a proactive, budget-friendly solution that bridges the gap between routine maintenance and full reconstruction.

Not sure whether an overlay is right for you? Our team is here to evaluate your surface, answer your questions, and provide a solution tailored to your property’s needs and budget.