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Our 7-Step Asphalt Pavement Installation Process

Asphalt installation is no piece of cake. Your asphalt pavement will have to bear the assault of constant traffic and heavy-duty vehicles for years to come. So creating one is a tedious task. An asphalt paving project costs heftily, so finding a trusted paving company that constructs a hard-wearing surface is necessary.

Surface Solutions offers premium paving and maintenance solutions in Salisbury, Maryland, at reasonable rates. Click here to schedule a free estimate.

Creating a durable and robust pavement requires flawlessly executing each step for a long time.

Step 1: Preparing the site

Remove the existing pavement if there is any.

  • Demolish it using heavy machineries like small bobcats and forklifts and remove the material with front loaders and large dump trucks.
  • Remove any remaining debris.

Step 2: Grading and Sloping

Do proper grading and sloping work for better water drainage.

  • Grade the ground with automatic motor graders and laser-guided transits so water can easily run-off the surface. Otherwise, it will cause extensive damage such as cracks, potholes, and heaving. 

Step 3: Sub-base installation

The sub-base is what provides stability to new pavement surfaces. It is the foundation layer of the asphalt surface that acts as a frost barrier to minimize winter damage caused by thawing and freezing.

  • Sub-base installation consists of different actions to reach appropriate base thickness, base stability, and compaction. Compaction determines the life span of the asphalt pavement.

Proof roll, undercutting, and repair

After the sub-base is compacted, a proof roll is done to test if it can support your new asphalt pavement.

  • Drive over the sub-base row by row with a quad-axle dump truck carrying around 72,000 pounds.
  • If the material gives way (more than an inch) because of the truck’s weight, then it isn’t supportive.
  • Dig down two or three feet (or 16 inches in the case of geo-grid) in the soft spots and replace the soft material with a stronger aggregate material.

Step 4: Binder installation

Once a strong sub-base has lain, and all soft areas are repaired, you need to add the binder.

  • The binder layer consists of a large aggregate mixed with oil. It provides strength to the new surface.

Step 5: Surface installation

After the supportive structures (the sub base and binder) are installed, the top layer is laid to offer a shiny finish and a smooth drive.

  • The surface layers consist of aggregate, oil, and sand.

Step 6: Butt Joints and transitions 

An asphalt surface is often connected to other surfaces like driveways, parking lots, and pavement. So contractors need to create a smooth transition between the old and new surfaces. The place where the old surface meets the new is called butt joints.

  • The grading and drainage of the transitional areas need special attention.
  • Butt joints should be such that pedestrians and drivers do not notice the difference when going from one surface to another. 

Step 7: Compaction

Once all the layers of asphalt and the butt joints are laid, the whole surface needs to be smoothed and compacted.

  • A roller truck is used for compaction and smoothening the new asphalt pavement, so there are no bumps in the new surface.

Surface Solutions offers matchless paving solutions in Salisbury, Maryland. Click here to schedule a free estimate.