If you’re managing a commercial property with aging pavement, an asphalt overlay might be the cost-effective solution you’re looking for. Rather than a full replacement, a commercial asphalt overlay restores the surface by adding a new layer of asphalt on top of the existing one. This process improves performance, extends the life of the pavement, and saves significantly on costs.
Understanding Commercial Asphalt Overlays
An asphalt overlay is a paving method where a new layer of asphalt is applied over an existing pavement structure. In commercial settings, overlays are often used for parking lots, drive lanes, industrial yards, and roadways. This method is ideal when the existing surface has minor to moderate damage, but the foundation (base layer) is still structurally sound.
A properly installed overlay can add 8–15 years of new life to your commercial pavement, making it a popular option for business owners and property managers aiming to extend the lifespan of their investment without the cost of total reconstruction.
When Is an Overlay the Right Choice?
Before selecting an overlay, a pavement evaluation is performed to assess the condition of the underlying layers. Overlays are most appropriate when:
- Surface cracking, fading, or minor raveling is present
- The base layer remains stable and uncompromised
- Drainage systems are still effective
- There are no major structural issues or severe alligator cracking
If the pavement has deep structural damage or drainage failures, full-depth reclamation or reconstruction may be a better solution.
Benefits of Commercial Asphalt Overlays
Overlays deliver several benefits to commercial properties:
1. Cost Efficiency
Overlays are more affordable than full replacement because they reuse the existing base. This reduces both material and labor costs.
2. Faster Project Completion
Since there’s no need to remove the existing asphalt entirely, overlays are quicker to complete. This minimizes business disruptions and downtime.
3. Improved Appearance & Safety
A fresh asphalt layer instantly upgrades curb appeal while also improving driving surfaces for vehicles and pedestrians.
4. Sustainability
Overlays reduce material waste, and in many cases, recycled asphalt can be used in the new layer—supporting greener construction practices.
5. Extended Pavement Life
A commercial asphalt overlay adds a new usable surface that can perform well for over a decade with proper maintenance.
The Overlay Process: Step-by-Step
Here’s a breakdown of what to expect during a commercial asphalt overlay project:
1. Inspection and Evaluation
Our team evaluates your pavement to confirm it’s a suitable candidate for an overlay. We assess structural integrity, drainage, and overall condition.
2. Surface Preparation
Minor repairs are made to cracks, potholes, and drainage systems. The surface is cleaned thoroughly to ensure proper bonding.
3. Milling (if needed)
In many commercial projects, the existing surface is milled (partially removed) to ensure the new asphalt layer aligns with surrounding surfaces like curbs and drainage systems.
4. Tack Coat Application
A tack coat (a thin layer of adhesive) is applied to bond the old surface with the new asphalt layer.
5. Asphalt Installation
The new layer of hot mix asphalt is laid using specialized paving equipment and compacted to create a smooth, durable surface.
6. Striping and Markings
Once the asphalt has cooled and set, line striping, traffic markings, and any necessary signage are added.
Overlay Maintenance for Commercial Pavements
To maximize the lifespan of your overlay, regular maintenance is essential:
- Seal coating every 3–5 years
- Routine inspections for cracks or wear
- Prompt crack sealing and pothole repair
- Regular cleaning to prevent chemical and water damage
Overlay vs. Full Replacement: How to Decide
An overlay is a great solution when the underlying pavement is still in good condition. However, for properties with significant base damage or drainage issues, a full-depth reconstruction may be necessary. Our team helps property managers evaluate which solution fits their timeline, budget, and long-term goals.
If you’re unsure whether an overlay is right for your commercial pavement, we’re here to help. Contact The Pavement Group for a professional evaluation and project estimate tailored to your property’s specific needs. If you have any questions, we’re here for you!
