Road Resurfacing: A Cost-Effective Way To Extend the Life of Roadways

Deteriorating road conditions combined with increasing traffic loads have put road repair in the spotlight as a national problem. Road resurfacing, a road maintenance method that adds a layer of asphalt or concrete to an existing road surface, is one of the quickest ways to rejuvenate roadways for safe travel and transport of goods.

Severe weather events are increasingly frequent and are expected to add $19 billion to paving costs annually until 2040. Road resurfacing projects provide contractors many opportunities to tackle short- or long-term contracts. Highways and bridges represent urgent and substantial infrastructure repair projects, while local roads, parking lots, and even driveways offer smaller projects for road resurfacing.

Using data-driven insights to choose projects, manage road construction equipment and keep projects on schedule can help companies efficiently perform road resurfacing and maintenance projects. This article details the benefits of resurfacing, methods and materials used, the steps in the resurfacing process and explains the difference between surface dressing and resurfacing.

Enhancing Road Safety and Efficiency Through Resurfacing

Road resurfacing helps maintain infrastructure by enhancing safety and improving cost efficiency — and the overall driving experience. Regular resurfacing can prevent the need for more costly repairs or complete reconstruction, reducing accident risks and lessening vehicle wear and tear.

Indicators that road resurfacing is needed include visible potholes and cracks that pose safety risks, rough surface textures suggesting underlying issues and poor drainage leading to water pooling. 

Additionally, faded road markings can signal significant wear and impair driver visibility, while increased road noise might indicate surface irregularities. Addressing these signs promptly helps keep roads safe and functional for all users.

The Three Methods of Road Resurfacing

Road resurfacing is a type of road maintenance that restores damaged roads to extend their life and make them safer for traffic. If the road's subgrade is in good condition, resurfacing is a cost-effective way to repair a damaged upper layer rather than full-depth reclamation, which removes and replaces the whole structure from surface to base.

There are three common methods used to resurface roads:

1. Overlay

   Overlaying a fresh asphalt layer is a quick way to rejuvenate a road with only shallow defects. This method of resurfacing restores structural integrity and fixes cracks without grinding, effectively extending the life of the road.

2. Hot-in-Place

   The hot-in-place technique is appropriate for road surfaces with minimal cracks and an asphalt binder still soft enough to adhere to a new asphalt layer. This method involves removing and heating the existing asphalt layer on the spot and then laying down the reprocessed asphalt. Because hot-in-place resurfacing recycles the materials, it is a cost-effective and more environmentally sustainable practice.

3. Mill and Fill

   Roads with more serious deterioration, where cracks have penetrated below the surface, can be resurfaced with the mill and fill method, sometimes called mill and overlay. If the subgrade and base layers are structurally sound and can withstand vehicle traffic, grinding off and replacing the asphalt surface layer will restore the road. After milling and hauling away the old asphalt, workers sweep and clean the road of any loose debris before applying a new asphalt layer.

After resurfacing, contractors need to reapply road markings. All resurfacing methods extend the road's life cycle, but the time until further repair or replacement is required depends on traffic load and weather conditions.

Typical resurfacing can last 10-15 years. Some roads may need maintenance in a considerably shorter time or last as long as 20 years.

Road Resurfacing Materials

Each road project will have different specifications and needs, with the exact mixes and types of materials varying due to local climate, roadway traffic, budgets, and applicable government regulations. Contractors should carefully evaluate the region and climate they’re in when deciding on which materials to use for the job. 

 Here are the general types of materials commonly used:

Asphalt

Asphalt is a common and popular resurfacing material because it is smooth, affordable, and can withstand temperature changes. It is a mixture of aggregate, filler, and bitumen. Though asphalt may require more frequent maintenance than other materials, it is easy to work with and drive on.

Bitumen 

Bitumen is a dark brown or black viscous liquid made from petroleum. It is used as a binder in asphalt and other construction products, and it can also be used as a binding or sealing layer for roadways.

Concrete

Concrete is exceptionally durable for higher traffic and heavier loads, but it can buckle in hot climates and is vulnerable to deterioration from road salt applications in colder locales. More commonly used for local roadways, concrete can last longer than other materials in the right conditions but is usually more expensive.

Composite Method vs. Composite Materials

Composite pavement refers to a method of road construction that uses a layer of asphalt on top of a concrete base, and some resurfacing projects fall into this category. 

However, newer composite materials that combine traditional materials with fiberglass, polyester resin, carbon fiber and other substances are being tested to increase strength and durability in road construction. Some of these innovative materials may become more common in resurfacing, especially for infrastructure like bridges and highways.

A Step-by-Step Guide to Road Resurfacing

Road resurfacing helps maintain safe and efficient transportation routes. This process involves several the following steps to ensure the road remains durable and reliable for daily use:

1. Engineers inspect and assess the road's condition to determine the extent of damage and the suitable resurfacing method.
2. Designs and detailed plan are created to outline the process, materials and timeline.
3. The road is prepared by cleaning the surface, repairing potholes and addressing drainage — with traffic management in place.
4. Milling machines remove the top layer of the road to create a smooth base for the new surface.
5. Workers apply a new layer of asphalt or concrete.
6. Rollers compact the new surface, ensuring a solid, uniform layer that adheres properly.
7. The surface cures and cools to achieve the desired strength and durability.
8. Once set, the surface undergoes a final inspection, and road markings and signage are reapplied for safety.

Understanding the Difference Between Road Resurfacing and Surface Dressing

Surface dressing is a type of maintenance that restores worn roads by sealing the pavement. It is often used as preventive maintenance and is intended to waterproof, preserve and improve the roadway's skid resistance. 

Bitumen and a thin layer of asphalt or chippings are usually used, but sealant types can vary. Surface dressing can’t repair cracks or other road defects.

Resurfacing is appropriate for roads with some deterioration and is a more extensive form of maintenance. It adds a complete surface layer to the road rather than just a sealant, as in surface dressing.

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Profiting and Innovating on Road Resurfacing Projects

Road resurfacing projects are a money-making opportunity for construction companies eager to help upgrade local and regional infrastructure. Geographical Information Systems (GIS) can save time and improve site logistics on roadway jobs. 

Project management software can help companies manage traditional road repair projects and utilize innovative methods and materials. Adding road resurfacing capabilities can allow contractors to participate in the many urgently needed roadway infrastructure projects being proposed nationwide.

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