New Pavement beautifies residential and commercial applications alike. Gator Paving is well staffed and equip with the newest paving equipment and technology to complete your project correctly the first time. Whether we are giving you an onsite estimate or working from a set of plans Gator Paving Company can complete your project in a timely and professional manner. The process of laying new pavement is relatively the same whether the job is a residential job or a large commercial job.
New Pavement Process
Step # 1 Excavation – The integrity of your new asphalt is only as good and the soil underneath it. It is in this very important preparation stage that the life of your asphalt is established. If in fact new pavement is paved over soft ground, top soil, or badly cracking old asphalt the new pavement application is sure to fail. A thorough examination will be done of your sub base material by our professional estimator. If the estimator finds that the sub base is unsuitable for new pavement the unsuitable material must be dug out and replaced with the appropriate gravel. In many cases we have to remove soft material, rotting tree stumps, loam and large stones. The unsuitable material will be excavated out and removed from your site.
Step # 2 Installation of Base Material and Grading – The proper installation of the base material is the key to the life of your pavement. On average, we use a 4-6” compacted base of 21A gravel (or equivalent material) we can also use recycled concrete that is ground down. Once the base material is installed, a professional excavation operator will move the gravel into a uniform smooth surface. On a driveway surface this gravel will be spread by a bobcat grading machine and on a larger job the gravel will be spread by a bulldozer of grader. The pitch of the gravel during installation is very important because it will determine where the water will flow once the new pavement is installed. Once the proper depth and pitch are established, the gravel will be compacted by a roller. In most cases the roller will have a vibratory feature on it that will not only roll the sub base but vibrate it as well to establish maximum compaction. The gravel will be installed in layers approximately 2-4” deep.
Step# 3 – Laying of Asphalt – Once the sub base material has been properly installed, the asphalt is ready to be laid. Depending on how deep the asphalt is specified to be will depend on how many layers or “lifts” the asphalt will be installed in. Usually parking lots require two lifts while driveways require only one. The asphalt is then purchase at an asphalt plant and brought to the job in dump trucks. It is important to have the right paving equipment to install the pavement while it is hot. Gator Paving Company has the newest paving equipment available on the market to ensure the highest quality surface possible. When comparing prices, please consider the type of equipment a company uses. Paving machines can vary in price from a few thousand dollars to a couple of hundred thousand dollars. Once the asphalt has been installed, it is ready to be rolled to final compaction.
Step# 4 Compaction – While the asphalt is still hot, it will be rolled by a very heavy vibratory roller to compact all of the sand, gravel and stone together. This step is very important. If the asphalt is not rolled correctly or at the right temperature the asphalt will not compact correctly and will come apart over time. Transitions from the new pavement to the street or sidewalk will be rolled so a smooth transition occurs. The edges of the driveway will be initially compacted with a plate tamp. The edges will also be tamped with a hand tamp at a 45 degree angle. It is important to put topsoil up the edges of your driveway to ensure the integrity of the asphalt for a long time to come. The topsoil will protect the edges or your drive from erosion or cars breaking an edge off the driveway.
Asphalt Maintenance & Strategic Maintenance Plans (SMP)
As with anything else, a little maintenance can go a long way in protecting your investment and saving you money over time. Whether you are maintaining a residential driveway or multiple facilities with very large parking lots the steps are relatively simple. Let’s face it, your parking lot or driveway is always the first impression a guest or a customer sees. Asphalt that is crisp clean well taken care of will go a long way in the impression you give your guests and customers. We recommend inviting one of our maintenance specialists to your facility to help you set up a budget and a long term plan for the maintenance of your asphalt. We call this process a Strategic Maintenance Plan (SMP). With an SMP in place you can avoid last minute budgeting or worse yet reactive budgeting. You can be ahead of the game with a SMP. You will actually get more budgeting dollars allotted to your facility if you have a written 5-7 year plan in place as opposed to last minute guessing of what needs to be done. Along with this process being budget friendly, you will be assured the value and beauty of your real estate will remain constant in this ever competitive market place. There are several maintenance procedures used to in cooperation with each other to maintain a structurally sound and aesthetically sound parking area.
Pavements in various conditions require different types of rehabilitation. Rehabilitation procedures can vary from minor routine maintenance to complete reconstruction.
Asphalt Maintenance Site Evaluation
Initially, a complete site evaluation of the parking lot will be conducted. All problem areas (pot holes, cracks, sink holes, dumpster areas, entrances and exits, striping) will be notated. During this phase, pictures may be taken and aerial photos may be used to draw out areas where the work may need to be performed. In taking the time to do an accurate Site Evaluation, repairs can be ranked from the most important to the least important. For example, a pothole in the entrance of an apartment complex or a hospital will take precedence over pavement cracking in the back of the building. The cause of many problems can be evaluated at this time. Some problems may be due to lack of maintenance as others may be due to a design flaw. In this phase, each recommended maintenance item will have a cost applied to it. Once a cost is associated with each repair, budgeting and allocation of funds may begin. SMP’s can be revised over time due to an increase or decrease in budgeting or an increase or decrease in need of repairs. During the Site Evaluation we are able to meet with any personnel to answer any questions and offer suggestions. Our site evaluation service is free of charge.
Pavement Patching and Repair
Potholes occur in pavement when water gets into cracked asphalt. Once the water penetrates the cracked asphalt and freezes, a pothole starts to form. Because water expands when it freezes, the small crack the water seeped into initially now becomes a larger crack. This process continues until the small crack is now a large pot hole. Water also erodes the base material underneath the asphalt. When the water washes away the foundation of the asphalt there is nothing left to hold the asphalt up and the result is pavement failure. Pot holes need to be saw cut into a square. The deteriorated asphalt will be removed to the approximate specified depth. If needed base course gravel will be replaced and then a new layer of hot asphalt will be installed and rolled. The new patch will be rolled with a multi ton vibratory roller and/or a vibratory plate tamp. The edges of the patch will be sealed to endure water does not penetrate the new asphalt and create another problem.
Pavement Removal and Repair
Overtime the structural integrity of asphalt fails. Large areas of ‘alligator cracking’ appear and the broken pieces of asphalt can be picked up. When the asphalt has reached this phase we recommended that the deteriorated area be completely removed and replaced with new asphalt. In doing this, the old asphalt will be milled out or taken out with a bobcat and new asphalt will be installed. The old asphalt will be removed as well as any undesirable sub base. New gravel and/ or hot asphalt will be place in the specified area and rolled with a multi ton vibratory roller or a vibratory plate tamp.
Asphalt Resurfacing (Overlay)
In cases of severe pavement failure, a cost effective method of fixing the problem is to do asphalt resurfacing commonly called an ‘overlay’. There are several steps/methods to making sure an asphalt overlay comes out correctly.
- The asphalt will be cleaned thoroughly. Large high powered blowers will be used to remove any debris.
- A true and leveling course of asphalt will be skim coated over any low areas to avoid ponding water.
- Milling out of transitions around entrance and exits, curbs and drainage basins. All material that is milled out will be removed and recycled.
Every site is unique. Your maintenance consultant will have a written set of specifications unique to your specific project. These methods will be discussed and agreed upon in advance.
Other options to be included with resurfacing are:
- Geotextile Fabric – A geotextile fabric may be installed on top of any existing pavement prior to the placement of new asphalt. Petromat or an equivalent fabric is a non-woven, petroleum base geotextile fabric used to retard reflective cracks between the existing pavement and the newly installed asphalt surface. This fabric acts a waterproofing membrane as well as adding structural support. After the area has been prepared, liquid asphalt cement will be applied to the surface and the geotextile fabric will be stretched across the area and adhered
- True and Leveling Course – Hot asphalt can be applied to low areas in the surface to correct years of traffic wear or settling in the pavement. This is normally done with a paving machine. Low areas will be marked out prior to paving and a skim coat of hot asphalt will be applied.
The milling out of an asphalt parking lot is a procedure in which the entire surface is milled out using a milling machine. The milling machine basically grinds down the existing asphalt 1-2 inches so the same amount of asphalt can be reinstalled. This procedure is especially beneficial when a parking lot has a lot of monolithic curbs. It is important not to change the flow of the water into the curb pans so milling will allow a smooth transition from the new asphalt into the existing curb. When milling out an existing parking lot, prior to the new asphalt being placed, a layer of tack coat will be applied to the existing asphalt to ensure adhesion of the new asphalt.
Once the asphalt has been milled out and transferred into the back of a dump truck, it will be taken back to the asphalt plant to be recycled into new asphalt. Asphalt is the #1 most recycled product on the earth today.
Left to the harsh elements, asphalt pavement will deteriorate rapidly. The asphalt binder that holds the pavement together begins to oxidize and weather soon after installation. Moisture penetrates the asphalt causing further damage and deterioration to the pavement. Sealcoating is one of the most important elements of a Strategic Management Plan. Pavement sealing is used to protect off-highway pavement surfaces against gasoline, oil, salt, water, and ultraviolet rays. In order for sealcoating to be done properly Silica sand is added to the mix at a ratio of approximately 2-6 lbs of sand per gallon of sealer. This sand, when added, fills in the voids in the pavement and adds an element of strength. The sand additive in the mix will fill and voids in the asphalt more effectively. For maximum effectiveness, sealcoating should be done within the first 12 months after the new asphalt is installed and then every 2 to 4 after that.
When covered with a dark black sealant, pavement looks and wears like new. Parking lot sealcoating >helps to project a positive image of the company, facility, or residential complex.
Slows oxidation and water penetration
Sealcoating fills surface voids, which reduces exposure to oxygen and UV rays and reduces the depth to which oil or gas can penetrate the pavement.
Sealcoating acts as a waterproofing agent, minimizing the rate at which water enters pavement. Without it, water can permeate more freely resulting in freeze/thaw expansion and contraction of the pavement.
Sealcoating resists oil and gas spills
Gasoline dripping from a topped-off fuel tank during hot weather can soften and break down unsealed asphalt pavements. Coal tars used in sealcoat are impervious to gas and oil spills.
Asphalt sealcoating is easier to clean and maintain
Sealcoats fill surface voids while coating the pavement surface. The resulting smooth and even texture makes the surface easier to maintain year-round. For example, snow is easier to remove from a smooth surface, and sweeping is far more effective on a smooth surface.
Sealcoating increases pavement flexibility
Sealcoat brings a dark black color to the pavement. The blacker it is, the more heat a pavement draws from the sun. And, the hotter it gets, the more pliable it becomes, which helps it to withstand traffic without cracking.
Protects asphalt from pressure washing
Restaurant parking lots often extend to areas near dumpsters, where food-processing machines are pressure washed. Food waste near the dumpsters may also need to be washed away if it can’t be swept away. Sealcoating protects asphalt cement from the high-volume water pressure and detergents used in pressure washing.
Asphalt sealcoating is cost effective
The price of asphalt will always be affected by crude oil prices, which fluctuate when supplies vary. Sealcoating preserves asphalt for pennies per square foot.
Preparation and Application
Prior to pavement sealing, any structural failures or cracks on the pavement must be repaired. All potholes must be removed and replaced, cracks must be cleaned and filled, and oil spots cleaned or primed.
The area to be sealed will be completely cleaned with high power blowers, brooms and/ or sweeper trucks. All debris and dirt will be removed from the area and disposed. Sealcoating should only be performed under the proper weather conditions. Sealcoating is not designed to be an asphalt crack filler, it is made for sealing the surface and protecting it from the elements such as UV light, salts and oils. The recommended air and pavement temperature should be at least 55 degrees with no rain in the forecast.
Allow 24 to 48 hours to dry. To ensure limited disruption to businesses, Gator Paving will divide off the parking lot accordingly and do one section at a time.
Filling Asphalt Cracks in your asphalt driveway or parking lot surface will be a very important part of extending the life of your pavement. The most important reason you need to maintain and repair the cracks in the asphalt surface is because you don’t want moisture to penetrate under the asphalt surface causing more damage to your driveway or parking lot.
The second reason you should fill the cracks in your asphalt is because vegetation will begin growing in them. As the roots on vegetation get bigger, the plant root can actually push the pavement up and create even more damage. This breaks the pavement surface and other problems begin occurring.
Even worse, if water does penetrate the crack and seeps under the asphalt surface, this will almost always creates a soft spot which in turn can create a Pot Hole and if you live where the temperatures create ground freezing, then this moisture under the asphalt surface will freeze and push the pavement up. You might have seen this on other driveways or parking lots to know what we are talking about and now you know why it has happened.
All of these conditions can usually be avoided by practicing good maintenance and keeping these cracks filled as they occur.
A simple crack is easily repairable. These cracks occur naturally as your asphalt gets older. On the other hand, if you have areas in your pavement that look like Alligator Skin, this is characterized by any smaller cracks that look like chicken wire it is possible more than crack filler may be needed to rectify the problem. Cleaning the cracks is time consuming but is the most important part of the process. Weed killer may be sprayed in the cracks and allowed to work for 7-10 days before the crack cleaning actually begins. The dead vegetation may then be burned with a torch and any other debris must be dug out by hand using the proper equipment. This is probably the most important part of the process! If you don’t get them clean, then the asphalt crack filler won’t stay in place and you have wasted your time and money.
Why it’s Important to Perform Crack Repair Every Year
Anywhere there is a place for water to find a way in to your blacktop is where water will continue to cause damage. It will widen the cracks, erode the foundation causing sinkholes, and in freeze-and-thaw cycles it will push the asphalt up.
Plus, it’s a perfect place for weeds to grow and their roots will wreak even more havoc. Cracks ¼ to ½ inches will be filled with crack filler. Cracks ½” and larger have become too large for crack filler to be effective and one of the other pavement maintenance options such as milling or an overlay of new asphalt may be appropriate.
Pavement Marking and Striping
Gator Paving Company offers full service striping and line marking. Parking Lot Design, Pavement Striping and Traffic Signs
Gator Paving Company performs parking lot striping and pavement marking services for property management companies, small business owners, restaurant chains, churches, builders, developers, government agencies and more.
Gator Paving Company can install thermoplastic pavement markings, parking lot paint striping, ADA handicap signs and curb painting services for customers. We can help you design, or redesign, your parking lot layout, paint or repaint lines on your business parking lot, shopping center parking lot or industrial facility.
If your property needs any Repairs or Maintenance prior to pavement striping and marking we can complete the necessary work for you. As a full service asphalt paving company we serve as a single source to resurface, re-image and restore your pavement.
All of this can be done with little inconvenience to our customers and their customers.
Asphalt Rejuvenation Process
The damaged surface area is:
- Surface is thoroughly cleaned
- Pre-testing is done to determine the product application rate
- The surface will be readied for crack sealing and repairs
- Reclamite® is applied
- The surface is left to dry (usually open to traffic within the hour!)
- Dusted to increase grip and road safety
- Ready for use
Asphalt Rejuvenators can be a maintenance department’s lowest-cost surface treatment for extending pavement life.
Crack sealing and infrared repairs are made to damaged areas before treatment.
The Reclamite® rejuvenating agent penetrates into the voids and migrates throughout the asphalt road surface.
Using the Reclamite® rejuvenating agent means that in some cases road marking renewal is not always necessary, saving your budget, saving time, saving disruption. If an area is not suitable to be sprayed with the large distributer truck, then a hand operated spray wand can be used in those areas.