There are two different methods we use to pave a driveway overlay and replacement.
We start by repairing any potholes that may exist in the driveway and then clean the surface. Once the surface has been properly prepared, we cover the existing asphalt with two and a half inches (once compacted) of new hot asphalt. This method is more economical than replacement paving (about half the expense), but will only last a fraction of the time of a total replacement. The results will vary depending on the quality of the original asphalt.
With this method we remove all of the existing asphalt with an excavator and dump truck, completely grade the base to ensure proper runoff and drainage. We than add base material where necessary and compact the entire base with a vibratory roller. The base material we use is called Item 4, or re-processed asphalt mixed with stone dust. These materials have excellent binding properties, and when used in this application form it is a superior underlay for the asphalt unlike sand, which does not compact well. This process is the backbone of the entire job, and when done properly will result in a mechanically sound driveway. After the base work has been completed, we then put down hot asphalt over the top of the base and compact it with a vibratory roller leaving, leaving three inches (once compacted). While this method is more costly than an overlay, it will also give you the most longevity and a more appealing finish. We also recommend sealing the new asphalt one year after the asphalt has had a chance to cure to prolong its life.
Please Call (203)286.6724