Overlay vs. Mill and Resurface
Overlay vs. Mill and Resurface
(OP)
We have a project on which we are adding turn lanes to an existing two lane, 25-mph, residential roadway. The existing roadway is less than 5 years old and in good shape. We called out for the entire section of roadway to be milled and resurfaced so that the interface between the new lane and the old lanes wouldn't ravel and crack. The contractor, who is reputable, suggests instead to place limerock (it's in Florida) to the level of the existing roadway where the new turn lanes are, lay down a tack coat on existing asphalt, and place 1 1/2" asphalt overlay. This would save the client some money, but I haven't seen overlays like this before.
Any comments?
Any comments?





RE: Overlay vs. Mill and Resurface
RE: Overlay vs. Mill and Resurface
Engineering is the practice of the art of science - Steve
RE: Overlay vs. Mill and Resurface
Steve, the tearing at the interface of the new lane and existing roadway was the reason we specified mill and resurface the entire roadway.
We could bring up the limerock on the lane addition only to the level of the limerock on the existing road, then lay 2 1/2" on the new lane along with the 1" overlay so that both lanes have the same thickness of limerock and asphalt. Does this seem reasonable?
RE: Overlay vs. Mill and Resurface
RE: Overlay vs. Mill and Resurface
You can still do something similar to his suggestion, but I would suggest the following:
1. Mill a 2-foot wide strip at the edge of the existing pavement, adjacent to the new turn lane. Bevel the existing pavement at 45 to 60 degree angle along the milled edge
2. Put the base material in for the turn lane and hold it to the level of the existing base.
3. Put a geotextile over the joint created along the interface of the two base materials.
4. Tack the base and the beveled edge
5. Pave to thickness of existing pavement.
Traffic across the bevel will compress the asphalt, not separate it.
They'll whine about doing the bevel, but you don't have a long run so it shouldn't be an issue.
lha and civilperson....As for the 1-1/2 inches over limerock for light duty pavement...it will work OK, but because it is a turn lane, you get more potential for shoving. If you suggest that much asphalt in this area, they will go nuts! We do not have freeze-thaw issues here, but thicker asphalt tends to rut because of the heat.
RE: Overlay vs. Mill and Resurface
Thanks for the comments. I think I will suggest what you propose.
Haven't heard from you in a while. Hope you're staying busy.
RE: Overlay vs. Mill and Resurface