Ultimate 8 Step Guide To The Industrial & Commercial Asphalt Paving Process

1. Asphalt Removal & Ground Demolition
2. Shooting the Grade
3. Preparing the Sub Base
4. ​Asphalt Sub Base Repair & Validation Rolling
5. Addition of Binder
6. Installation of New Asphalt
7. Connecting Butt Joints & Insuring Smooth Transitions
8. The Final "Roll - Down"​

Written By: Bernard Brown II 

Step 1: Asphalt Removal & Ground Demolition
The first step of the commercial and industrial asphalt paving process is to get rid of the current surface in place, whether it be grass, old asphalt pavement with cracks, concrete, or cement pavers. The breaking of the ground is done using heavy duty machinery, such as milling machines, excavation machines, loading machines, and large dump trucks. These machines are used to break up, scoop, and lastly remove the debris from the job site in order to prepare it for the next step of  the process. The debris is then taken to a dumping site nearby or sent to a different plant to be recycled.

Step 2: Shooting The Grade
Once the area is removed clear of all debris and unneeded  materials, the B.F.Brown Asphalt Paving team of engineers, will use innovative technologies and machinery in order to guarantee that the water will never sit or form puddles, but rather effortlessly drain from the pavement into nearby gutters and other water runoff areas. This step is super important due to the fact that improper grading leads to drainage problems which ultimately will lead to greater issues down the line, such as potholes, heaving, and cracks. 

Step 3: Preparing The Sub-Base
The sub base is the most important part of the asphalt paving process, since it provides support and anti freeze protection during the winter months. The thicker the sub base the stronger the top layer of pavement will be. The National Pavement Association recommends at least 4 inches of sub base, yet for stronger more durable pavement go with 5 to 6 inches of sub base. 
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 Step 4: Asphalt Sub Base Repair & Validation Rolling
​Once the sub base is prepped and laid using our Bomag Paving Machine, we roll the sub base thoroughly with rolling machines to make sure that it is compact and will withstand heavy force . We fact check (validation roll) the force that it can hold by allowing one of our hauling trucks to slowly roll over the sub base to make sure that it does not break or unsettle at all, if it does we perform hand work in order to fix and stabilize the sub base, making it as solid and foundational sound as possible.

Step 5: Addition of Binder
Once the sub base is rolled, compacted, and validated; binder is added to the sub base. Binder is what gives the asphalt its harness and durability. The easiest way to spot binder is by looking at the size and shape of the rocks within the binder/aggregate mix. The most ideal binder typically has low stiffness at construction temperatures, high stiffness at high in surface temperatures, low stiffens in low surface temperatures, and excellent long term durability. 
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Step 6: Installation Of New Asphalt 
After the binder, which can be purchased in bulk, is added to the sub base, the final layer "top" is added to the preceding layers. "Top " consists of very small fine aggregate particles; unlike binder it has a very smooth attractive dark black appearance to it. We recommend that our customers do not allow trucks or heavy machinery to drive on this until up to 72 hours after it is finished, in order to prevent tire marks and other damages to the settling pavement. 
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Step 7: Connecting Butt Joints & Insuring Smooth Transitions 
In order to make sure that there is a smooth seamless transition from old to new existing asphalt paving surfaces, one must be certain to connect all butt joints and use precise hand work and looting skills in order to meet the old surface, whether concrete or asphalt, to the new with precision. This will help prevent further damage as well as provide a safer driving experience for all parties involved. 
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Step 8: The Final "Roll-Down"
Once the butt joints are met with precision and the "top" has been laid, it is time to compact and compress the asphalt with a rolling machine in order to pack it down and make sure it is perfectly smooth with no holes, gaps, or bumps. Upon doing this, the project is complete and within 72 hours will be ready to go!
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