Extending Road Life in a Busy Commercial District with Asphalt Overlays

Overview
The downtown commercial hub of Rivertown faced severe pavement deterioration due to constant heavy truck traffic, utility work, and changing weather conditions. Local businesses complained of delivery delays and safety hazards caused by potholes, rutting, and uneven surfaces. Instead of a costly full reconstruction, the city opted for an asphalt overlay solution to restore the road quickly while minimizing business disruptions.

Challenges

• High traffic volume: The area experienced nearly 18,000 vehicles daily, including heavy freight trucks.
• Limited work windows: Road closure time was restricted to overnight hours to keep businesses running.
• Underlying base concerns: Some sections had sub-base weaknesses from years of water infiltration.

Solution
The project team conducted detailed milling to remove damaged asphalt layers while preserving as much of the stable base as possible. They used a high-performance polymer-modified asphalt mix designed for rut resistance and durability under heavy loads. Areas with base failure received full-depth reclamation before overlaying. Traffic control plans ensured work was completed in phases, allowing partial road access at all times.

Results

• Faster completion: Entire project finished in 10 nights, reducing disruption to just over a week.
• Cost savings: Overlaying saved the city 35% compared to full reconstruction.
• Improved ride quality: Smooth, skid-resistant surface improved both safety and comfort.
• Extended lifespan: Expected road life increased by 12–15 years before major rehabilitation would be needed.

Key Takeaway
Strategic use of asphalt overlays can dramatically extend roadway life and improve driving conditions without the expense and disruption of full reconstruction — especially in high-traffic commercial districts.