Asphalt Overlay Services

When a paved surface becomes damaged, some property owners assume that replacement is the only option. However, complete excavation is both expensive and time-consuming, so it should not be the first line of defense against minor defects. 

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Asphalt Overlay

Asphalt overlay services represent a faster, more affordable pavement restoration method. In the asphalt overlay process, the existing concrete or asphalt is used as a base for a new layer of asphalt, which is poured over the damaged surface. The added 1.5″ to 2″ of asphalt fills cracks, levels elevation, and mitigates drainage issues. The result is a smooth surface that performs like new, all without the hassle of tearing up the old surface.

As a full-service paving company, Limitless Paving & Concrete is ideally suited to provide asphalt overlay for Maryland-area companies. Our professionals will assess the extent of your pavement damage, then determine and execute the ideal restoration strategy.

When to Choose Asphalt Overlay

Asphalt overlays are appropriate for many, but not all asphalt repair jobs. In essence, an asphalt overlay serves as a large-scale patch job, so while it can correct minor damage, it cannot address larger structural problems. The surface to be covered should be structurally sound and have a minimum thickness of approximately 1.5 inches. It should also be able to withstand crack filling, smoothing, and cleaning to prepare the surface for the overlay. Asphalt with significant structural problems, or which are too thin to undergo necessary repairs, should be replaced instead. A replacement should also be considered if extensive milling will be necessary before adding an overlay.

Additional considerations in selecting an overlay include the size and geometry of the area to be repaired, including factors like pitch and elevation. While it may seem counterintuitive, asphalt overlays tend to be more cost-effective for larger surfaces and lots. Excavating and replacing a small surface area only costs marginally more than an overlay, so replacement may be a better investment. As the surface area increases, the cost of excavation becomes more prohibitive, in which case an asphalt overlay may be preferable. This is also true of very flat lots, which might require extensive milling.

asphalt overlay work on roadway

In general, an overlay is the right choice under the following conditions:

  • The pavement is damaged but structurally intact
  • The asphalt will not require extensive milling in preparation for an overlay
  • The solution is expected to last up to 15 years

Clients with complicated lots, severely damaged asphalt, or the need for an extremely durable solution should consider a full replacement instead.

Asphalt Overlay Process

The asphalt overlay process is relatively straightforward, and a Limitless Paving & Concrete expert will guide you through every step of the process.


First, an engineer assesses the site to verify that an overlay is appropriate. If the inspection reveals large potholes, significant structural damage, or drainage problems, they may suggest a replacement instead. These types of problems can persist underneath an overlay and worsen over time, so a more comprehensive solution is necessary in these cases. Your Limitless representative will identify faults and suggest a restoration plan unique to your property and budgetary constraints.


Once you’ve decided to go forward with an asphalt overlay, the contractor will begin the preparatory process. Depending on the extent of the damage, this may include minor or extensive milling to remove the upper layers of asphalt. The milling process uses a cold planer to grind and recycle the upper layers of asphalt, evening out the surface of the asphalt so that the new overlay has a level foundation. If the asphalt is in good enough condition, it may be possible to forgo milling, but when there is widespread deterioration, milling and paving is often cheaper than replacement.

Additional preparations might include base repair, especially if there are isolated regions of serious damage. Base repairs can be corrected for minor potholes, root damage, cracks, or ruts, although extensive faults still indicate the need for replacement.

Your Limitless team will discuss your pavement damage before and during the overlay preparation process to ensure you understand how defects might influence the longevity of your overlay.


The last step of the asphalt overlay process is the paving itself. The exact thickness of the overlay depends on the condition of the base, but it typically ranges from 1.5″ to 2″ in depth. Limitless draws on decades of paving experience to deliver a smooth, high-quality overlay that adds years to your pavement’s working life.

Benefits of Asphalt Overlay Services

Asphalt overlay carries a number of substantial benefits over more extensive excavation and repaving. In particular:

Cost Savings: Because asphalt overlay services retain the base layer of pavement, they are often a more affordable option compared to milling, excavation, and repaving. What’s more, performing an asphalt overlay on aging pavement can prolong its lifespan by preventing defects from becoming more pronounced. Performed at the right time, asphalt overlaying can prevent costly repairs and save money in the long term.

Speed: Replacing a driveway, parking lot, or similar structure can be time-consuming. Even before paving can begin, the surface must be milled and removed, which can lead to lengthier closings than with a more selective approach.

Effectiveness: Although asphalt overlays can’t solve every problem, they can rectify a range of problems ranging from cracks and minor potholes to drainage and elevation problems.
Thanks to these advantages, many property owners find that an asphalt overlay is affordable, efficient, and yet no less effective than other restoration techniques. The experts at Limitless Paving & Concrete can discuss the advantages and disadvantages of our service offerings to help you select one that meets your needs and budget.

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Choose Limitless Paving & Concrete for Reliable Asphalt Overlay Work in Maryland

It’s important to repair worn or aging asphalt before the damage becomes significant. Asphalt overlay is an excellent choice for minor to moderate repairs, and Limitless Paving & Concrete is an excellent choice of contractor to do it. Over the past decades serving Montgomery County, we’ve built a reputation for honesty, quality, and reliability. When you need pavers who get the job done on-time and on-budget, and exactly to-spec, think Limitless.

The first step in any pavement repair, asphalt overlay or otherwise, is to consult an experienced professional who can assess the situation. To get started with a free estimate from Limitless Paving & Concrete, contact us or give us a call today.

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