Have you ever passed a road construction project and wondered how the process worked? It’s never too late to learn. An asphalt road is one of the most common roadway types in the United States thanks to its strength, durability, and cost-efficiency. However, most commercial property owners, HOA board members, and homeowners don’t know the asphalt road making process.
Morgan Pavement is one of the leading asphalt manufacturers in Utah who perform countless asphalt paving installations, repairs, and repaving services every year. Not only does our team understand the asphalt installation process inside and out, but we also love educating others on it.
Let’s look at an overview of the history of asphalt roads in the U.S. before understanding the modernized installation process.
History of Asphalt Roads
Asphalt is a rock formation that naturally occurs, mixing sand, limestone, and asphalt. Today, over ninety percent of roads in the U.S. are human-made mixtures and by-products of crude oil manufacturing. But the use of asphalt is nothing new.
The use of asphalt started in ancient Mesopotamia for ancient baths and water tanks. Phoenicians also used asphalt when building water ships. The first use of asphalt in road building began around 625 B.C. in Babylon. Then, the Romans incorporated the natural material in their ancient roadways to smooth the surface for their military.
In 1870, Edmund J DeSmedt, a Belgian chemist, laid the first asphalt pavement mixture in the U.S. in Newark. He also used asphalt from Trinidad Lake to pave Pennsylvania Avenue in Washington D.C. That same year, a commercial hot mix production facility built by Cummer Company used asphalt pavement to lay the groundwork for their building. The next year, Nathan Abbott filed the first asphalt patent in Brooklyn, New York.
Since then, experts have been refining asphalt mixtures with new technology trying to improve the final products for roads and pathways. Not only have they introduced drum mixers, mechanical spreaders, and other mechanics to improve the installation process, but they found hundreds of different ways to manufacture road construction.
The U.S. government had even pushed for increased use of asphalt roads. In 1956, Congress passed the Interstate Highways Act that gave fifty billion dollars to state governments to construct roads. This act greatly improved road construction as manufacturers searched for ways of building larger roads across their states. At this time, the industry received electronic-level controls, wider finishes, vibratory steel wheel rollers, and other technologies that improved asphalt road construction.
Then, in 1986, Congress established the National Centre for Asphalt Technology that continues to test and improve asphalt across the country. Today, asphalt materials are one of the most recycled materials in the country, with over 70 million metric tons recycled annually.
The Asphalt Road Installation Process
As discussed, the making of asphalt roads has changed over time. Companies are using advanced technologies to install asphalt pavement faster and more efficiently than ever before. Current roadways are nothing like those used in Babylon or Rome. But modern asphalt roads are more enduring, more environmentally-friendly, and last years above the rest.
Here is a step-by-step guide to the asphalt installation process performed by an asphalt professional like Morgan Pavement.
1. Demolition
The first step to laying down an asphalt road is making sure the existing surface is free of all existing materials. It also requires smoothing the surface so that it is level and ready for installation. What demolition looks like is an asphalt pavement company using heavy machinery to remove the old surface and any other debris. The machinery usually includes bobcats, forklifts, dump trucks, and front loaders.
Any asphalt, concrete, or other surface type removed is then collected and recycled. These materials work well in new asphalt mixtures and are one of the most environmentally-friendly road materials used. In fact, the Environmental Protection Agency no longer considered asphalt a hazardous air pollutant.
2. Grading and Sloping
Once demolition is complete, Morgan Pavement will grade and slope the surface for proper water drainage. The process includes using laser-guided transits and motor graders to pave the foundation. Without grading and sloping, an asphalt road will collect water and cause unnecessary damage like potholes and cracks.
3. Sub-Base Foundation
Next on deck is the installation of the asphalt road’s sub-base. The sub-base provides stability by supporting the asphalt and also acts as a barrier for weather damage. This portion of the asphalt road includes determining the sub-base thickness and compacting the surface for increased stability. If the sub-base isn’t installed correctly, the asphalt road’s durability will decrease dramatically.
4. Proof Roll and Undercutting
After laying down the sub-base, Morgan Pavement contractors will proof roll the existing surface to ensure that this foundation is ready to support the asphalt mixture. The proof roll acts as a sort of gravel test, which includes driving a loaded dump truck row-by-row over the sub base to make sure the gravel is appropriately in place. If any areas flex more than an inch under the weight, a technician will use the undercutting technique to repair the soft spot.
Undercutting involved digging down into the soft surface and replacing the gravel with soft clay or a more potent aggregate mixture. This process creates a solid support base for the new asphalt without digging up the entire sub-base and starting from scratch. The pavers will continue this process until the whole sub-base proves it is a strong enough foundation to support the asphalt layer.
5. Binder Layer
Once the sub base is approved, the Morgan Pavement team will add the binder layer. The binder is a massive mixture made with oil that only adds to the overall strength and durability of the asphalt road.
6. Asphalt Installation
After laying down the binder, the asphalt surface is installed. This is the top layer of the asphalt road that ultimately provides a smooth ride for all transition vehicles and automobiles. The asphalt surface comprises of small aggregates like sand and oil. The combination of these materials creates asphalt’s well-known black finish, commonly known as an asphalt road.
7. Butt Joints
Once the pavers install the asphalt road, there are a few final touches that must be done. Most new asphalt roads connect to other surfaces. That is why it is up to our paving contractors to smooth each transition that connects the old roadway to the new. This process includes grinding certain butt joints, installing extra grading, or whichever special attention the area requires.
8. Installation Complete
After all of that hard work, the paving contractor will go over the asphalt road once more with a roller truck. This extra roll ensures there are no small bumps, loose materials, or any stone left unturned. Once finished to satisfaction, the asphalt road is ready to go. If done right, it will last for years to come.
Here is everything else you need to know about asphalt paving.
Your Asphalt Paving Contractor: Morgan Pavement
The installation process requires a steady hand. Let Morgan Pavement be your steady hand. Simply stated, our asphalt pavements are built to last. Whether you need a new asphalt road or require asphalt maintenance services, trust us to get your asphalt work done. Our asphalt services are also customized to fit a variety of industries, including commercial, residential, and government municipalities. Contact us to learn more about your asphalt road options today.
