asphalt road construction Process
Road construction can be a source of frustration when you are trying to get to work and have to detour around the work in progress. It’s an even bigger frustration when the work is not in process, however. Faulty roads are dangerous too.
Recent statistics show that more than 38,000 individuals lose their lives each year on United States roadways. Poor road conditions are a leading cause of road accidents. In order to prevent accidents due to road conditions, it is imperative for local, state, and national entities to maintain the roads.
New road construction is the building of new roads and highways, often performed by licensed commercial paving contractors. Road construction is the process of keeping a road in a state of good repair. The task consists of paving, reclaiming and/or rehabilitating the degraded pavement so it can be brought to a more optimized and safe condition. Road construction can entail repairing a portion of the road or completely demolishing and rebuilding the entire road. It can also include the construction of all or part of an overpass or bridge. Utility and phone line repairs or most any other jobs that take place near a travel way are technically classified as a form of road construction. Road surface work is the most common type of road construction that’s conducted in the United States.
The asphalt road construction procedure involves using asphalt, concrete, liquid asphalt, rebar, soil stabilization, pavement, and asphalt milling machines or other pavement recycling equipment, and various other road repair materials.
Recent statistics show that more than 38,000 individuals lose their lives each year on United States roadways. Poor road conditions are a leading cause of road accidents. In order to prevent accidents due to road conditions, it is imperative for local, state, and national entities to maintain the roads.
New road construction is the building of new roads and highways, often performed by licensed commercial paving contractors. Road construction is the process of keeping a road in a state of good repair. The task consists of paving, reclaiming and/or rehabilitating the degraded pavement so it can be brought to a more optimized and safe condition. Road construction can entail repairing a portion of the road or completely demolishing and rebuilding the entire road. It can also include the construction of all or part of an overpass or bridge. Utility and phone line repairs or most any other jobs that take place near a travel way are technically classified as a form of road construction. Road surface work is the most common type of road construction that’s conducted in the United States.
The asphalt road construction procedure involves using asphalt, concrete, liquid asphalt, rebar, soil stabilization, pavement, and asphalt milling machines or other pavement recycling equipment, and various other road repair materials.
When is asphalt road construction needed?
Anytime roads are heavily traveled, wear and tear occurs. Weather plays a part in road deterioration too. There are a number of issues highway repair and highway paving companies address when they are completely road construction such as:
Potholes
A pothole is defined as a depression that is in a road’s surface, usually asphalt pavement. Usually it is the final result of water in the soil structure underneath the pavement and the stress of traffic and/or weather on the weakened structure. Technically, a pothole must be shaped like a bowl with a dimension of at least six inches.
Potholes have the capability to cause tremendous damage to vehicles. They can cause a flat tire and suddenly send the vehicle into another lane of traffic, resulting in injury or death.
Potholes are typically repaired by asphalt repair companies, either that work for the state or county or independently. The process of repairing a pothole involves tearing off the damaged asphalt and using one of a number of techniques to fill the hole and make it level with the pavement that is undamaged.
Uneven Road Surfaces
Uneven road surfaces are a huge problem on America’s roadways. Driving on an uneven surface increases the chances of a motorist having a wreck. Their vehicle can be thrown into oncoming traffic or the vehicle can even tip over.
Uneven pavement can be the result of erosion or wear and tear, poor road maintenance, or improperly laid slabs. The process required to repair it depends upon the type of damage. Often an asphalt milling machine is needed to remove the damaged pavement. Then an asphalt maintenance company relays the surface.
Broken Concrete
Broken concrete can cause flat tires, a number one cause of car accidents. It can also throw a vehicle off the road or into another lane, another leading cause of accidents.
Broken concrete can occur due to several scenarios. Wrecks, normal wear and tear from traffic, extreme weather conditions, and the heavy toll big trucks take on pavement are among the top causes cement breaks.
Replacement concrete is more involved than asphalt replacement. Typically, concrete must be busted up using a sledgehammer and pick. A mix of sand, rock, and/or stone is used for the cement replacement formulation that concrete consists of. Then, the mix is poured into the gaps and is smoothed. Concrete takes a week or longer to dry (or cure) usually whereas asphalt only takes days.
Exposed Rebar
Exposed rebar is one of the most dangerous road problems. The rebar is sharp and if a motorist runs over it, their tire is almost guaranteed to go flat. The vehicle is likely to go into oncoming traffic or to be thrown off the road.
Exposed rebar requires the expertise of an concrete or asphalt road construction crew to repair. First, the surface that is damaged and the surface around the exposed rebar must be removed. Sometimes a sandblaster is required. Then, once the area is prepared, the new surface material can be laid.
Sinkholes
Sinkholes are a major source of trouble on roadways. They spell instant trouble for drivers whose vehicle can be thrown off the road or into oncoming traffic or can flip over if the hole is large enough.
These types of holes are cavities inside the ground. They form when an underlying layer of rock is eroded. The pavement loses its support and gives way. Weather and water are the main causes for sinkhole formations.
Sinkholes are repaired much like potholes are. The damaged pavement is removed and recycled and fresh material is laid in to fill the hole.
Road Cracks
A road crack may sound like a minor issue on a roadway. They are not minor. Road cracks are a leading cause of potholes. Cracks can become huge and can cause accidents as well.
Crocodile cracking are the cracks along the roadside that are crescent-shaped. If they are left untreated, they become larger and eventually turn into potholes. The most common causes of cracks in the road are overloading of the road, poor drainage, seepage, lack of proper design, and climate factors.
An asphalt maintenance company is required to fill in road cracks before they turn into holes that will require much more labor and expense. To fill a crack, a hot pour is generally used once the area has been treated. If the weather is too cold, a cold mix will be used. Sometimes, if the crack is small, a tar-like substance can suffice at least temporarily.
Potholes
A pothole is defined as a depression that is in a road’s surface, usually asphalt pavement. Usually it is the final result of water in the soil structure underneath the pavement and the stress of traffic and/or weather on the weakened structure. Technically, a pothole must be shaped like a bowl with a dimension of at least six inches.
Potholes have the capability to cause tremendous damage to vehicles. They can cause a flat tire and suddenly send the vehicle into another lane of traffic, resulting in injury or death.
Potholes are typically repaired by asphalt repair companies, either that work for the state or county or independently. The process of repairing a pothole involves tearing off the damaged asphalt and using one of a number of techniques to fill the hole and make it level with the pavement that is undamaged.
Uneven Road Surfaces
Uneven road surfaces are a huge problem on America’s roadways. Driving on an uneven surface increases the chances of a motorist having a wreck. Their vehicle can be thrown into oncoming traffic or the vehicle can even tip over.
Uneven pavement can be the result of erosion or wear and tear, poor road maintenance, or improperly laid slabs. The process required to repair it depends upon the type of damage. Often an asphalt milling machine is needed to remove the damaged pavement. Then an asphalt maintenance company relays the surface.
Broken Concrete
Broken concrete can cause flat tires, a number one cause of car accidents. It can also throw a vehicle off the road or into another lane, another leading cause of accidents.
Broken concrete can occur due to several scenarios. Wrecks, normal wear and tear from traffic, extreme weather conditions, and the heavy toll big trucks take on pavement are among the top causes cement breaks.
Replacement concrete is more involved than asphalt replacement. Typically, concrete must be busted up using a sledgehammer and pick. A mix of sand, rock, and/or stone is used for the cement replacement formulation that concrete consists of. Then, the mix is poured into the gaps and is smoothed. Concrete takes a week or longer to dry (or cure) usually whereas asphalt only takes days.
Exposed Rebar
Exposed rebar is one of the most dangerous road problems. The rebar is sharp and if a motorist runs over it, their tire is almost guaranteed to go flat. The vehicle is likely to go into oncoming traffic or to be thrown off the road.
Exposed rebar requires the expertise of an concrete or asphalt road construction crew to repair. First, the surface that is damaged and the surface around the exposed rebar must be removed. Sometimes a sandblaster is required. Then, once the area is prepared, the new surface material can be laid.
Sinkholes
Sinkholes are a major source of trouble on roadways. They spell instant trouble for drivers whose vehicle can be thrown off the road or into oncoming traffic or can flip over if the hole is large enough.
These types of holes are cavities inside the ground. They form when an underlying layer of rock is eroded. The pavement loses its support and gives way. Weather and water are the main causes for sinkhole formations.
Sinkholes are repaired much like potholes are. The damaged pavement is removed and recycled and fresh material is laid in to fill the hole.
Road Cracks
A road crack may sound like a minor issue on a roadway. They are not minor. Road cracks are a leading cause of potholes. Cracks can become huge and can cause accidents as well.
Crocodile cracking are the cracks along the roadside that are crescent-shaped. If they are left untreated, they become larger and eventually turn into potholes. The most common causes of cracks in the road are overloading of the road, poor drainage, seepage, lack of proper design, and climate factors.
An asphalt maintenance company is required to fill in road cracks before they turn into holes that will require much more labor and expense. To fill a crack, a hot pour is generally used once the area has been treated. If the weather is too cold, a cold mix will be used. Sometimes, if the crack is small, a tar-like substance can suffice at least temporarily.
Who Pays for road construction?
The main contributors for the funding of highway and road construction is up to the federal, state, and local governments. Much of the funding of building and maintaining highways is allocated from the United States Highway Trust Fund. The majority of the fund comes from vehicle and fuel taxes.
The trust fund was established in the 1950's to help finance the US Interstate Highway System and other similar transportation projects carried out by US pavement services. The fund has since gone all but bankrupt, however.
Over the past three years, over 103 billion bucks were borrowed from the US Treasury to pay for road construction. Since 2013 when it became apparent that funds were running low, 15 states jacked up prices on fuel taxes. It is projected that by 2022, the price of highway and road construction will reach an all-new high of 103 billion dollars per year.
The use of public-private partnerships, also referred to as P3's, is becoming a popular trend in recent years, however. The way a P3 works is that private firms attain government money to build, operate, and/or maintain parts of a given road network.
Road construction is one of those things nobody wants to pay for, but no one wants to be without. As long as there are roads, there must be road construction.
The trust fund was established in the 1950's to help finance the US Interstate Highway System and other similar transportation projects carried out by US pavement services. The fund has since gone all but bankrupt, however.
Over the past three years, over 103 billion bucks were borrowed from the US Treasury to pay for road construction. Since 2013 when it became apparent that funds were running low, 15 states jacked up prices on fuel taxes. It is projected that by 2022, the price of highway and road construction will reach an all-new high of 103 billion dollars per year.
The use of public-private partnerships, also referred to as P3's, is becoming a popular trend in recent years, however. The way a P3 works is that private firms attain government money to build, operate, and/or maintain parts of a given road network.
Road construction is one of those things nobody wants to pay for, but no one wants to be without. As long as there are roads, there must be road construction.
Road Degradation Prevention
Road construction repair can be expensive, inconvenient, and time consuming. To prevent repairing roads, they must be maintained. Catching a crack before it becomes a pothole save tons of time and money.
Sealcoating is another way road construction can be prevented. Sealcoating for asphalt pavements is mixture of a small amount of particles, like sand or fine grains, that is combined with liquids in order to achieve a protective and/or restorative quality. The formulation usually contains dissolved asphalt, water, and mineral fillers. It can be found with both oil and water base but oil base is most widely used on roads since it offers the best results. The product is applied with a squeegee or broom or as a spray. It dries within hours and is ready for traffic to roll over it immediately following.
Sealcoating is another way road construction can be prevented. Sealcoating for asphalt pavements is mixture of a small amount of particles, like sand or fine grains, that is combined with liquids in order to achieve a protective and/or restorative quality. The formulation usually contains dissolved asphalt, water, and mineral fillers. It can be found with both oil and water base but oil base is most widely used on roads since it offers the best results. The product is applied with a squeegee or broom or as a spray. It dries within hours and is ready for traffic to roll over it immediately following.
The Asphalt Road Paving ProcesS
When roads require more than just a little pavement patching, asphalt will be laid. The process is so advanced, many attend asphalt paving school in order to master the technique.
Asphalt paving is much easier and quicker than concrete paving, but it still requires a number of steps, a crew to execute the work, and time to complete the job. Even small jobs basically stick to seven basic steps in the asphalt paving process. Larger jobs follow them completely.
The 8 steps of the asphalt road paving process are:
Step 1: Demolition and Removal
In order to repair a road, the pavement must be removed from the existing surface, no matter if it is asphalt, concrete, or pavers. Demotion is the act of completely removing the pavement by using heavy machinery, like forklifts, front loaders, large dump trucks, and bobcats. The debris is removed and taken away.
A milling machine is often used by asphalt milling companies. The machine removes and collects the damaged asphalt so it can be recycled. Asphalt is the most recycled material in the world and the milling machine is one reason why that is possible.
Step 2: Grading and Sloping
After the pavement is cleared and cleaned, the surface is prepared for water to drain properly. To make sure it is executed to exact specifications, laser-guided transits and automatic motor graders are used to grade the surface to ensure the proper sloping of water run-offs. Since water is one of the main culprits of road deterioration, it is vital to get this step correct.
Step 3: Prepare the Sub Base
The sub base of new asphalt is arguably the most important part of the set-up. It is responsible for providing stability to support the new asphalt pavement. It acts as a barrier for winter weather, like frost which is important because the freezing and thawing process accounts for a tremendous amount of damage to the pavement. The base thickness, base stability, and the compaction are crucial steps. If the sub base is not perfect, the asphalt surface will not be up to standard either.
Step 4: Proof Rolling, Undercutting, and Repair of the Sub Base
When the sub base is graded completely and compacted as well, the proof rolling will help to ensure the surface underneath is strong enough and is ready and able to support the new asphalt.
Proof roll entails driving a dump truck with a quad axle that is preferably loaded with over 70,000 pounds of material over the surface, row by row. If the gravel has more than an inch of flex under the weight, the base is not adequate.
If the proof roll locates soft areas in the sub base, the area is repaired until it is supportive which involves digging 2 or 3 feet under the surface to apply stronger aggregate material to the mix.
A geo-grid is sometime employed rather than the undercutting process. The geo-grid entails digging only 16 inches then laying a grid down to basically bridge the materials together to create a solid support structure that the new asphalt will go over. This process is much more economical and time-friendly.
Plowing is sometimes conducted to achieve a solid sub base. It is done by undercutting in order to improve the strength of the affected and compromised area rather than removing the soft soil and clay.
Step 5: Binder and Surface
When the sub base is deemed strong enough and is laid properly, any areas that are soft are identified and repaired, the time has come to add the binder layer. This layer utilizes a larger aggregate mix, like larger rocks or stone chunks. It is mixed with oil, making it very durable and strong.
Step 6: New Asphalt Surface Installation
Surface asphalt is comprise of small aggregate, like smaller rocks or crushed stone, which is mixed with sand and oil. The unit weight of asphalt must be figured to ensure the proper amount is laid. When the supportive structure are installed, the top layer of the new asphalt is carefully put down to give a clean and smooth ride to the traffic. This formulation makes a dark black mixture that is smooth and appealing to look at.
Step 7: Butt Joints and Transitions
When asphalt connect to existing driveways, parking lots, or roads, a smooth transition is needed. The areas where old asphalt meets the asphalt or concrete driveway, butt joints make the transition a smooth one. The goal is to make sure drivers and pedestrians alike notice no difference between the two surfaces when crossing from one to the other.
When the asphalt and the butt joints are laid and the surface is entirely smooth and compact, a roller truck is used to go over the new pavement to smooth and compact it even further. The process is conducted to make sure there are no aggregate or stone bumps sticking through the new surface at any points.
Step 8: Final Review
A complete and thorough inspection should be conducted after the installation process. Once it is given the final approval, the new pavement should be extremely durable and shout last years before there are any problems that need to be address with repair road construction.
Asphalt paving is much easier and quicker than concrete paving, but it still requires a number of steps, a crew to execute the work, and time to complete the job. Even small jobs basically stick to seven basic steps in the asphalt paving process. Larger jobs follow them completely.
The 8 steps of the asphalt road paving process are:
Step 1: Demolition and Removal
In order to repair a road, the pavement must be removed from the existing surface, no matter if it is asphalt, concrete, or pavers. Demotion is the act of completely removing the pavement by using heavy machinery, like forklifts, front loaders, large dump trucks, and bobcats. The debris is removed and taken away.
A milling machine is often used by asphalt milling companies. The machine removes and collects the damaged asphalt so it can be recycled. Asphalt is the most recycled material in the world and the milling machine is one reason why that is possible.
Step 2: Grading and Sloping
After the pavement is cleared and cleaned, the surface is prepared for water to drain properly. To make sure it is executed to exact specifications, laser-guided transits and automatic motor graders are used to grade the surface to ensure the proper sloping of water run-offs. Since water is one of the main culprits of road deterioration, it is vital to get this step correct.
Step 3: Prepare the Sub Base
The sub base of new asphalt is arguably the most important part of the set-up. It is responsible for providing stability to support the new asphalt pavement. It acts as a barrier for winter weather, like frost which is important because the freezing and thawing process accounts for a tremendous amount of damage to the pavement. The base thickness, base stability, and the compaction are crucial steps. If the sub base is not perfect, the asphalt surface will not be up to standard either.
Step 4: Proof Rolling, Undercutting, and Repair of the Sub Base
When the sub base is graded completely and compacted as well, the proof rolling will help to ensure the surface underneath is strong enough and is ready and able to support the new asphalt.
Proof roll entails driving a dump truck with a quad axle that is preferably loaded with over 70,000 pounds of material over the surface, row by row. If the gravel has more than an inch of flex under the weight, the base is not adequate.
If the proof roll locates soft areas in the sub base, the area is repaired until it is supportive which involves digging 2 or 3 feet under the surface to apply stronger aggregate material to the mix.
A geo-grid is sometime employed rather than the undercutting process. The geo-grid entails digging only 16 inches then laying a grid down to basically bridge the materials together to create a solid support structure that the new asphalt will go over. This process is much more economical and time-friendly.
Plowing is sometimes conducted to achieve a solid sub base. It is done by undercutting in order to improve the strength of the affected and compromised area rather than removing the soft soil and clay.
Step 5: Binder and Surface
When the sub base is deemed strong enough and is laid properly, any areas that are soft are identified and repaired, the time has come to add the binder layer. This layer utilizes a larger aggregate mix, like larger rocks or stone chunks. It is mixed with oil, making it very durable and strong.
Step 6: New Asphalt Surface Installation
Surface asphalt is comprise of small aggregate, like smaller rocks or crushed stone, which is mixed with sand and oil. The unit weight of asphalt must be figured to ensure the proper amount is laid. When the supportive structure are installed, the top layer of the new asphalt is carefully put down to give a clean and smooth ride to the traffic. This formulation makes a dark black mixture that is smooth and appealing to look at.
Step 7: Butt Joints and Transitions
When asphalt connect to existing driveways, parking lots, or roads, a smooth transition is needed. The areas where old asphalt meets the asphalt or concrete driveway, butt joints make the transition a smooth one. The goal is to make sure drivers and pedestrians alike notice no difference between the two surfaces when crossing from one to the other.
When the asphalt and the butt joints are laid and the surface is entirely smooth and compact, a roller truck is used to go over the new pavement to smooth and compact it even further. The process is conducted to make sure there are no aggregate or stone bumps sticking through the new surface at any points.
Step 8: Final Review
A complete and thorough inspection should be conducted after the installation process. Once it is given the final approval, the new pavement should be extremely durable and shout last years before there are any problems that need to be address with repair road construction.
Ensuring Safe Road Construction
A road construction process depends on the severity of the damage and the extent of the project. Even the simplest project requires safety because traffic vs. man is never a fair match. Surprisingly, hundreds of accidents take place every year that injure or kill the drivers.
One of the main causes for road construction accidents is the failure to give motorists enough warning that they are entering a work zone. Signs should be erected and plenty of them. Bright orange cones should be set carefully in place. Barriers and barrels should clearly line out the specific areas where the work is taking place.
Heavy equipment should be marked too. Cones and barriers should warn motorists of them whether they are in motion or not. Materials should be stored out of the way and if that is not possible, they should be marked and blocked off.
Workers should wear bright colored vests that make them highly visible and should wear them at all times. If work is being conducted at night, the vests should have reflective strips.
When it’s all said and done, any road construction process is made easier and better with upgraded knowledge, experience, and technology. Knowing what those advancements are and how to implement them is priceless.
One of the main causes for road construction accidents is the failure to give motorists enough warning that they are entering a work zone. Signs should be erected and plenty of them. Bright orange cones should be set carefully in place. Barriers and barrels should clearly line out the specific areas where the work is taking place.
Heavy equipment should be marked too. Cones and barriers should warn motorists of them whether they are in motion or not. Materials should be stored out of the way and if that is not possible, they should be marked and blocked off.
Workers should wear bright colored vests that make them highly visible and should wear them at all times. If work is being conducted at night, the vests should have reflective strips.
When it’s all said and done, any road construction process is made easier and better with upgraded knowledge, experience, and technology. Knowing what those advancements are and how to implement them is priceless.
