Asphalt Reconstruction vs. Patching: Making Informed Choices for Long-lasting Pavement

Asphalt reconstruction is the process of completely removing and replacing existing asphalt. In some cases, this includes the underlying base layers as well. This approach is comprehensive and designed to address severe damage and structural issues.

On the other hand, patching is a localized repair used to fix isolated areas of damaged or failing asphalt (think small potholes, cracks, etc.).While it involves removing and replacing damaged asphalt like reconstruction, it only focuses on the damaged portions, not the entire paved area. 

Now that we’ve defined our terms, let’s look at the pros and cons of each method.

Asphalt Reconstruction

Pros

1 – Comprehensive Solution<

Reconstruction is a comprehensive solution to failing asphalt. When done correctly, it addresses all issues, and you won’t need to worry about underlying issues causing problems in the future.

2 – Improved Pavement Strength 

Reconstructed asphalt is stronger than patched asphalt, especially if the base layers are redone. The reconstructed area will be better equipped to handle heavy traffic loads, weather changes, and other stressors.

3 – Enhanced Longevity

Reconstructed asphalt lasts longer than patched or resurfaced asphalt. While longevity depends on factors like use, maintenance, and weight of traffic, a reconstructed roadway will last up to 25 years. Patching, on the other hand, extends the life of a paved area by only 2-10 years.

4 – Addressing Subgrade Issues

Because reconstruction involves removing all the top layers of asphalt, it lets you address any subgrade issues that exist. While reconstruction doesn’t entail replacing base layers, it allows you to inspect them more closely and make an informed decision.

5 – Opportunity for Design Changes 

Since you’re completely reconstructing the asphalt, it’s a great time to make design changes, like adjusting lane widths, adding turning lanes, or improving drainage, to better accommodate traffic flow.

Cons

1 – Higher Cost 

Because reconstruction entails the complete removal and replacement of the asphalt, it costs significantly more upfront than other forms of asphalt repair and maintenance.

2 – Takes More Time

Reconstructing asphalt takes a lot longer than less invasive repairs like patching. That means you’ll need to plan how to minimize traffic disruption. For example, if you’re redoing your parking lot, you’ll need to arrange alternative parking.

3 – Environmental Impact 

Completely reworking old pavement generates waste materials that negatively impact the environment if handled poorly. Thankfully, recycling is possible in most cases.

Patching 

Pros

1 – Cost Effective

Patching is a cost-effective option for dealing with asphalt issues. It allows for targeted repairs, which saves on labor and material costs.

2 – Quick Repairs

Patching is usually a quick, effective fix, depending on the size and extent of the problem. This means you won’t have the same headache of traffic disruption you’d face with reconstruction.

3 – Preventative Maintenance 

Quickly patching minor issues prevents them from worsening and causing more extensive problems in the future.

4 – Improved Safety 

Patching is a straightforward, affordable way to address parking lot and road safety hazards to keep drivers, pedestrians, and bikers safe.

5 – Localized Solution 

If one area of your asphalt is failing, patching allows you to address that issue without replacing the parts that are still in good condition.

Cons

1 – Limited Effectiveness 

While patching is great for minor issues, it doesn’t work well for widespread damage or underlying issues. For example, if there is a problem in the base layers of your asphalt, patching will only be a temporary fix.

2 – Less aesthetically pleasing 

Patching won’t blend seamlessly into the surrounding asphalt, reducing the visual appeal of the paved area.

3 – Temporary disruption 

Patching won’t disrupt traffic as much as reconstruction, but some disruption may still happen depending on the location of the repair. Keep this in mind when scheduling the work. 

As we’ve established, there are pros and cons to asphalt reconstruction and patching. Which method is best depends entirely on the particular situation.

So when is it best to patch your asphalt?

Patching is ideal in situations of isolated or minimal asphalt damage. If a few cracks are forming or potholes have developed, but the paving seems solid otherwise, patching is the better option. This will extend the life of your pavement, and the upfront cost won’t be as significant.

Asphalt reconstruction is ideal for situations with widespread damage where the asphalt is generally worn out or failing, or the structural base layers have issues. Here are a few problems that indicate reconstruction is best:

• Excessive raveling or oxidation
• Majorly deteriorated topcoat 
• Significant cracking, sinkholes, and other signs of subgrade issues

If you’re unsure what’s right for your situation, ask a pavement management expert for advice!

There are numerous types of reconstruction and patching available. Let’s take a brief look at a few of the options available in each category.

Reconstruction Types

1. Full-depth reclamation(FDR): A comprehensive, permanent fix that involves pulverizing the asphalt and its base to create a stabilized base course. Since this involves recycling existing materials, it is considered an environmentally friendly technique.
2. Mill and Fill: This consists of removing existing pavement 1-2” deep using a milling machine and installing new asphalt. Mill and fill reconstruction lasts 10-15 years.
3. Removal and Replacement: This method is necessary when asphalt reaches the end of its life cycle. It involves the complete removal and replacement of asphalt and sublayers.

Patching Types

1. Surface patching: A quick solution for shallow potholes where the base layers are still in great shape. This isn’t meant to be a long-term fix and is best for situations that need immediate resolution.
2. Mill or partial-depth patching: Damaged material is milled or removed about 1-2” deep—a good, longer-term solution for shallow potholes and some types of cracks.
3. Full-depth patching: This involves removing and replacing the damaged area down to (and sometimes including) the base layers, and is the longest-lasting patch method.