If you own a commercial property, manage a residential complex, or simply want to maintain your driveway, you know how expensive asphalt repairs and replacements can get. But what if there was a cost-effective trick that could save you thousands on those expensive road repairs? Enter asphalt milling — the unsung hero of pavement maintenance.
In this blog, we’ll reveal how asphalt milling works, why it’s so affordable, and how it can drastically extend the life of your asphalt surfaces without breaking the bank.
What Is Asphalt Milling?
Asphalt milling is a process that involves removing the top damaged layer of an asphalt surface using specialized machinery. Instead of ripping out the entire pavement and starting from scratch — which is costly and time-consuming — milling grinds away just the worn, cracked, or deteriorated asphalt.
The result? A clean, rough base that’s ready for a new layer of fresh asphalt. This not only restores the surface to a like-new condition but also creates a stronger bond with the new asphalt, enhancing durability.
Why Is Asphalt Milling the Cost-Saving Trick You Need?
1. Avoid Full Pavement Replacement
Full asphalt removal and replacement require breaking up and hauling away all layers of the old pavement. This process involves heavy equipment, significant labor, and higher disposal fees, which quickly add up to a hefty bill.
Asphalt milling, on the other hand, focuses only on the top layer, removing just enough to get rid of damage and prepare the surface for repaving. This targeted approach saves material costs, reduces labor time, and minimizes disposal expenses.
2. Recycle Old Asphalt Material
One of the best benefits of milling is that the removed asphalt isn’t just waste. The milled asphalt chunks, also called reclaimed asphalt pavement (RAP), can be reused in new asphalt mixes or as a base layer for roads. This recycling reduces raw material demand and lowers overall project costs.
3. Faster Project Completion
Because milling removes only a portion of the asphalt, projects typically finish faster than full replacement jobs. Faster turnaround means less disruption to traffic and daily operations, saving you money on downtime and temporary repairs.
4. Improves Surface Quality and Longevity
By removing damaged sections and providing a rough surface for new asphalt, milling helps create a stronger bond between layers. This reduces the chances of premature cracking, potholes, or surface failure, which means fewer costly repairs in the future.
How Does Asphalt Milling Work?
Here’s a simple step-by-step overview of the milling process:
- Assessment and Planning: Experts inspect your asphalt surface to determine the depth of milling required, usually between 1 to 3 inches, depending on damage severity.
- Preparation: The area is cleared of vehicles, debris, and any obstacles.
- Milling Machine in Action: A large milling machine with rotating drums equipped with carbide teeth grinds the asphalt surface, removing the damaged layer.
- Collecting the Milled Asphalt: The milled material is collected via conveyor belts attached to the machine and loaded into trucks for recycling or disposal.
- Surface Inspection: After milling, the base surface is inspected for any issues that might need repair before repaving.
- New Asphalt Application: Fresh asphalt is laid over the milled surface and compacted to create a smooth, durable finish.
When Should You Consider Asphalt Milling?
- Your pavement has surface cracks, rutting, or potholes, but the base layer is still sound.
- You notice uneven or rough surfaces affecting vehicle safety or appearance.
- You want to resurface a driveway, parking lot, or roadway without the cost of full removal.
- You’re aiming for a sustainable, eco-friendly pavement repair method.
- Your pavement needs correcting elevation or slope issues to improve drainage.
Asphalt Milling vs. Other Repair Methods
| Repair Method | Cost | Time to Complete | Durability | Environmental Impact |
|---|---|---|---|---|
| Full Asphalt Replacement | High | Long | Very durable | High waste & energy use |
| Asphalt Overlay (No Milling) | Medium | Short | Less durable (possible future failure) | Medium |
| Asphalt Milling & Overlay | Low to Medium | Medium | High durability | Low waste, recyclable |
Asphalt milling with an overlay gives you the best balance between cost, durability, and eco-friendliness.
Benefits of Asphalt Milling in a Nutshell
- Cost Savings: Saves thousands by avoiding full removal and using recycled materials.
- Faster Repairs: Minimizes downtime and disruption.
- Sustainability: Recycles old asphalt, reducing landfill waste.
- Improved Pavement Life: Creates stronger surfaces that last longer.
- Safety: Eliminates uneven surfaces and potholes that can cause accidents.
- Flexibility: Can correct slopes and surface irregularities.
Tips to Get the Most Out of Asphalt Milling
- Work with experienced contractors who use modern milling equipment.
- Plan milling during mild weather to ensure proper asphalt bonding.
- Schedule milling as part of regular pavement maintenance to prevent costly damage.
- Consider mill depth carefully — too shallow might not remove all damage, too deep could be expensive.
- Use milled asphalt material in other projects if possible to maximize recycling benefits.
Final Thoughts: Don’t Ignore Asphalt Milling
Asphalt milling is more than just a pavement repair technique — it’s a smart investment that can save you thousands, extend the life of your roads or driveways, and contribute to a greener environment. Before jumping into a full replacement or costly repairs, ask your contractor if asphalt milling is right for your project.
This simple but powerful trick might just be the solution you need to keep your pavement looking fresh, safe, and durable, without draining your budget.