Mill and Overlay in Harlingen, TX

Mill and overlay is a resurfacing method: a milling machine grinds off the worn top layer of asphalt, and a new layer of hot-mix is paved in its place. It is the same approach the City of Harlingen's Paving Division uses on streets in its Street Improvement Program, and it works just as well on parking lots and larger driveways. Milling keeps the finished surface at the same height, so curbs, gutters, slabs and doorways still line up, and it gives the new asphalt a rough, clean surface to bond to.

When it fits

Mill and overlay is for pavement whose base is still doing its job. The surface may be faded, raveling, rough or covered in fine cracks, but it is not sinking, rutting deeply or breaking into potholes over large areas. Where a few areas have failed, we cut those out and rebuild them first, then mill and overlay the whole surface. Where most of the pavement has failed, an overlay will not last, and reconstruction is the better investment.

Milling versus a straight overlay

A straight overlay adds new asphalt on top of the old, raising the surface by an inch and a half to two inches. That can be fine in open areas but causes problems at curbs, garage doors and building entrances, and on flat Harlingen lots it can change how water drains. Milling first, at least along the edges and transitions, keeps the grade where it should be. We decide where to mill based on the transitions and drainage.

The steps

• Mark and repair failed areas down to the base
• Mill the surface or the transitions to the planned depth
• Sweep and clean the milled surface
• Apply a tack coat so the new layer bonds
• Pave and compact the new asphalt
• Restripe commercial lots once the surface is ready

Cost

On HomeGuide's numbers, a commercial-style overlay of an inch and a half to two inches runs $1 to $3 a square foot, driveway resurfacing $3 to $7, and resurfacing sound pavement instead of replacing it usually saves a fifth to nearly a third of the cost. Base repairs and milling depth affect the final number, and we price them as separate lines.

Working around heat and rain

Fresh overlays need the same care as new paving: a few days in hot weather before heavy traffic, and a cure period before sealing. We schedule overlays to avoid storm days, because a tack coat and fresh mix should not be rained on.

Is your lot a candidate?

Good candidates have a surface that is worn, faded or rough, with cracks that are mostly narrow and isolated potholes rather than whole failed sections. Poor candidates have ruts, large soft areas or cracking across most of the surface. We walk the lot with you and mark which areas fall into each group.