Fabric Overlay

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When widespread surface cracking develops on aging pavement, an asphalt fabric overlay is a reliable alternative to costly excavation and replacement of the cracked and deteriorated asphalt.

Most cracked and distressed surfaces arise from surface water seeping through untreated cracks in the pavement. When water enters the base of the pavement, the base material can become compromised, leading to further cracking. High traffic volumes and vehicles carrying heavy loads (garbage trucks and delivery trucks can be especially damaging) can also lead to excessive surface cracking. Simply attempting to seal or applying a skin patch to these heavily damaged areas will provide only a temporary solution as the existing cracks will quickly reflect through the new surface.

Although reflective cracking cannot be completely eliminated, the use of a fabric overlay significantly slows the reflective cracking process by forming a moisture resistant barrier that prevents water from passing through cracks, joints, and the pavement itself, preserving the structural integrity of the base. In addition, the fabric forms a shock absorbtion layer in the asphalt. This greatly reduces tensile stresses within the pavement, resulting in a dramatic increase in the life of the asphalt overlay.

What is the fabric?

The fabric in a fabric overlay is a non-woven, petroleum-based geotextile fabric which is field saturated with an asphalt cement tack coat. When placed between pavement layers, the fabric becomes an integral part of the pavement, forming a barrier to water seepage and absorbing stresses to reduce reflective and fatigue cracking of the new asphalt surface layer.

The process for applying an asphalt fabric overlay begins by cleaning the existing surface of dust, dirt, vegetation, and moisture. Low areas are filled with hot-mixed asphalt and large cracks are sealed to maximize the performance of the fabric. Hot oil is applied to the surface, followed by the placement of the fabric. Hot-mixed asphalt is then installed over the fabric and compacted. During the paving process, the heat and pressure from the compaction of the hot asphalt cause the oil to soak through the fabric. This creates a waterproof membrane that effectively adheres to both the new and old asphalt pavements.

Long-term field evaluations have shown that the proper use of paving fabrics in asphalt overlays can increase pavement life up to 50%. Utilizing asphalt fabric overlays will reduce maintenance costs and improve the effectiveness of your pavement management system without the need to completely remove and replace your existing pavement.

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