Asphalt Repair Calculator

Asphalt Repair Calculator

Asphalt Repair Calculator For Contractors and Construction Professionals, Property Owners and Municipalities

The asphalt repair calculator is useful for estimating the amount of asphalt material needed for a specific repair project. Users can input details such as the area to be repaired, the depth of repair, the type of repair (e.g., surface patching, pothole filling, crack sealing), and the type of asphalt mix (hot mix or cold mix).

With over 25 years of experience as a licensed civil engineer specializing in asphalt materials and road construction, I have developed extensive expertise in efficient pavement techniques and high-performance mix designs. Most recently, I successfully completed a major road construction project in the United States, further building my reputation in the construction industry.

Through my new website, I provide educational resources on asphalt calculations and repairs to share the knowledge I’ve gained after decades in the field.

Asphalt Repair Issues

Asphalt pavements require repair over time due to various issues that develop. Some of the most common situations that necessitate asphalt repair include:



    1. Thermal cracking often shows up as parallel lines across pavement. It’s caused by the asphalt expanding and contracting with temperature changes. Areas with wide temperature swings see more thermal cracking.
    2. Fatigue cracks appear as interconnected or meandering cracks. They develop over years of traffic loads stressing the pavement. You’ll often see them in wheel paths first.


    1. Potholes rapidly develop after winter freezes and thaws. Water seeps into existing cracks, then expands as ice to further deteriorate the pavement.
    2. Neglecting to fill early stage cracks allows potholes to form. The cracks allow water under the surface, eroding the base.
    3. High traffic areas like bus routes and intersections experience more potholes if not maintained well. Loads worsen existing cracks.


    1. As asphalt binder hardens with age, the surface starts flaking off under traffic. Like a scab peeling off.
    2. Insufficient compaction during paving leaves air pockets in the asphalt. This leads to rapid disintegration from weather and wear.
    3. Poorly sealed edges and joints ravel quickly. sealant prevents water intrusion leading to deterioration.


    1. Depressions often correspond to settlement issues in the substrate. Improper soil compaction or erosion under the base can cause dips.
    2. If depressions form soon after paving, it usually indicates a problem with the initial compaction of asphalt. Rollers didn’t compact evenly.

The primary causes of these asphalt repair situations include weathering and aging, moisture damage, and traffic loads over time. Keeping up with necessary maintenance and repairs is crucial for extending the lifespan of any paved surface.

Identifying Needed Repairs

Regularly inspecting asphalt pavement surfaces is crucial to identifying issues in need of repair. Some tips for effective inspection include:

  • Look for any cracks, potholes, raveling or depressions. Note the type, extent and location of defects. Measure crack widths.
  • Check surface smoothness with a straightedge ruler. If large gaps show underneath, it indicates depressions or swelling.
  • Identify the distress type – is it alligator cracking, block cracking, rutting, etc? Each type has different causes.
  • Evaluate drainage and water runoff. Inadequate drainage accelerates pavement deterioration.
  • Assess previous repairs – are patches failing? Does sealing need replacing?

The key is thorough visual inspection on a regular basis. This allows you to pinpoint problem areas early and schedule preventative repairs before major replacement is needed.

Repair Techniques

Several repair techniques can address various asphalt pavement defects:

  • Patching – Isolated deep repairs. Remove damaged pavement, fill with new hot or cold mix asphalt. Pros: Versatile, customizable repair. Cons: Can settle over time if not compacted well. Best for localized problems like potholes or raveling.
  • Crack Sealing – Filling cracks with liquid bitumen. Prevents water intrusion. Pros: Affordable, extends pavement life. Cons: Temporary fix, cracks may reappear. Best for minor hairline cracks.
  • Milling and Resurfacing – Removing top layer with a milling machine, and replacing it with a new overlay. Pros: Fixes extensive damage, and restores smoothness. Cons: Costly, requires specialty equipment. Ideal for widespread issues like major rutting.
  • Hot Mix vs. Cold Mix – Hot mix provides a more durable repair but requires hauling and compaction at high heat. Cold mix is convenient but temporary. Cold mix suitable for small patches, hot mix better for large repairs.

The right technique depends on the type and extent of damage. Combine preventative crack sealing with localized patches or full resurfacing as needed.

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DIY Repair Tips

As an experienced civil engineer, I recommend any DIYers take proper safety precautions when doing asphalt repairs. Wear reflective safety vests, gloves, eye protection and boots on the job site. Use traffic cones to direct vehicles away from work areas.

For patching, start by marking repair boundaries and cutting out the damaged area with a chisel, pick or saw. Ensure straight edges and a clean break. Tack the hole perimeter before filling with hot or cold patch material, compacting in layers. Let patches cure before opening to traffic.

When sealing cracks, thoroughly clean and dry the cracks with compressed air. Fill with liquid bitumen sealant using a squeegee or pouring pot, smoothing flush with the surface. Allow proper curing time before exposing to traffic.

Proper prep work, using quality materials, and taking safety seriously are keys to effective DIY asphalt repairs.

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Repair Planning

Planning ahead for asphalt repairs ensures you complete projects at optimal times. Ideal repair weather is warm and dry—schedule summer or fall for best outcomes. Only do emergency winter repairs if absolutely necessary.

Coordinate repair timing with usage schedules. For a parking lot, plan repairs at low volume periods or block off sections. Do road repairs at night or on weekends to minimize traffic impacts.

Check if any permits are required for the repair work. For public roads, utility crossings or extensive projects, permits regulate work allowed. Local municipalities also often require permits.

Careful planning allows efficient repairs under safe conditions with minimal disruption to pavement use. As a civil engineer, I recommend proactively planning repairs rather than waiting for emergency situations.

The Most Effective Methods and Practices for Asphalt Pavement


Basic equipment for DIY asphalt repair includes safety gear, hand tools like rakes and tampers for prep work, patching mix and crack fillers, compaction equipment from hand tampers up to plate compactors, joint sealants, and caulking.

For more extensive repairs, equipment like pavement saws, milling machines, power rollers or paving machines may be required. Always use equipment properly and safely.

Quality hot and cold patch material and crack sealants specifically designed for asphalt repair are essential for good results. Don’t cut corners with subpar materials.

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I'm Steve Axton, a dedicated Asphalt Construction Manager with over 25 years of experience paving the future of infrastructure. My journey with asphalt began by studying civil engineering and learning about core pavement materials like aggregate, binder and additives that compose this durable and versatile substance. I gained hands-on experience with production processes including refining, mixing and transporting during my internships, which opened my eyes to real-world uses on roads, driveways and parking lots. Over the past decades, I have deepened my expertise in asphalt properties like viscosity, permeability and testing procedures like Marshall stability and abrasion. My time with respected construction companies has honed my skills in paving techniques like milling, compaction and curing as well as maintenance activities like crack filling, resurfacing and recycling methods. I'm grateful for the knowledge I've gained about standards from Superpave to sustainability best practices that balance longevity, cost and environmental friendliness. It's been an incredibly rewarding career working with this complex material to build the infrastructure future.