How to use the asphalt on asphalt calculator

Most overlay quotes come down to one number, the tons of mix, and the asphalt on asphalt calculator gives you that number. Work it out yourself first so you can read a contractor’s quote with some confidence. For a plain square feet to tons figure on a new pavement, our asphalt calculator is the quickest route:

1. Measure the old surface. Measure the length and width of the area to be paved over, in feet. For an irregular driveway or lot, split it into rectangles, work out each one, and add them together.
2. Choose the overlay thickness. Type the compacted thickness in inches or pick a preset. Most driveways get 1.5 to 2 inches, and lots with truck traffic get 2.5 to 3 inches. Remember the surface rises by this amount.
3. Pick the surface condition. The buffer covers the low spots and ruts the new layer fills. Use 5% for a smooth surface, 10% for a typical one, and 15% for an uneven or rutted one.
4. Add a price per ton if you have one. Enter your plant price to see a material cost and a cost per square foot. Leave it blank for weight only.
5. Calculate, then check the other tabs. Press Calculate for the tons and truck loads. The other two tabs compare overlay and replacement costs and screen your pavement to see if an overlay is realistic.

Can you put asphalt over existing asphalt?

You can, and it is one of the most common ways to renew a tired driveway or lot. Laying asphalt on asphalt, usually called an overlay or resurfacing, works because the old pavement acts as a ready-made base. What it cannot do is cure a failing base. If water has softened the stone under the surface, the new layer will crack and sink in the same places as the old one.

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Alligator cracking is the one to take seriously. It means the base is moving under traffic, and no thickness of new asphalt on top will stop that. The third tab above turns this table into a quick check for your own pavement.

Can you pave over cracked asphalt?

Yes, but only some cracks. The size and pattern of the cracking decide whether you can pave over cracked asphalt or have to dig it out first. A new layer hides cracks for a while, but cracks in the old surface tend to work up through it, so each one should be treated before the overlay goes down.

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If you can fix every crack on this list, the overlay is worth doing. If most of the surface is alligator cracked, a new overlay is only a short-term cover, and the replacement figure in the next section is the better comparison.

Asphalt overlay vs replacement cost

The asphalt overlay vs replacement cost question comes up on almost every asphalt on asphalt job. The real choice is usually between a new top layer and a full tear-out. The overlay costs less and takes a day, but it leaves the old base in place, and so it also leaves any weaknesses in that base.

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An overlay costs less because there is nothing to haul away and no new base stone. The compromise is reflective cracking, where cracks in the old layer slowly work up through the new one, and a higher surface that can leave a lip at garage doors, curbs, and sidewalks. The replacement figure includes removal, so it is above the $3 to $7 range quoted for a new driveway on bare ground. Our asphalt vs concrete cost guide compares lifespans in more detail.

How thick should an asphalt overlay be?

For the asphalt on asphalt calculator, thickness is the number that matters most. Asphalt on asphalt driveways are normally overlaid with 1.5 to 2 inches of compacted hot mix. Parking lots with delivery trucks usually need 2.5 to 3 inches. The layer cannot be too thin, because the stones in the mix need room to compact. A common rule is a thickness of at least two to three times the largest stone in the mix, which is why overlays much below 1.5 inches wear out fast.

Whatever you choose, the surface rises by the same amount. Two inches of overlay on a driveway leaves a 2 inch step at the garage door and may change how water drains toward the house. That is why contractors mill the edges, and why the height question is on the third tab. To see how the hot mix is placed and what to set on the paver, read the roller loss steps on our hot mix asphalt calculator.

How to put asphalt on asphalt: step by step

1. Clean the surface. Sweep or blow off dirt, loose stone, and plants. Remove oil stains where the surface is soaked, since oil stops the bond.
2. Repair first. Fill cracks, and dig out and patch holes and soft spots. Level any dips deeper than about an inch with patch mix or a leveling course.
3. Mill the edges. Where the overlay meets a garage slab, curb, or gutter, the edge is often milled down 12 to 18 inches so the new layer sits flush instead of leaving a lip.
4. Apply the asphalt tack coat. Spray a thin coat of asphalt emulsion over the entire surface so the new layer bonds to the old. Our bitumen calculator sizes the tack.
5. Place and roll. Hot mix arrives from the plant at about 300°F to 325°F. It is spread by a paver and rolled while still hot, down to the finished 1.5 to 2 inches.

Asphalt patch before the overlay

Holes and soft spots need an asphalt patch before the overlay, not after it. For a shallow hole, clean it out and fill it with patch mix. For a deep one, dig out to firm ground, backfill with compacted stone, and patch with hot mix. Cold patch is a stopgap that suits small, shallow repairs, and hot mix bonds and lasts better. Compact every patch so it sits level with the surface, because a low patch becomes a dip in the new layer.

Asphalt tack coat rate

An asphalt tack coat is a thin spray of emulsion that glues the new layer to the old one. It is applied at about 0.05 to 0.10 gallons per square yard, which is roughly 4 to 8 gallons for a 700 sq ft driveway. The surface must be clean and dry, and the overlay should go down once the emulsion has turned from brown to black, or “broken”. Too much tack can make the layer slip, so use the rate and no more.

The formula for overlay tonnage

The asphalt on asphalt calculator uses the same weight calculation as any other paving layer. The only difference is that you use the overlay thickness and not the thickness of the whole pavement:

At the standard hot mix density of 145 lb/ft³ this simplifies to area × thickness × 0.00604. One cubic yard weighs about 1.96 tons, and a cubic yard holds 27 cubic feet. The table gives net tons before any buffer, so add 5 to 15% depending on how uneven the old surface is.

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For truck counts and conversions between tons and square yards, use the asphalt tonnage calculator. If a plant quotes a different density, check it with the asphalt density calculator.

Worked examples

Three typical asphalt on asphalt jobs, worked out by hand so you can check the asphalt on asphalt calculator.

Asphalt overlay cost per square foot

The asphalt overlay cost is usually quoted at $1.75 to $3.50 per square foot for materials and installation, so a 500 sq ft driveway runs about $875 to $1,750 and a 1,000 sq ft one about $1,750 to $3,500. These are planning numbers. The material alone, at $80 to $200 per ton and 2 inches thick, comes to roughly $0.97 to $2.42 per square foot, and the rest is labor, equipment, tack, and repairs.

The second tab of the asphalt on asphalt calculator compares the overlay and replacement price for your area. Surface repairs, the distance from the plant, and the price of oil and binder all move the total. For a full budget with labor and base work, use our asphalt driveway cost calculator.

Other ways to renew an old asphalt surface

• Crack sealing and sealcoat. If the pavement is sound and only faded, sealing the cracks and applying a sealcoat can add a few years for a fraction of the overlay price.
• Asphalt millings. Recycled asphalt from road milling projects can be spread and compacted for a low-cost rural driveway or farm road. Size the quantity with the crushed asphalt calculator.
• Tar and chip. Chip seal is a cheaper surface treatment over a sound base. See how it compares in the tar and chip cost calculator.
• Full depth reconstruction. When the base has failed, rebuilding the stone and surface together is the only lasting fix. The pavement calculator works out each layer.

Mistakes that shorten an overlay’s life

These are the usual reasons asphalt on asphalt jobs fail early:

• Overlaying a failing base. This is the most common reason overlays crack within a couple of years.
• Skipping the tack coat. Without it the layers can slide against each other and peel.
• Ignoring the height rise. Check garage doors, curbs, and drains before you decide on a thickness.
• Going too thin. Under 1.5 inches the mix is hard to compact, and it wears out fast.
• Paving over standing water. Regrade first, or the water will find its way under the new layer.

More paving calculators

For a quick square feet to tons figure on a new pavement, try our main free asphalt calculator square feet page.

Frequently asked questions

Summary

Laying asphalt on asphalt is the cheapest way to renew a driveway or lot whose base is still sound. Check for alligator cracking, soft spots, and drainage first, plan for the rise in height, and use a tack coat. Then work out the tons with the asphalt on asphalt calculator above and get at least two quotes before you commit.

Sources and resources

• National Asphalt Pavement Association (NAPA)
• Asphalt Institute

This page is for planning. Have a paving contractor check the base and the cracking before you order, and confirm tonnage and mix with your plant.

How to use the asphalt vs concrete driveway cost calculator

You will get better quotes if you know the rough numbers first. Work through the three tabs in this order. For the tons of asphalt a driveway needs, our asphalt calculator gives the weight and material cost:

1. Enter the driveway size. Type the length and width of the driveway in feet. A single-car driveway is often about 12 by 40 feet, and a double-car one about 20 by 40 feet.
2. Choose your region and materials. Pick the part of the US you are in, then the asphalt type and concrete finish. Regional prices differ a lot, so this changes the result more than any other input.
3. Read the installed cost. Press Calculate on the first tab to see the installed cost range for each material and how much the cheaper one saves.
4. Check the cost over time. The second tab adds sealing, resurfacing, and upkeep over 10 to 40 years. The cheaper driveway at install is not always the cheaper one over the long run.
5. Use the quick guide. The third tab asks five questions about your climate, budget, and plans, and tells you which material fits better.

Asphalt vs concrete driveway cost per square foot

Asphalt is cheaper to install, usually by about half. Concrete costs more at the start but lasts longer and needs less routine care. These are installed prices, meaning materials, labor, and normal base preparation, for a driveway built on bare ground.

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A 600 sq ft driveway comes to about $1,800 to $4,200 in asphalt and $3,600 to $9,000 in plain concrete. Asphalt is cheaper for three reasons. The material costs less per square foot, the crew finishes in a day, and the surface is placed hot and rolled, and it is ready for light traffic within a day or two, where concrete needs about a week before cars can use it.

What drives the cost of a new driveway

The asphalt vs concrete driveway cost per square foot is only the start. These are the items that move a quote up or down:

• Size. Bigger driveways cost more in total, but the price per square foot usually falls a little.
• Thickness. Asphalt is typically 2 to 3 inches over a stone base, and concrete 4 inches or more. Heavier use calls for more.
• Removing the old driveway. Tearing out and hauling away a driveway adds to the bill. For a worn but sound asphalt surface, an overlay is cheaper, see asphalt on asphalt.
• Excavation and base. Poor soil, slopes, and soft ground mean more digging and more stone.
• Drainage. Grading, culverts, and drains can add a lot on a sloped lot.
• Finish. Stamped, stained, or exposed aggregate concrete costs much more than plain concrete.
• Labor, permits, and location. Local labor rates and permit fees vary widely across the country.

For a full budget with grading, base, and labor for an asphalt driveway, use our asphalt driveway cost calculator.

Asphalt or concrete driveway at a glance

This table sums up the asphalt vs concrete driveway cost and how the two compare once they are installed.

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Which driveway lasts longer, and what does upkeep cost?

Upkeep changes the long-run asphalt vs concrete driveway cost. Concrete generally lasts longer, about 30 to 40 years against 20 to 30 for asphalt. Both depend on the base, the drainage, the traffic, and how well they are maintained. A good base under a thin surface beats a bad base under a thick one.

Asphalt asks for more routine care: a sealcoat every 3 to 5 years, prompt crack repair, cleaning oil stains, and a resurfacing after about 15 to 20 years. Concrete asks for less: washing, a sealer every 4 to 5 years, and filling cracks when they appear. Concrete repairs cost more when they are needed, but they come less often.

The second tab does this calculation for your own area, region, and time period. Its assumptions are shown under the result, so you can adjust them in your head if your quotes are different.

Asphalt vs concrete driveway cost by region

The asphalt vs concrete driveway cost changes with labor rates, material supply, and local rules. These are typical installed ranges per square foot, and your own quotes should always override them.

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Types of asphalt and what they cost

Not every asphalt driveway uses standard hot mix. The type changes the price, and recycled asphalt is the budget option.

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Recycled asphalt is cheapest because the material is reclaimed pavement, so you pay for less new binder and stone. It is rolled and compacted like hot mix. Our crushed asphalt calculator sizes the tons and cubic yards.

Asphalt, blacktop, tarmac, bitumen, and tar

These words are often mixed up, and the difference matters when you compare quotes.

• Asphalt and blacktop. Blacktop is a common name for asphalt pavement. For a driveway, the two are the same thing. Some contractors use it for a hot mix surface course.
• Tarmac. Originally a tar-bound macadam. It is an older technology, and the word is now used loosely for asphalt.
• Bitumen. The petroleum binder that holds the stone together in asphalt.
• Tar. A coal-derived binder that was once used on roads and is no longer used in modern paving.
• Concrete. Uses Portland cement as the binder, not bitumen, which is why it is rigid where asphalt is flexible.

The bitumen calculator covers binder and tack coat quantities for asphalt work.

Which is better in snow and heat?

Asphalt performs better in cold climates. It stays flexible through freeze and thaw, its dark surface warms in the sun and melts snow faster, and it is less affected by de-icing salt. Concrete handles winter well too, but salt can flake the surface, particularly on a slab less than a year old.

In hot climates the picture reverses. Concrete reflects sunlight and stays cooler, while asphalt can soften in extreme heat and show dents from a kickstand or a jack. Concrete is also the stronger choice under heavy parked loads such as RVs.

How asphalt and concrete driveways are installed

Both driveways are built in the same order, and most of the cost and the risk sit in the first two stages. A driveway is only as good as the ground and stone under it, whichever surface goes on top.

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Concrete takes longer because it has to cure and gain strength, which is why it reaches full strength at about 28 days. The base stone under either driveway can be sized with our paver base calculator or the pavement calculator.

Pros and cons

Price is only one part of the asphalt vs concrete driveway cost decision, so here is what else each material brings.

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For an eco-friendlier driveway, ask your contractor about recycled asphalt or concrete mixes with a lower cement content.

Signs it is time to replace your driveway

• Large potholes or sunken areas
• Wide, deep cracks, or web-like alligator cracking
• Standing water that does not drain
• Uneven, heaving, or crumbling edges
• Repairs that keep coming back

When repairs start costing a lot, replacement is usually the better investment. If an asphalt driveway is worn but the base is sound, an overlay can renew it for far less. You can read how in our guide to laying asphalt on asphalt.

Worked examples

Three examples of the asphalt vs concrete driveway cost for common jobs, using the ranges above.

More paving calculators

For a quick square feet to tons figure, try our main free asphalt calculator square feet page.

Frequently asked questions

Final verdict: which driveway should you choose?

On asphalt vs concrete driveway cost alone, asphalt wins at install, and it is easier and cheaper to repair. Concrete costs more at the start, lasts longer, and needs less upkeep. The right choice depends on your budget, your climate, and how long you plan to stay. Run your own numbers in the asphalt vs concrete driveway cost calculator above, then get at least two local quotes for each material before you decide.

Sources and resources

• National Asphalt Pavement Association (NAPA)
• American Concrete Pavement Association (ACPA)

Prices are planning ranges and change by region, season, and contractor. Always confirm with local quotes.