Reset your pavement fast with mill and overlay
Mill and overlay resets busy lots fast without starting over. If your parking lot or roadway is rutted, cracked, or faded, mill and overlay can deliver a clean, smooth surface with less downtime and a lower cost than a full rebuild. At Asphalt Contractors, we help commercial and residential property owners across Southeast Wisconsin choose the right resurfacing strategy, complete the work on schedule, and keep traffic moving safely.
Asphalt Contractors Inc., established in 1979 in Union Grove, Wisconsin, is a full-service paving contractor with a proven track record. We design, manufacture, and install asphalt. That means better control over quality, faster turnarounds, and competitive pricing. Whether you manage a high-traffic retail center, an industrial yard, a school campus, or a multifamily community, our team can plan and deliver a mill and overlay that fits your goals and budget.
What is mill and overlay
Mill and overlay is a two-step asphalt resurfacing method. First, we mill, or grind, a measured depth of the worn asphalt surface. Then we install a new asphalt overlay on top of the milled base. The base layers and subgrade stay in place if they are sound. The result is a fresh, level driving surface that looks new and performs like it, without the cost and downtime of a full reconstruction.
This approach is ideal when the top layer has cosmetic or surface-level problems, but the underlying structure is still in good condition. By removing only what is worn and then replacing it, you get a strong, long-lasting surface and keep your lot open sooner.
How mill and overlay works
Step 1: Milling the existing asphalt
Milling removes the damaged surface with a specialized machine that grinds the asphalt to a precise depth. Typical depths range from 1 to 2 inches depending on condition, traffic load, and drainage needs. Milling can also re-establish curb reveals and correct minor elevation issues so water drains away from buildings and ADA paths.
The milled asphalt is collected and recycled. Asphalt Contractors recycles millings whenever possible, which supports sustainability and helps control material costs for our clients.
Step 2: Installing the new overlay
After milling, we sweep and tack coat the surface to promote bonding. Then we place a new hot-mix asphalt layer, compact it with rollers, and check smoothness and compaction. The new overlay often ranges from 1.5 to 2 inches. Heavier traffic areas may require thicker lifts or a modified mix for better rut resistance.
Once cooled and compacted, the surface is ready for line striping and signage. Many lots can reopen the same day or the next morning, depending on size and weather.
When to choose mill and overlay
Mill and overlay performs best when the asphalt base is still sound and the problems are mostly at the surface. Consider this option if you see the following signs.
- Widespread surface cracking or raveling without deep structural failure
- Ruts in wheel paths that need to be leveled
- Ponding or minor drainage issues that can be corrected by re-establishing slopes
- Faded or oxidized pavement that no longer holds striping
- Scattered potholes and patches covering less than 25 to 30 percent of the lot
If your lot shows extensive base failures or deep fatigue cracking, a deeper repair may be necessary. Asphalt Contractors will evaluate core samples and subsurface conditions before recommending the best path. In some cases, full-depth reclamation or pulverize and pave is more appropriate and still offers good value.
Benefits of mill and overlay for busy lots
- Speed: Crews can complete many mill and overlay projects in one to three days, depending on size.
- Lower cost: Reusing the base layers avoids the expense of excavation and new aggregate.
- Better drainage: Milling allows fine-tuned grading for improved water flow and fewer puddles.
- Quiet, smooth ride: A fresh surface reduces noise and improves customer comfort.
- Sustainability: Recycling millings reduces waste and the demand for virgin materials.
- Minimal disruption: Phased work zones keep sections of your lot open while we work.
- Curb appeal: Dark, clean asphalt and crisp striping make your property look well maintained.
Timeline: how fast can you reopen
Timing depends on size, layout, weather, and traffic control. Here is a general outline for a mid-sized commercial parking lot in Southeast Wisconsin.
- Pre-job planning and permits: 1 to 2 weeks. Asphalt Contractors will assess the site, confirm scope, and schedule crews and deliveries.
- Milling: 1 day for many lots, longer for large or phased sites.
- Cleaning and tack: Same day as milling or early the next day.
- Overlay paving and compaction: 1 day for many projects.
- Striping and signage: Same day or next morning, depending on temperatures and cure time.
- Reopen to traffic: Often same day for light traffic or next day for full use.
We can phase high-traffic areas during off-peak hours or nights to keep your business running. Asphalt Contractors coordinates with property managers to minimize disruption and set clear detour routes.
Mill and overlay cost factors
Every site is different, but several factors drive pricing for a mill and overlay.
- Square footage: Larger areas usually reduce cost per square foot.
- Milling depth and overlay thickness: More material and time affect cost.
- Mix design: Polymer modified or high-performance mixes add durability and cost.
- Access and phasing: Night work, tight areas, or complex traffic control can add labor time.
- Drainage corrections: Fine grading or curb adjustments add scope.
- Repairs before overlay: Localized base repairs or patching may be needed.
- Striping and ADA upgrades: New layouts or extra markings influence final price.
In Southeast Wisconsin, a typical mill and overlay often ranges from about 2.50 to 6.00 per square foot, depending on the items above. These are general ranges. Asphalt Contractors will provide a detailed proposal so you can budget with confidence.
Mill and overlay vs other pavement options
Mill and overlay vs sealcoating
Sealcoating protects and refreshes pavement color but does not fix structural problems, ruts, or significant cracking. Mill and overlay removes damaged asphalt and adds new structure for a longer life cycle. Sealcoating is great for maintenance between resurfacing projects, not as a substitute for mill and overlay.
Mill and overlay vs patching
Patching is targeted and cost effective for small, isolated failures. If large portions of your lot show wear, patching alone becomes inefficient. Mill and overlay delivers a uniform surface, better ride quality, and a consistent look across the entire lot.
Mill and overlay vs full reconstruction
Full-depth reconstruction removes asphalt and base, then rebuilds from the ground up. Choose this when there are widespread base failures or when major grading changes are needed. Mill and overlay saves time and money when the base is stable and only the surface is worn.
Mill and overlay vs pulverize and pave
Pulverize and pave blends the existing asphalt into the base and then adds a new asphalt surface. This can be a good middle ground when the base needs work but full reconstruction is not required. Asphalt Contractors can advise whether mill and overlay or pulverize and pave will deliver the best performance for your site.
Technical options from Asphalt Contractors
Asphalt mixes and additives
Asphalt Contractors manufactures asphalt, which lets us fine tune the mix for your traffic loads and weather conditions. For heavy truck areas, we can use a mix with higher stone content or polymer modifiers for rut resistance. For cold climates, we select binders that resist thermal cracking and improve flexibility.
Leveling and profile corrections
Milling can remove ruts and waves so the new overlay sits flat. If your lot has low areas that collect water, we can add a thin leveling course before the overlay to correct the profile. A smooth, even surface extends pavement life and reduces slip hazards.
Drainage and ADA upgrades
Mill and overlay is a good time to improve drainage and ADA access. We can adjust slopes within tolerance, grind at transitions, and coordinate with concrete crews for compliant curb ramps, truncated domes, and landing areas. Asphalt Contractors understands Wisconsin codes and can help you plan upgrades.
Line striping and traffic control
Fresh pavement deserves clean markings. We provide professional layout, striping, arrows, numbers, ADA symbols, and crosswalks. If you want to reconfigure parking counts, add loading zones, or enhance pedestrian safety, we will help redesign the plan so it fits your operations.
Our proven process
1. Site visit and evaluation
We begin with a walkthrough to assess surface wear, drainage, subgrade hints, and traffic patterns. If needed, we take cores to check base thickness and condition. Asphalt Contractors then recommends the right milling depth, overlay thickness, and any repairs needed for a long-lasting result.
2. Transparent proposal
You receive a clear scope of work, phasing plan, schedule, and price. We outline any alternates so you can weigh options for cost and performance.
3. Scheduling and communication
We coordinate with your team on timing, signage, and access. For retail centers and medical facilities, we often schedule off-peak or nighttime work so customers can continue to visit safely.
4. Safety and traffic management
Our crews set up barricades, cones, and flagging as needed. We divide the lot into zones to keep some stalls open while we work. Communication is clear and consistent throughout the project.
5. Milling, cleaning, and paving
The milling machine removes the set depth. We sweep, apply tack, and install the new overlay using calibrated pavers and rollers. Quality checks include thickness, temperature, joints, and compaction.
6. Striping and turnover
We stripe after the pavement has cooled and is ready. We walk the site with you to confirm scope, then open the lot to traffic on the schedule we set together.
Why choose Asphalt Contractors
- Experience since 1979 with thousands of paved and resurfaced lots
- Own asphalt manufacturing for better quality control and budget value
- Modern equipment for clean milling, precise paving, and smooth finishes
- Certified crews focused on safety, quality, and efficient scheduling
- Local knowledge of Southeast Wisconsin weather and soils
- Full service capabilities including concrete, site prep, and crushing
Asphalt Contractors serves Racine, Kenosha, Walworth, Waukesha, and Milwaukee counties and nearby communities. Our team is based in Union Grove and ready to respond quickly.
How long will a mill and overlay last
With proper design and maintenance, a mill and overlay can last 10 to 15 years or more. Lifespan depends on traffic loads, winter freeze and thaw cycles, drainage, and upkeep. Routine crack sealing, sealcoating on schedule, and prompt patching of isolated issues will extend service life. Asphalt Contractors offers maintenance plans to help you protect your investment.
Common questions about mill and overlay
Can you pave over my existing asphalt without milling
Sometimes, but not always. Paving without milling can raise elevations and cause drainage or trip hazards. Milling allows us to remove worn material, improve bonding, and keep curb reveals correct. We advise milling in most cases for the best long-term results.
Will I need to close my entire parking lot
Not usually. We can phase work so parts of the lot remain open. We plan traffic flows and staging areas to reduce disruption and maintain access for customers, deliveries, and emergency vehicles.
What overlay thickness is best
Many lots perform well with 1.5 to 2 inches of new asphalt. Heavy truck routes or loading zones may require thicker sections or a modified mix. We design thickness based on your site conditions and traffic.
What time of year is best in Wisconsin
Late spring through early fall is ideal because temperatures support proper compaction and bonding. We monitor weather closely to schedule work when conditions will deliver long-lasting results.
Is mill and overlay sustainable
Yes. Milling removes only the worn layer and the removed material is recycled. By reusing the base layers, mill and overlay reduces waste, energy use, and trucking compared to full reconstruction.
Can you fix drainage problems during mill and overlay
Many minor drainage issues can be corrected by milling to adjust slopes and adding level courses where needed. Severe drainage or flooding may require additional grading or drainage structures. We will include those recommendations in your proposal if necessary.
Preparation tips for property managers
- Notify tenants and customers of dates and phasing
- Post temporary wayfinding and detour signs
- Move portable items such as dumpsters, carts, and planters
- Schedule deliveries outside of active work hours
- Confirm access for emergency services and ADA parking during each phase
Asphalt Contractors provides a clear schedule and communication plan so everyone knows what to expect and when to expect it.
Get a fast, accurate quote
Ready to refresh your pavement with mill and overlay. Asphalt Contractors can evaluate your lot, recommend the right scope, and deliver a clear price and timeline. Our team has the equipment, materials, and experience to complete your project on time with minimal disruption. Contact us to schedule a site visit and get your customized mill and overlay plan. Book now and see how quickly your busy lot can look and perform like new.
From Union Grove to Milwaukee, Kenosha, Racine, Waukesha, and Walworth counties, Asphalt Contractors is your local partner for mill and overlay and full-service asphalt solutions. Let us pave the way with professional planning, quality materials, and a smooth finish that lasts.
