Asphalt Repair Case Studies — Commercial Projects Across the Wasatch Front
Real project scopes, timelines, and outcomes for facility directors evaluating commercial asphalt repair contractors in Utah.
Office Park — Mill-and-Overlay Completed Over Weekend, Lehi, UT
Project scope: A 6,000 sq ft primary drive aisle in a 4-building office park in Lehi had widespread surface oxidation, transverse cracking at 5-foot intervals, and rutting from delivery truck turning movements—all signs of a sound base with a failed surface course. Reconstruction was not warranted; mill-and-overlay was the correct scope. Scope: 1.5-inch mill Friday evening, SS-1h tack coat Friday night, 2-inch SP-12.5mm surface course Saturday morning, re-striping of drive aisle and accessible stall markings Saturday afternoon. Timeline: Friday 6 p.m. milling begins; Saturday 10 a.m. surface course complete; Saturday 2 p.m. striping complete; Monday 6 a.m. lot fully open. Zero tenant disruption. Total project cost: $24,600. Previous contractor had quoted $89,000 for full reconstruction—a scope rejected by the property manager who had the base cored and confirmed it was sound.
Retail Anchor — Utility Cut Restoration, Orem, UT
Project scope: A municipality-installed water main tap left a 2-foot-wide, 240-foot-long trench cut across a retail anchor's primary customer entry drive in Orem. The municipality restored with cold-mix that rutted within 60 days. Scope: Saw-cut to 4-foot width, full-depth excavation to 8 inches, aggregate sub-base replacement on 60 feet of saturated sub-base encountered mid-project, compact base, tack coat, SP-12.5mm fill in 2 lifts. Total repair: 960 sq ft. Three nights of work (access closure 9 p.m. to 5 a.m.). Final work included an ADA cross-slope check at all accessible route crossings. Documentation package provided for the property management company's subrogation claim against the municipality. Settlement: municipality reimbursed full repair cost plus documentation.
HOA Common Area — Phased Driveway Rehabilitation, Draper, UT
Project scope: A 312-unit HOA in Draper had 14 shared driveway access lanes totaling 28,000 sq ft across the complex. Pavement age: 18 years. Condition: widespread alligator cracking in turning areas (3 lanes required full-depth reclamation), transverse cracking throughout (all lanes needed crack seal), surface oxidation (all lanes needed seal coat). Phased approach to stay within HOA capital budget: Year 1—full-depth reclamation on 3 worst lanes (8,400 sq ft), crack seal all remaining lanes. Year 2—seal coat and re-stripe all lanes. Year 3—crack seal and selective patching. Budget: $87,000 over 3 years versus $210,000 for full replacement in Year 1. HOA board approved the phased plan at a regular board meeting using our 3-year projection document.
Industrial Facility — Forklift Damage Rehabilitation, West Valley, UT
Project scope: A 180,000 sq ft warehouse in West Valley had severe rutting and potholing in its primary forklift travel path—a 12-foot-wide, 400-foot-long lane running from loading dock to rack storage. Forklift tire loading had compressed the base over 12 years, creating 2 to 4-inch depressions and pothole clusters. Scope: Full-depth reclamation of the 4,800 sq ft travel path: grind existing asphalt and base, grade, compact, 6-inch Class 6 aggregate base, 2.5-inch SP-19mm binder course, 1.5-inch SP-12.5mm surface course—total 4 inches of new asphalt over enhanced base. Thermoplastic safety striping reapplied. Timeline: 4-day phased closure of the travel path, alternating halves. Facility maintained partial dock operations throughout. Outcome: property manager documented zero forklift-related surface damage incidents in 2-year follow-up.
Recent Asphalt Repairs Projects
Common Questions
- How do you handle access coordination for phased projects in occupied buildings?
- We provide a phasing plan in writing before the project begins, showing which sections close on which dates and which access routes remain open. For projects affecting ADA accessible routes, we confirm with you that temporary accessible access is maintained per ADA requirements throughout. We build our schedule around your operational requirements, not the other way around.
- What is a pavement core and when should I request one?
- A pavement core is a 4-inch-diameter cylindrical sample drilled from the pavement surface, allowing measurement of lift thicknesses and assessment of base material. Cores cost $150 to $300 each depending on depth. We recommend a core when: a contractor is recommending full reconstruction and you want independent confirmation of base condition; you are evaluating a property acquisition and need to understand remaining pavement life; or you have recurring failures in a specific area and want to diagnose the root cause.
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