Yes, you can pave over existing asphalt, but only when the pavement beneath is structurally sound, and the site conditions support it.
The real question isn’t “Can you do it?”
It’s “Should you?”
At Burnaby Blacktop Ltd., we often see properties where an asphalt overlay was done to save money, only to fail within a few years because the wrong decision was made at the start. Understanding when an overlay makes sense and when excavation is unavoidable is what separates long-lasting pavement from expensive repeat work.
What Most Don’t Tell You About Asphalt Overlays
Most online articles oversimplify asphalt overlays as a cheaper, faster solution. What they don’t explain is that asphalt does not fail from the top down; it fails from the bottom up.
If the base beneath your asphalt is compromised, adding more asphalt on top only hides the problem temporarily. Cracks, depressions, and potholes will reappear, often faster than before.
That’s why professional contractors don’t recommend overlays blindly. We inspect, test, and evaluate first.
When Asphalt Overlay Is a Smart Solution
An asphalt overlay can be an excellent option when the existing pavement structure is still doing its job.
Overlay Is a Good Idea When:
✔ The base is stable and well-compacted
✔ Cracking is mostly surface-level (not alligator cracking)
✔ There are no widespread soft spots or settlement issues
✔ Drainage is functioning properly
✔ The pavement hasn’t been overlaid multiple times already
✔ Traffic loads haven’t increased beyond the original design
In these cases, an overlay can:
- Extend the pavement life
- Improve the appearance and safety of your asphalt
- Costs less than full replacement
- Minimizes downtime for commercial or strata properties
But only if preparation is done correctly.
That preparation includes crack routing, patching, levelling, and correcting minor drainage issues before any new asphalt is placed.
When You Must Excavate and Start Fresh
This is where many properties make the wrong call.
Full Excavation Is Necessary When:
❌ The base has failed or is pumping water
❌ There is widespread alligator cracking
❌ Potholes are deep and recurring
❌ The pavement is holding water after rain
❌ The site has poor drainage or slope issues
❌ Heavy vehicle traffic has increased (delivery trucks, garbage trucks, industrial loads)
❌ The asphalt has already been overlaid multiple times
In these situations, an overlay will not solve the problem. The new asphalt will crack along the same failure points, sometimes within a single winter.
We will sometimes recommend excavation, as this will allow us to:
- Remove unstable material
- Correct drainage at the source
- Rebuild the base to support current traffic loads
- Reset elevations properly
- Deliver pavement that actually lasts
While we understand that excavation has a higher upfront cost, it will almost always save you money in the long run (over the life of the pavement).
Drainage: The #1 Factor That Determines Overlay vs Excavation
Here’s an insight many paving contractors won’t explain clearly:
If water is trapped beneath your asphalt, an overlay will fail.
In the Lower Mainland, water is relentless. Poor drainage leads to:
- Base saturation
- Freeze-thaw damage
- Asphalt cracking from below
- Accelerated deterioration
At Burnaby Blacktop, drainage evaluation is one of the first things we assess. If water cannot escape the pavement structure, excavation and drainage correction are often required before any new asphalt is placed.
Why Burnaby Blacktop Is the Right Contractor for This Decision
Many paving contractors only do asphalt. That creates a conflict; overlays are faster and easier, so they get recommended even when they shouldn’t.
Burnaby Blacktop Ltd. is different.
We handle:
- Excavation and grading
- Drainage installation
- Asphalt paving
- Concrete work
- Long-term maintenance
Because we manage the entire process, we don’t have to force one solution to fit every site. We recommend what’s right for the property, not what’s easiest to sell.
What That Means for You:
✔ Honest assessments, not upsells
✔ Clear explanation of risks and options
✔ Solutions designed for long-term performance
✔ Pavement built for real traffic and real weather
✔ Fewer surprises and fewer repeat repairs
This is especially critical for commercial, strata, municipal, and industrial properties, where failure impacts safety, liability, and budgets.
A Realistic Way to Think About the Decision
Instead of asking: “Can we get away with an overlay?”
The better question is: “What will perform best over the next 10–20 years?”
Sometimes that answer is an overlay. Sometimes it’s partial excavation. Sometimes it’s a full rebuild.
The right choice depends on inspection, not assumptions.
So, Can You Pave Over Existing Asphalt?
✔ Yes, when conditions allow.
❌ No, when structural issues, drainage problems, or base failure exist.
Keep in mind: Making the wrong choice doesn’t just shorten pavement life; it often doubles the total cost over time.
Not Sure Which Option Is Right for Your Property?
If you’re managing a commercial, strata, municipal, or industrial property and considering paving over existing asphalt, the smartest first step is a professional evaluation.
Contact Burnaby Blacktop to schedule a site inspection.
We’ll explain whether an asphalt overlay makes sense or whether excavation is the smarter long-term investment.