Searching for asphalt overlay Burlington WI insights you can trust? You are in the right place. This guide compares asphalt overlays with mill and pave, breaks down real-world costs, explains expected lifespans, and shows you how to spot failure signs before small issues become large repairs. As a local leader, Armored Asphalt helps homeowners and businesses choose the right fix for driveways and parking lots across southeast Wisconsin and northeast Illinois. Read on for expert tips, then request a free on-site quote.

Asphalt Overlay Explained

An asphalt overlay is a new layer of hot mix asphalt installed over an existing paved surface. Before overlaying, a contractor cleans, repairs cracks and potholes, applies a tack coat for bonding, and then places 1.5 to 2 inches of fresh asphalt. Overlays renew the surface, restore smoothness, and add years of service when the underlying base and asphalt structure are still sound.

Mill and Pave Explained

Mill and pave involves grinding off a set depth of the old asphalt with a milling machine, repairing any base failures, then installing new asphalt. Mill and pave is more comprehensive than a simple overlay and is chosen when the old surface has widespread cracking, rutting, or drainage problems. Milling also allows the new surface to match curbs, garage slabs, and door thresholds without creating trip hazards or ponding water.

Which One Do You Need

If your pavement has a stable base, limited cracking, and acceptable drainage, an overlay is often the faster, more budget-friendly option. If you see structural damage, frequent puddles, or height conflicts around curbs and transitions, mill and pave is the better long-term solution. Armored Asphalt evaluates both options on-site so you can make a confident decision.

Every property is unique, but you can use these ranges to plan. Pricing varies with project size, asphalt thickness, repairs required, access, and current material costs in southeast Wisconsin.

• Asphalt overlay: usually 2.00 to 5.00 per square foot for residential driveways and light-duty lots, depending on prep and thickness
• Mill and pave: usually 5.00 to 12.00 per square foot for similar areas, based on milling depth, base repairs, and mix design
• Small driveways with minimal repair fall near the low end of each range
• Commercial parking lots with milling, patching, and striping trend higher
• Drainage corrections, leveling courses, and undercut repairs can add to either option

These are planning ranges, not quotes. Armored Asphalt provides written estimates after a site visit, including line-item details for milling, patching, thickness, crack fill, sealcoating, and striping if requested.

How Armored Asphalt Builds a Fair Quote

Our team inspects the existing asphalt thickness, base condition, drainage patterns, and traffic use. We note critical transitions like garage floors and curb lines. Then we tailor the scope to your goals, whether that is best value, longest life, or a phased approach. Clear pricing plus flexible scheduling helps homeowners and managers plan around operations and seasons.

In Burlington and the surrounding freeze-thaw climate, asphalt performance is tied to seasonal cycles, maintenance, and traffic loads. Expect these typical lifespans when the surface is properly designed and maintained.

• Asphalt overlay: about 7 to 15 years
• Mill and pave: about 15 to 25 years
• Residential driveways with light traffic often last longer
• Busy commercial lots or heavy truck areas trend toward the lower end
• Annual crack filling and periodic sealcoating can significantly extend life

An overlay does not fix a failing base. If the underlying aggregate or subgrade is weak or saturated, an overlay may look great for a year or two but then fail prematurely. Mill and pave lets crews address structural issues and control surface elevations for better drainage, which is vital for long-term durability in Wisconsin winters.

• Alligator cracking that looks like reptile skin or a shattered pattern
• Rutting where tires have worn grooves that hold water
• Heaving or settlement from freeze-thaw cycles or poor subgrade support
• Pumping of water or fines through cracks or joints
• Widespread potholes and patches that keep returning
• Drainage problems that leave puddles for hours after rain
• Surface already too high against garage slabs, curbs, or doors
• Severe edge failures along driveways or lot perimeters

If you see two or more of these signs, an asphalt overlay is likely a temporary fix. Armored Asphalt will recommend milling and base repair so you invest once and avoid repeated short-term patches.

• Existing asphalt is mostly stable with limited cracking
• Base and subgrade are firm and drain well
• No height conflicts at curbs, sidewalks, or threshold transitions
• Only minor puddling that a leveling course can correct
• Budget and timeline favor a quick upgrade

For many Burlington WI driveways and light-duty parking lots, asphalt overlay is a cost-effective refresh that looks new and rides smooth. Armored Asphalt can also mill just at tie-in areas to manage height while overlaying the main surface.

Asphalt Overlay Steps

1. Inspect and mark repair areas
2. Clean and blow off the surface to remove dirt and debris
3. Complete full-depth patches where needed
4. Fill cracks with rubberized crack seal
5. Apply tack coat for secure bonding
6. Place a leveling course where needed to correct low spots
7. Install the overlay, typically 1.5 to 2 inches
8. Compact with steel and pneumatic rollers for proper density
9. Transition at aprons, sidewalks, and drains
10. Stripe commercial lots after cure if included

Mill and Pave Steps

1. Mill off 1.5 to 3 inches or more as specified
2. Clean milled surface thoroughly
3. Repair soft spots and base failures
4. Adjust drainage, inlets, or slopes if needed
5. Apply tack coat
6. Place binder course where specified for structure
7. Place surface course for smooth ride and appearance
8. Roll to density and check joints
9. Fine-tune transitions at curbs and thresholds
10. Stripe after proper cure

Most residential overlays take a day. Mill and pave can take one to three days depending on size and repairs. Armored Asphalt stages work to keep access open whenever possible and communicates schedules up front.

• Driveways: Lower traffic, but garage thresholds and sidewalk transitions matter. Overlays are common if height can be managed and the base is stable.
• Parking lots: More traffic and turning forces at entrances and aisles. Milling is often used to control elevations and extend life, especially at loading zones or dumpster pads.
• Drainage: Wisconsin snow melt and spring rains make slope design critical. Milling gives precise control of water flow to reduce ice and ponding.

1. Crack filling: Each fall before freeze to keep water out of the base
2. Sealcoating: Two coats starting about 12 months after paving, then every 2 to 3 years
3. Pothole patching: Address quickly to prevent spreading
4. Winter care: Use proper deicers and a plow with a rubber edge when possible
5. Striping: Refresh lines to improve safety and reduce surface wear

Armored Asphalt offers complete maintenance services, including hot mix patching, cold patching in winter, rubberized crack filling, two-coat sealcoating, and pavement striping for commercial lots. Our maintenance plans help your new overlay or mill and pave reach its full lifespan.

• Myth: An overlay fixes any pavement problem. Fact: Structural failures, drainage issues, and base problems often require milling and repair.
• Myth: Thicker is always better. Fact: Thickness must match base strength and use. Poor base plus thick asphalt still fails.
• Myth: Sealcoating replaces paving. Fact: Sealcoat protects and extends life but does not add structure.
• Myth: You must wait all summer to pave. Fact: With the right temperatures and dry conditions, spring through fall works well in Burlington WI.

How much does an asphalt overlay cost in Burlington WI

Most overlays run 2.00 to 5.00 per square foot depending on repairs, thickness, and site access. Mill and pave typically costs 5.00 to 12.00 per square foot. Armored Asphalt provides free written quotes so you know exactly what is included.

Will an overlay fix drainage problems

Minor puddles can be corrected with a leveling course. If water stands in several areas or slopes toward buildings, milling and regrading is the better fix. Proper drainage is essential for long life in our freeze-thaw climate.

How long does a new overlay or mill and pave last

Overlays typically last 7 to 15 years with regular maintenance. Mill and pave can last 15 to 25 years. Actual life depends on traffic, base strength, and care.

Can you overlay over cracked asphalt

Yes, if cracks are limited and the base is stable. We will fill cracks with rubberized sealant before the overlay. If you have widespread alligator cracking, we recommend milling and base repair.

How soon can I drive on a new surface

Light vehicle traffic is often allowed within 24 hours for overlays in warm weather. For mill and pave, timing varies by thickness and temperature. Armored Asphalt will provide clear guidance for your project.

Do I need a permit

Most private driveways do not require a permit, but commercial work or changes to aprons and approaches may need municipal approvals. Armored Asphalt helps you navigate local requirements.

What thickness is best

Residential overlays are often 1.5 to 2 inches. Mill and pave can include a 1.5 to 2 inch surface over a binder course for added strength. We match thickness to your use and budget.

Can you pave in cooler months

Yes, within limits. Asphalt placement needs proper temperatures and dry conditions for compaction and bonding. We schedule around weather to protect quality.

• Local expertise: Based in Kenosha and experienced with Burlington WI soils, freeze-thaw cycles, and municipal standards
• Comprehensive services: Paving, patching, pothole repair, crack filling, sealcoating, and parking lot striping
• Quality materials: High-grade mixes and rubberized crack fill for durable results
• Two-coat sealcoating: Helps your pavement last twice as long between sealing
• Clear communication: Detailed scopes, itemized pricing, and dependable scheduling
• Commercial snow plowing: Winter services in Kenosha, Pleasant Prairie, and Racine to protect your pavement investment

Armored Asphalt is a customer-focused team that treats your property like our own. From small driveway overlays to full mill and pave projects for busy parking lots, we deliver workmanship that stands up to Wisconsin weather.

Service Areas

Armored Asphalt proudly serves southeast Wisconsin and northeast Illinois, including Burlington, Kenosha, Pleasant Prairie, Paddock Lake, Salem, Union Grove, Yorkville, Raymond, Caledonia, Mount Pleasant, Sturtevant, Racine, Winthrop Harbor, Zion, Beach Park, Waukegan, and Gurnee.

If your pavement is mostly sound and you want a fast, budget-friendly refresh, asphalt overlay Burlington WI projects often deliver great value. If your lot shows structural cracking, rutting, or height and drainage issues, mill and pave is the smarter investment. The right choice comes from a careful site inspection and a clear plan for repairs, thickness, and slope.

Armored Asphalt will evaluate your base, advise on risks, and present options. We explain the tradeoffs so you can choose a solution that fits your timeline and budget while protecting long-term performance.

Ready to compare asphalt overlay Burlington WI with mill and pave for your property? Contact Armored Asphalt for a no-pressure inspection and detailed estimate. Call (262) 515-4150 or email armoredsealcoating@gmail.com. Our team will review your goals, measure your site, and recommend the best approach for lasting results.

Whether you need a smooth new driveway, a refreshed parking lot with crisp striping, or a full mill and pave to correct drainage and structure, Armored Asphalt is here to help. Protect your pavement, enhance curb appeal, and stretch your budget with a plan tailored to your property.

Request your free quote today and see why Burlington homeowners and facility managers choose Armored Asphalt for paving, maintenance, and year-round care.