Case Study

Deep lift asphalt repairs involve removing failed pavement layers and rebuilding the asphalt structure from the base up. These works are commonly used on freeways, arterial roads and high-traffic transport corridors where surface patching alone will not resolve structural pavement failure. Roadsafe Asphalt delivers deep lift asphalt repairs designed to improve durability, ride quality and long-term asset performance.

Installing asphalt in layers (75mm, 75mm, and 50mm) allows for maximum compaction and structural integrity. If 200mm were laid in a single pass, it would be difficult to achieve the density required to prevent future rutting. Each layer is rolled and compacted individually to create a solid, unified block of pavement.

On high speed freeways, joints are the most common point of failure. We use precision profiling to create clean, vertical edges and apply a high quality tack coat (bitumen emulsion) between the old and new surfaces. This creates a waterproof seal and a smooth transition, preventing water ingress and “bumps” for motorists.

For heavy duty environments like the West Gate, we typically use high performance mixes designed for high stress resistance. This often includes larger aggregate sizes for the base layers to provide stability and a finer, polymer modified wearing course for the top 50mm to provide better grip and durability.

Safety is our primary priority. Works on the West Gate Freeway are executed under strict Traffic Management Plans (TMP), often during night shifts or scheduled lane closures. This protects both our crew and the public while ensuring we have the clear access needed to operate heavy plant equipment like profilers and rollers.

Because we use a multi layer approach, the heat dissipates more efficiently than a single thick pour. However, because of the depth, we monitor the surface temperature closely. On a freeway project, we use high compaction rollers to reach the required density quickly, typically allowing the road to be reopened to heavy traffic shortly after the final rolling is completed.

A 350 sqm area at 200mm depth involves moving a significant volume of material. By splitting the work into three distinct layers, we can maintain a continuous workflow profiling the area, then immediately following with the first base lifts. This efficiency allows us to complete large scale patching within tight night-shift windows.

Asphalt patching helps infrastructure owners maintain safe and compliant road networks while extending pavement life. Strategic asphalt repairs reduce the risk of potholes, water ingress, cracking and premature pavement failure, helping government agencies and major organisations reduce long-term maintenance costs and traffic disruption.

Government agencies and asset owners should look for contractors with proven experience in freeway asphalt works, traffic management capability, large-scale plant and equipment resources, safety compliance systems and the ability to deliver works under strict operational timeframes. Roadsafe Asphalt provides asphalt paving, reinstatement, civil works and specialised equipment hire across Victoria.