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What’s the Difference Between Overlay and Re-sheeting?
When it comes to renewing asphalt surfaces, the terms overlay and re-sheeting often get used interchangeably — but they’re not quite the same thing. Choosing the right method can affect the performance, cost, and longevity of your surface. Here’s a breakdown of the difference, and when each is most appropriate.
What is an Asphalt Overlay?
An overlay is a fresh layer of asphalt that’s placed directly over the existing surface. It’s typically used when the underlying structure is still sound, but the top layer has worn down or developed surface-level damage (like minor cracking or oxidation).
Aerial view of new street and parking construction site.
Key features of an overlay:
Usually 30–50mm of new asphalt
Surface is cleaned and may be tack-coated for adhesion
Cost-effective and quick to install
Extends surface life without full-depth removal
Best used for:
Car parks and roads with cosmetic wear or minor surface issues
Budgets that require a short- to mid-term solution
Areas that don’t need major structural work
What is Re-sheeting?
Re-sheeting involves milling or removing the top layer of the existing asphalt before applying a new one. This allows for better surface levelling, compaction, and bonding, and is often used when the old surface has started to deteriorate more significantly.
empty asphalt road in downtown of modern city during daytime. copy space for parking lot.
Key features of an overlay:
Removal of worn asphalt using a road profiler
Application of a new asphalt layer (same depth as overlay, or more if needed)
Smoother transitions at kerbs, driveways and utilities
Improves structural integrity and surface drainage
Best used for:
Heavily worn or uneven surfaces
Roads with potholes, deformation, or poor drainage
Projects that need longer-lasting results
Which one do you need?
The right approach depends on the condition of the existing surface and the long-term goals of your project.
Overlay is ideal if the base is stable and you just need a fresh, clean finish.
Re-sheeting is better when there are level issues, structural wear, or drainage concerns.
The white and yellow lines of the pedestrian crossing at the intersection of roads in the city. Road safety. Zebra road markings, crossing point of the road, traffic rules
“At Roadsafe Asphalt, we assess every site before recommending a solution — and we’re happy to walk you through the options based on your specific needs.”
Elias Mantinaos
Director of Roadsafe Asphalt
Need Advice or a Site Assessment?
Whether you’re resurfacing a car park, upgrading a shopping strip, or maintaining a council road, we can help you make the right call. Talk to one of our asphalt specialists with your project details.
