New asphalt driveway crumbling

[JimR1998]

Light loads continue to make holes/imprints in my driveway and now the top layer of aggregate is starting to flake off where we park.

Contractor at first seemed like he would stand behind it but now he's back to saying "it's normal". "Any point load will leave a hole especially if it is sunny." He said it will need to go through winter to harden before he can patch and seal. He showed me a pamphlet from the Asphalt Press Industry that said similar: it is normal for kickstands to cause holes (from a kids bike not a motorcycle). Turning tires is also not good for it, per the book. It's a freaking driveway!!! Asphalt Press link

I'm not sure they are the end-all for asphalt information.

To get it tested will cost $600+ and I didn't buy any DOT-spec mix so there's nothing for it to pass or fail.

This was a $10k+ job and will cost even more to mill out and replace without disturbing perimeter cobblestones. He can't overlay because the level will be too high. Are there any other valid remedies?

I may take him to court. Is there anything objective I can point to besides pictures to illustrate the job is defective? Does it sound like I am being picky? The stones are highly annoying as they track inside and my dad has a walker and they get stuck in the wheels.

Driveway Pics

 

[58Yeoman]

I'm no expert, but that looks awfully rough for a new driveway.

 

[Bigblockyeti]

What was the total asphalt volume put down? How was the substrate compressed? Was the asphalt laid in multiple lifts and rolled between? What was the weather like when it was laid? How long ago was it laid?

 

[JimR1998]

What was the total asphalt volume put down?

2.5" of asphalt. The job size was 3 tri-axles for about 5000 sqft.

How was the substrate compressed?

Substrate was a solid binder base that was there for 10 years. The binder base was thick and had no problems even with heavy cement mixers over the years so I don't think that's the issue. They basically laid this on top. The main purpose was to get a smoother more uniform surface.

Was the asphalt laid in multiple lifts and rolled between?

Single lift rolled but they did not use the vibration setting. Some sections where they could not get the roller were hand tamped. And one section they shoveled down asphalt and rolled/tamped without using the screw machine to apply.

What was the weather like when it was laid? How long ago was it laid?

Chilly in the morning, about 40 degrees. Plant is 30 mins away. Warmed up to about 60. They hosed down a section with water right after laying it to test for drainage.

Also right at the start of Covid (April 1) and the plant was running on a low volume, per the contractor.

 

[jshillin]

That looks really rough. Doesn't look like a finish coat at all.

The rest of the questions I had were just answered at the same time...

 

[Ralf11]

does your state have any time limits on when you can file a complaint against a contractor?

either in court or an administrative complaint with a licensing agency -

 

[mcj115]

I live in the Harrisburg area and had my driveway resurfaced the second week in April....so similar timeframe and climate.

It is true that turning wheels and bicycle kickstands can mar the surface. I have two spots on my drive from when my wife and parents turned their steering wheel while stationary' but those areas have almost healed themselves in the direct summer sun.

But your paving job looks poor. I have zero aggregate coming loose. While not an expert that appears to be lack of compaction when first laid.

The new surface of my drive of approx 3100 sqft ran approx 4k with a little milling added in.

 

[joey1320]

Not knowing much about asphalt other than what i see from parking lots and such, that looks really poor. I wouldn't be happy with it, that's for sure.

 

[BillK]

That almost looks like asphalt millings instead of actual "asphalt" ???? The original asphalt driveway here at my house looked better than that when it was 25 years old !! I would see if you can get a second opinion from another contractor or maybe even ask someone from the plant to come and look at it for you. That is just plain terrible.

 

[Bigblockyeti]

Based on the answers, I agree to one of the former posts, looks like inadequate compaction. The binder could be suspect but without any specs as to what it was supposed to be, it would be difficult to be out of spec.

 

[PassnThru]

Yeah - that's pathetic. I've had my driveway repaved and it looked better before it was done than yours does right now. It literally looks like they didn't compact at all.

 

[Showkey]

Agree the driveway is a mess. It’s NOT suppose to do that........

From the link below looks like RAVELING..........

Have you ever walked through a parking lot and noticed loose gravel and grit? If so, you have likely seen raveling first hand. Raveling is the breakdown of pavement by the loss of asphalt and rocks.

https://murphreepaving.com/8-common-asphalt-pavement-issues-and-how-to-fix-them/

Link to asphalt grades:

https://www.allstarpaving.com/are-there-different-types-of-asphalt-and-if-so-what-should-i-use/

 

[575cat]

Ya just millings compacted .

 

[kaymccampbell]

It looks like insufficient binder, cold product, insufficient compaction, at the least. There is a huge cold joint running up the middle, that should have been addressed during application.
After seeing that about 30% of asphalt jobs are done correctly, I decided to go the crusher run route.
My sympathies.

We had two jobs done across the street from each other in our neighborhood recently.
The new truck gypsies on one side. An established municipal paving contractor on the other. Both drives cost within $1000 of each other. You can see the difference, just driving by. The gypsy job reflects all your ills, and has one car, that leaves the drive once a week. The other one has a fleet of vehicles in and out daily, including UPS trucks. It looks good.

 

[JimR1998]

It looks like insufficient binder, cold product, insufficient compaction, at the least. There is a huge cold joint running up the middle, that should have been addressed during application.

The binder is the tar/liquid in the mix, right? It looked tarry and was steaming when they applied it. Nothing struck me as improper in the installation but I don't really know what to look for.

I guess I was expecting a more uniform, consistent finish. Some areas of the driveway are larger pebble aggregate and a few feet away they are very tiny almost like sand.

A few questions:

What should I be looking for when this gets fixed? How should the joints be handled? Is it OK to stop when the truck runs out, get more, come back and restart? Or do they need multiple trucks to keep the job going? Should I be checking temp as the mix is laid? Should they use the vibratory setting? What mix should I request or am I at the mercy of what's being produced at the plant that day? How uniform should the finish be?

I hate having to watch contractors. When we had concrete done I micromanaged the process BUT it's perfect 10 years later. I feel like that's easier to understand than asphalt.

 

[doctordirt]

Asphalt comes in different mixes. The mixes have different stone sizes, type of stone, and types and amounts of binder. This looks like a relatively course mix, more as what would be applied to a road or street. I would recommend placing a leveling course over the existing, however unfortunately you do not have the elevation to do so. You will probably have to live with it or tear it out and start over.

 

[Lassen Forge]

To my uneducated eye it looks like the AC was too cold when they put it down, and was already curing before they rolled it. I'd bring out the grinder, get rid of that mess, and have it redone. Sure, virgin AC is soft when it's new, and a bicycle certainly can put punchholes in it, but this isn't just soft, it's raveling. As Kay mentioned, there's a cold joint in the middle...

For ten grand I probably wouldn't be happy either.

 

[jack stand]

I didn't read all the posts, but he either let the mix get way too cool for proper compaction. Bought some junk mix, or both. Are home improvements a state regulated (licensed) activity?
Yes newly placed asphalt is 'tender' and point loads such as kick stands, floor Jack's, etc can and will deform the surface, that will diminish after a few cool evenings but in the blazing sun, turning (steering) your vehicle tires while stopped can damage it for quite a while. This guy screwed you.
The test will give you the compaction and the makeup of the mix, basically evidence, the question is does the guy have insurance or the ability financially to dig that **** out and do it right. Then you'll have attorney costs on top of the testing. Sorry man!

 

[nadogail]

IMHO, If your contractor does not fix that driveway; your next call is to the appropriate Contractors License Board.

You did use a licensed contractor, didn't you?

 

[johninct]

I am not an expert but things that should be done are:
2 courses
10 ton roller ( NOT EQULAVENT)
Done on a warm day

 

[bradpac]

IMHO, If your contractor does not fix that driveway; your next call is to the appropriate Contractors License Board.

You did use a licensed contractor, didn't you?

In most other states, licensed contractors don't exist for most trades.