Before anything physical happens, there is a conversation. You get in touch, describe what you need, and we ask a few questions. Things like how big the area is, what it is going to be used for, whether there is an existing surface that needs to come up, and what sort of vehicle traffic it will cop.
For residential jobs like driveways, this is usually a pretty quick chat. For bigger projects like road resurfacing or commercial car parks, it might take a bit more back and forth to nail down the scope.
One thing people are often surprised by is that the quote stage is not just about price. A good asphalt contractor will also be looking at drainage, access for equipment, and whether the ground underneath is going to hold up. These are the things that separate a surface that lasts 15 to 20 years from one that cracks within a couple of seasons.
After that initial conversation, the next step is a site visit. This is where the contractor comes out, has a proper look at the area, takes some measurements, and assesses what is going on beneath the surface.
A lot of people skip over this step in their minds, but it is genuinely one of the most important parts of the whole process. Melbourne's soil conditions vary wildly depending on where you are. Sandy ground near the coast on the Mornington Peninsula behaves very differently to clay-heavy soil in the eastern suburbs. The type of base preparation needed, and the thickness of asphalt required, changes depending on what the ground is doing.
During this visit, a contractor worth their salt will also check things like existing drainage, nearby trees with invasive root systems, and how stormwater currently flows across the site. If your driveway slopes toward the house rather than away from it, that is something that needs to be addressed before any asphalt goes down.
You will get your quote after this visit. It should include the scope of work, the materials to be used, the estimated timeline, and the total cost. No hidden extras, no vague line items.
Once you accept the quote, a date gets booked. For smaller residential jobs, this might be just a week or two out. Larger commercial and industrial projects may need more lead time, especially if council approvals or traffic management plans are involved.
Here is something that rarely gets talked about: what you need to do before the crew arrives. For homeowners, that usually means moving cars off the driveway, pulling wheelie bins out of the way, and making sure there is nothing blocking the area. If you have garden beds right up against the driveway edge, it is worth pulling any loose soil or mulch back a bit so the crew has a clean edge to work with.
For schools, there is a bit more planning involved. Most school ground projects are scheduled during holidays or over weekends so there is zero disruption to students and staff. We work closely with principals and facility managers to make sure the timing works and that the right areas are fenced off.
For businesses, the big question is always about customer access. If you are getting a car park resurfaced, that might mean doing the work in stages so half the car park stays open at any given time. It is all about communication, and a good contractor will have a plan for this before the job starts.
If there is an existing asphalt, concrete, or gravel surface, it needs to come up first. This is where the heavy gear arrives — a bobcat, sometimes a small excavator, and a tipper truck or two. The old material gets ripped up, loaded onto trucks, and taken away. In many cases, old asphalt can be recycled, which is a nice bonus for anyone who cares about keeping waste out of landfill. This stage can be noisy — there is no getting around it. For most residential driveways, the removal is done within a day. Bigger commercial projects can take a couple of days.
Once the old surface is gone, the area needs to be graded so that water runs off the surface and does not pool. Proper grading is the single most important factor in how long your asphalt will last — pooling water is what leads to cracks, potholes, and premature failure. The crew uses laser-guided equipment to make sure the falls are correct. For driveways, the surface should slope gently away from the house. For car parks, water needs to flow toward drainage pits or the street. For pathways and footpaths, crossfalls are set to minimise tripping hazards and ensure accessibility. Any soft or waterlogged spots are dug out and replaced with stable fill material before anything else goes on top.
The sub-base is the layer of compacted crushed rock that sits underneath the asphalt — the foundation of the whole surface. Typically it is around 100 to 200mm of crushed rock, compacted in layers using a vibrating roller or plate compactor. The thickness varies depending on the ground conditions and how much traffic the surface needs to support, so a residential driveway needs less than a busy car park handling delivery trucks. This step should not be rushed — if the sub-base is not compacted properly, the asphalt on top will move over time and you will end up with an uneven surface.
A truck arrives with hot asphalt mix — crushed rock aggregate, sand, and bitumen, the black, sticky binder that holds it all together. The mix leaves the plant at around 150 to 160 degrees Celsius and needs to be laid while it is still hot and workable. It is spread across the prepared surface, either by hand for smaller or tighter areas, or using a paving machine for larger jobs. The crew works quickly because asphalt cools fast, especially during Melbourne's cooler months. For a standard residential driveway, the asphalt goes down in about a day, sometimes just a few hours.
Once the asphalt is spread, it gets compacted with a heavy roller, which gives the surface its density and strength. The roller passes over the surface multiple times, squeezing out air pockets and locking the aggregate together. You will notice the surface go from a rough, textured finish to a smooth, uniform look as the roller does its work, with edges and tight spots finished off with a smaller plate compactor. This is also where the contractor checks levels one more time, addressing any low spots before the asphalt sets.
After rolling, the crew tidies up transitions where the new asphalt meets existing surfaces like concrete kerbs, garage floors, or older pavement, so there is no bump when driving or walking across them. The site gets a thorough clean, with any loose material, debris, or equipment removed. For jobs that include speed humps, line marking, or edge treatments, these are typically completed after the asphalt has had a chance to cure.
This is the question everyone asks, and the answer depends on the season and the size of the job.
In most cases, you can walk on new asphalt within a few hours. Light vehicle traffic is generally fine after 24 to 48 hours. However, the surface continues to cure and harden over the following weeks. During the first month, you should avoid parking in the same spot for extended periods, as the weight can leave impressions in the surface while it is still settling.
Melbourne's weather plays a role here too. In summer, asphalt stays softer for longer because the heat keeps it pliable — you might notice slight tyre marks on very hot days during the first season, and that is completely normal. In cooler weather, the surface firms up faster.
If it rains shortly after laying, do not panic. Once the asphalt has been compacted and rolled, light rain will not damage it. Heavy rain during the actual laying process is a different story, which is why experienced contractors keep a close eye on the forecast and will reschedule if conditions are not right.
Possibly. If garden beds are right next to the work area, there might be some minor disturbance. We always try to minimise impact, but it is worth moving any prized plants or delicate border edging before the crew arrives.
Yes, freshly laid asphalt has a distinct bitumen smell. It is strong on the day of laying but fades within a day or two. If you are sensitive to strong smells, you might want to keep windows closed on that side of the house while the work is happening.
Not during active rainfall. The asphalt needs to bond with the base properly, and water on the surface prevents that from happening. A light shower after the surface has been compacted is fine, but laying in the wet is not something any reputable contractor will do.
This is a big one, especially in established suburbs. If tree roots have already damaged an existing surface, they will do the same thing to a new one unless the issue is addressed. Sometimes that means removing the root, sometimes it means adjusting the design. Either way, it is better to deal with it upfront than pretend it does not exist.
For most residential driveways, no. But if the work involves a crossover — the section between your property and the street — you will likely need council approval. For commercial projects or anything on council land, permits are standard. Your contractor should be able to guide you through this.
With proper installation on a solid base, a well-laid asphalt surface can last 15 to 20 years or more. Regular maintenance, like fixing small cracks early and keeping drainage clear, will push it toward the longer end of that range. If you ever need repairs or resurfacing down the track, that is always an option too.
We have been doing this for over 30 years across Melbourne, and one thing we have learned is that people do not just want a good result. They want to understand what is happening and why. They want to know that the crew showing up at their house knows what they are doing, that the materials are right for the job, and that they are not going to be left with a mess or a surface that falls apart in two years.
That is exactly why we wrote this guide. Because if you understand the process, you can ask the right questions, make better decisions, and feel confident that you are getting value for money.
If you are thinking about a new driveway, car park, footpath, or any other asphalt surface, give Mike a call on 0411 412 707 or get in touch with us online. We are happy to walk you through the process for your specific project, provide a free quote, and answer any questions you might have. No pressure, no jargon, just straight talk from people who have been laying asphalt across Melbourne's south-east, the Mornington Peninsula, and South Gippsland for three decades.
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