Full-Depth Reclamation + Maintenance Seal: How Newport Transformed Their Roads for a Fraction of the Cost

Roads for a Fraction of the Cost

Small towns across America face the same challenge: aging roads, limited budgets, and increasing maintenance needs. The town of Newport found an answer—combining Full-Depth Reclamation (FDR) with a maintenance seal using their Asphalt Zipper® machine. The result? Dramatic cost savings, longer road life, and a smoother driving experience for residents.

From Potholes to Pavement Pride

Newport’s roads had gone years without proper maintenance. Potholes were widespread, repairs were short-lived, and the budget couldn’t stretch to traditional contractor paving—at roughly $60,000 per block. Instead, the city turned to FDR with an Asphalt Zipper machine, reusing the existing pavement and base material.

By reclaiming the old asphalt and mixing it with the underlying aggregate, crews created a stable, pothole-free foundation. Then, they applied a high-flow emulsion (HFE-150) and fully graded maintenance rock. This “autoseal” locks out water, protects the base, and extends service life 8–15 years with minimal upkeep.

Cost Savings That Add Up

• Traditional contractor cost: $60,000 per block
• Newport’s FDR + seal cost: $4,000 per block
• Savings: $56,000 per block

When scaled to 40 city blocks, that’s $2.4 million in value kept in the community—money that can go toward other infrastructure needs.

Step-by-Step Process

1. Mark & Grind – Crews identify problem areas, then use the Asphalt Zipper to grind deteriorated pavement into reusable material.
2. Grade & Compact – The reclaimed mix is spread, watered, and compacted for a solid base.
3. Seal Application – Apply HFE-150 oil and cover with graded maintenance rock.
4. Final Seal & Maintenance – After curing, chip seal and fog seal extend the life of the surface.

Performance in the Field

• Durable Base – Mixing reclaimed asphalt with local rock produces a surface “hard as a rock.”
• Smooth Finish – Results rival new pavement for appearance and drivability.
• Longevity – Preventing water intrusion means fewer potholes and less emergency maintenance.
• Ease of Operation – With basic training, operators can reclaim multiple blocks per day.

Why It Works for Small Agencies

• Uses existing materials—reducing hauling and disposal costs.
• Low equipment investment—many towns already own most of the needed tools.
• Allows municipalities to self-perform road work without waiting on outside contractors.
• Frees up budget for drainage, high-traffic areas, and other critical projects.

The Takeaway

For municipalities with limited funding and big road repair needs, Full-Depth Reclamation with a maintenance seal is one of the most cost-effective pavement preservation methods available. Newport’s results speak for themselves: better roads, happier residents, and millions in savings.

If you’re an Asphalt Zipper owner, your machine can be the key to transforming your town’s streets—without breaking the budget.