millandfill

Mill-and-fill, also known as milling and filling, is a road resurfacing technique used to restore the surface profile and ride quality of asphalt pavements. The process involves removing a portion of the existing asphalt layer (milling) and replacing it with new asphalt material (filling or overlay). The reclaimed material can be recycled into new asphalt mixes (RAP) or disposed of, depending on local practices.

The standard sequence begins with a pavement assessment to determine milling depth and the adequacy of the underlying base. A cold milling machine removes the designated thickness from the pavement surface, producing a milled mat and a new, uniform surface. The work zone is cleaned, any necessary repairs to the base are performed, and a tack coat is applied to promote adhesion. A paving machine lays the new asphalt overlay, which is then compacted by rollers to achieve the desired density and smoothness. Traffic management measures are implemented throughout the operation.

Applications for mill-and-fill include urban streets, arterial roads, and highway segments where surface distress is primarily non-structural and a full-depth reconstruction is unwarranted. Benefits typically include reduced material use, faster completion times, and improved ride quality at a lower cost than complete resurfacing. Limitations depend on the condition of the structural base and environmental factors such as weather and traffic volume.

Environmental considerations focus on RAP recycling, dust and noise control, and proper disposal of milled material. Mill-and-fill remains one of several resurfacing options available to road authorities.