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Plano's public works department started its fifth year of ultra-thin asphalt overlay projects July 12.
The city started yearly projects in 2021 and 35% of Plano's roads have been overlaid with asphalt since.
The big picture
Drew Zaeske, the city’s Community Investment Program manager, said the city started overlay work at Legacy Drive with plans to do the same at Independence Parkway, Parker Road and Park Boulevard.
Asphalt overlays at Legacy Drive and Independence Parkway are expected to be mostly completed by mid-August, Zaeske said. He said the city’s timeline could change based on weather conditions or other conflicts.
This year’s asphalt roadwork should be completed by the end of September, Zaeske said. He said work for the four roads will cost a total of $5.4 million.
The city first piloted its asphalt overlay project on Independence Parkway in 2017. Plano Director of Public Works Abby Owens said the city is monitoring this section of the street to better understand the lifespan of the new roads.
“Instead of having to go back and do concrete repairs every eight to 12 years, our goal is to extend the life of those overlays by about 15 years, then go back, mill the overlay and do any remaining concrete repairs,” Owens said.•
Explained
Streets with cracked concrete are first repaired with concrete panels, according to city documents. An emulsion layer is then applied to the road to protect the new concrete before finally getting an asphalt overlay.
“The emulsion layer that goes underneath the overlay itself is what’s sealing the concrete and protecting it,” Owens said. “As long as we can continue to keep the water from getting in between cracks and causing it to split whenever it freezes and expands, that’s what we’re aiming for here.”
Diving in deeper
Arterial street reconstruction and overlays made up $130 million of the city’s 2025 bond funding.
Zaeske said some leftover funds from a bond approved by voters in 2021 also contributed to this year’s asphalt overlay projects.
Owens said the city’s current road repairs can cost an estimated $2.4 million per mile by using asphalt overlays, while concrete street replacement without the overlay can cost $14 million per mile.
All asphalt overlay projects have taken place at night between 8 p.m. and 6 a.m. to avoid impacting commuters, Zaeske said.
Looking ahead
Zaeske said the city has scheduled asphalt overlay projects through 2034. Parts of roadways for Communications Parkway, McDermott Road, Custer Road and Coit Road are in the process of concrete repairs so that they can receive asphalt overlays in 2027.
The city completed asphalt overlays for parts of Parker Road, Midway Road, Hedgcoxe Road, Independence Parkway and Alma Drive in 2025. Zaeske said 48 of 136 miles planned for overlays have been completed. Asphalt projects from 2026 will add another 8 miles to the total.
“As the region continues to grow, maintaining existing infrastructure is one of the most effective ways to keep people and goods moving efficiently throughout Plano,” Mayor John Muns said.
