If you've followed me for any amount of time, you already know one thing about me: I don’t pretend to be something I’m not. I ask a lot of questions about things I don’t know, which is likely why I make a decent Podcast Host.
I’ve spent over two decades in the asphalt world doing sealcoating, crack sealing, striping, paving, patching, business development, and helping contractors grow. But when it comes to paving large scale, I’ll be the first to admit: I don’t have the reps behind the screed that many of you do. Because of that, I wasn’t about to sit down and act like I’m the authority on expert mat quality.
I do however, have many friends that are. So for this article, I brought in someone who is.
My friend Tyler Rugg, Operations Manager at Laurel Asphalt, lives and breathes paving every day. His crews are known for clean practices, intentional planning, and consistently strong mats… the kind of work that speaks for itself. When the editor of this magazine asked if I could come up with some insight on what can be done before the Asphalt goes down, to improve Mat Quality, Tyler was the first person I called.
What follows are his best insights. They are real, practical, and earned through experience. Advice on what crews can do before the first ton ever hits the hopper to ensure a smoother, more consistent mat.
1. Communication
The paving industry as a whole, struggles with consistent communication between their customers and crews. To eliminate this, disconnect, separate preconstruction meetings with the customer and crew are essential. Meeting with the customer eliminates any confusion prior to the job, lays out expectations for both parties, and keeps them involved throughout the process. Customer communication reduces the odds of unforeseen stoppages or delays. A preconstruction meeting with the entire crew can eliminate any questions or concerns such as the job layout, staging areas, expected quantities, foreseeable issues, drainage slopes, and the specific goal for the day. When everyone understands the plan and their role, the likelihood of producing a smooth, uniform mat increases dramatically.
2. Preparation Is Key
Proper preparation is one of the strongest predictors of a successful mat. The paver will always follow what lies beneath it, meaning any imperfection below will be recreated above. A quality gravel base must be smooth, compacted, and set to the correct slope. For overlays, the surface must be cleaned and milled where needed to ensure smooth transitions. Applying tack well ahead of paving allows for steady, consistent paving. Skipping or rushing any part of this preparation process turns an otherwise simple project into a costly and time-consuming challenge.
3. Jobsite Layout
Before a single ton of asphalt is placed, the crew should have a complete understanding of the entire layout of the jobsite, including but not limited to, the direction and sequence of paving. The perimeter must be laid out prior to marking each pass in the exact sequence that it will be paved. After everything is mapped out, walk the site again to confirm that no pass leads into an obstacle or a dead-end. Proper layout prevents bottlenecks, unnecessary handwork, and last-minute changes that compromise mat consistency.
4. Designated Cleanout and Staging Areas
Unorganized truck cleanout and staging areas are one of the most overlooked contributors to uneven mats. Establishing a designated cleanout area ensures trucks are not dropping cold material where the paver will run or where the next truck will be backing in. Proper staging areas also create order and flow amongst trucks. This minor planning will have a big impact on maintaining the smoothness and uniformity of the finished mat.
5. Reduce the Paver Operator’s Responsibilities
Paver operators should be solely focused on running the machine and maintaining mat consistency. When operators have added responsibilities for ordering material, calculating remaining tonnage, or handling logistics, these distractions inevitably affect the mat. Delegating these responsibilities to another crew member allows for timely material deliveries which create a steady, predictable material flow. This would allow the operator to maintain consistent paving speed, stopping less frequently and overall, more efficient paving.
Bonus Tip: Pull From the “Right” Plant With the “Right” Mix
The closest or cheapest plant is not always the best choice. The “right” plant is the one that can load trucks quickly, consistently, and with a mix that matches your needs for the day. If a plant is producing heavy volumes of base mix and you need a smaller amount of top mix, expect delays and potential mix inconsistencies. Also, mixes vary from plant to plant even under DOT Specifications. If your project requires more handwork, using a plant that has more fines in their mix will be helpful compared to those with a stonier mix. Selecting a plant aligned with your project’s material requirements helps maintain uniformity and reduces downtime, leading to a smoother, more quality finish.
Big thanks to Tyler for stepping in and sharing real paving knowledge from the field. Articles like this only matter when they’re grounded in actual experience, and Tyler’s insights are the kind that help crews work smarter, faster, and with better results.
Here’s to a safer, smoother, more productive paving season ahead.
