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Premium Commercial Tarmac Surfacing & Asphalt Paving Services
Most commercial asphalt fails within seven years because it’s built to car park specs, not commercial realities. We engineer yours for actual loads and install it without shutting your site down.
Commercial sites need engineering, not guesswork
Delivery vans all day. Articulated lorries turning tight. Forklifts loading pallets.
Standard asphalt can’t handle it. Within five years, you’re looking at rutting, cracking, and emergency repairs eating your maintenance budget.
The problem isn’t the asphalt itself. It’s the specification underneath it.
Commercial tarmac surfacing, built to last...
Pavement thickness calculated from actual vehicle counts. Sub-bases engineered for HGV stress. Polymer-modified binders that flex under load instead of cracking.
We deliver this across the South West, South Wales, and Thames Valley. Full lifecycle service from ground investigation through to Section 38 adoption sign-off, all backed by NHSS accreditation and our ISO quality standards.
What we can deliver for your site...
Why commercial asphalt fails early (and what it costs you)
The tarmac/asphalt mistakes that destroy surfaces
- Inadequate pavement thickness for actual traffic loads (design based on assumptions, not reality)
- Weak or unstable sub-base allowing settlement and rutting
- Wrong asphalt specification for vehicle types (car park spec under HGV traffic)
- Poor compaction creating voids that allow water infiltration
- Insufficient drainage causing base erosion and accelerated failure
- Soft binder grades that can't handle heavy turning shear
- No maintenance programme allowing minor cracks to become structural failures
The real-world impact...
There's a better approach...
Tar and chip surfaces engineered for whole-life value
Design for reality, not standards
We measure what’s actually using your site. Then engineer accordingly.
Traffic-matched specifications:
ESAL methodology calculates your exact loading from vehicle counts and weights. Pavement designed for proven demand, not textbook assumptions. HGV-rated where needed, standard commercial where appropriate.
Tarmac that lasts 15-25 years, not 5-7:
Polymer Modified Bitumen extends life 40-60% versus standard binder. CBGM foundations prevent base failure. Three to five times longer service life. Lower annual cost despite higher upfront.
Operational continuity guaranteed:
Phased delivery maintaining partial access. Night-shift installation for 24/7 sites. Traffic management keeping you operational. Most projects: operational within 48 hours.
Fixed-fee certainty:
Know total cost before we start. Budget accurately. No provisional sums. No surprises from "unforeseen conditions" (our ground investigation finds them first).
Compliance documentation included:
Test certificates proving compaction. CE-marked materials. As-built surveys. Everything needed for Section 38 adoption or building control sign-off.
Rapid emergency response:
Safety-critical damage fixed within 48 hours. Permanent hot-mix repairs, not patches. Minimise downtime, protect reputation.
Why developers and contractors choose Highways Plus
Budget certainty. Programme confidence. Regulatory compliance.
Your asphalt isn’t decorative. It’s load-bearing infrastructure that must perform for 20 years.
What sets us apart
We engineer for actual loading, not guesswork:
Calculate your site’s ESAL from real vehicle data. Design pavement thickness accordingly. Not generic car park specs under HGV traffic.
NHSS accreditation and ISO standards:
Full compliance shield for Section 38/278 adoption work. ISO 9001 (quality), 14001 (environmental), 45001 (safety). Your technical approval simplified.
Polymer-modified binders as standard on heavy-duty work:
PMB extends life 4-6 years versus conventional bitumen. Proven in ports and logistics. 90%+ fuel resistance. We specify it where it matters.
Phased delivery maintaining operations:
Keep your site partially open during works. Chapter 8 traffic management. Stakeholder comms sorted. Done in days, not weeks.
Complete lifecycle service:
Ground investigation, design, Section 278 approvals, installation, adoption management. One partner, one point of accountability.
Fixed-fee adoption packages:
Backlog Defect Resolution service clears Section 38 defects for predictable cost. Bond release accelerated, capital unlocked.
Methodical process, zero surprises
We offer… clear programmes, transparent costs and minimal disruption on every commercial tarmac surfacing and asphalt paving project.
What you get...
Phased delivery where operationally critical – sections done sequentially, maintaining access.
Timelines: 2-3 days for overlay resurfacing (per 1,000sqm), 5-10 days for full reconstruction with drainage, 8-16 weeks for new-build including Section 38 approvals.
Site investigation and traffic analysis:
CBR testing determines ground strength. We count your actual HGV movements, measure axle loads, calculate ESAL. Design matched to proven demand, not assumptions.
Specification and fixed-fee proposal:
Written engineering spec showing pavement build-up, material grades, compaction requirements. Fixed price including contingencies. You know total cost before we mobilise.
Approvals and traffic management:
Section 278 applications if needed. Chapter 8 traffic plans. Stakeholder notifications. Utility diversions coordinated. Programme agreed with minimal operational impact.
Surface preparation and foundation works:
Existing surface milled or removed. Sub-base tested and reinforced where needed. Drainage installed or upgraded. Foundation right before asphalt goes down.
Asphalt installation and quality control:
Machine-laid or hand-laid to specification. Nuclear density gauge verification during compaction. Material test certificates. Light traffic: 24 hours. Full HGV loads: 48 hours.
Handover and documentation:
As-built surveys. Compaction test results. Materials certification. Maintenance schedule. Everything needed for adoption sign-off or building control approval.
Commercial tarmac surfacing CASE STUDY
Logistics distribution centre yard, Thames Valley
The Challenge:
15,000sqm yard serving 24/7 operations. Seven years old, already failing. Extensive rutting in turning areas from continuous artic traffic. Water pooling in three zones causing ice hazards in winter.
Operations director facing £200k+ emergency reconstruction but couldn’t afford extended closure – single day shutdown meant £30k revenue loss from missed shipments.
Previous contractor had spec’d standard AC14 binder (suitable for retail car parks, not HGV yards). Sub-base inadequate for continuous turning shear.
Our Solution:
Traffic analysis showed 40+ articulated movements daily, concentrated turning stress in loading zones. Designed heavy-duty spec: PMB Stone Mastic Asphalt surface course, AC20 dense base, 300mm CBGM foundation.
Phased reconstruction over 18 days working night shifts (7pm-6am). Site maintained 70% operational capacity throughout. Enhanced drainage with slot drains positioned along wheel paths.
Full compaction verification with nuclear density gauges. Materials CE-certified. As-built documentation for lease compliance.
The Outcome:
- Completed in 18 nights (19-night programme) - one day early
- Zero operational shutdowns - 70% capacity maintained throughout
- Surface now rated for 20+ year design life versus seven-year failure
- Drainage eliminated - no pooling even in 50mm/hour storms
- £487,000 total (£32.47/sqm including night premium) - 20-year solution versus £15k+ annual patching on failed surface
Proven delivery of commercial tarmac surfacing across diverse sectors
Different operations, different loading patterns. Same need for surfaces that perform without constant intervention.
Sectors that rely on us:
Logistics and distribution:
Extreme heavy-duty for continuous HGV traffic. PMB specifications for turning shear. Fuel-resistant surfaces in refuelling zones. Night-shift delivery maintaining 24/7 operations.
Industrial estates and manufacturing:
Mixed commercial traffic surfacing. Reinforced loading bay areas. Chemical-resistant specifications for process industries. Phased delivery maintaining tenant access.
Port and marine terminals:
Engineered for reach-stackers (90-tonne static loads). Shear-resistant SMA for tug routes. Saltwater-exposure specifications. Coordination with vessel schedules.
Retail and commercial property:
Aesthetic finishes handling high volumes. Rapid turnaround during off-peak periods. Compliant disabled access. Professional line marking to BS standards.
Public sector and highway authorities:
Section 38/278 compliant installations. DMRB design methodology. SHW specification adherence. Full adoption documentation package.
Development and construction:
Project enabling works and site preparation. Section 278 junction alterations. Adoption management for estate roads. Fixed-fee backlog defect resolution.
Your Commercial tarmac surfacing questions, answered...
How long does commercial asphalt actually last?
Properly engineered for commercial traffic: 15-25 years with routine maintenance (seal coat every 3-5 years). Standard domestic-grade under commercial loading: 5-7 years before structural failure. Depends on sub-base specification, asphalt thickness, traffic type, and maintenance. We engineer for your actual usage, not generic standards.
What's the difference between AC10, AC14, and AC20 specifications?
Numbers indicate aggregate size: AC10 uses 10mm stone (surface courses), AC14 uses 14mm (binder courses, medium traffic), AC20 uses 20mm (base courses, heavy structural loading). Larger aggregate distributes load better but creates coarser finish. We select appropriate grades for each layer based on your traffic analysis.
Do you need to close my site during works?
Not entirely. We phase delivery – work one section whilst others remain operational. Most clients maintain 60-80% capacity during works. For 24/7 operations, we work night shifts with daily handovers. Complete closures only needed for very small sites where phasing isn’t practical.
What's Polymer Modified Bitumen and why does it matter?
PMB adds polymers to standard bitumen, making it harder and more flexible. Benefits: 40-60% longer service life, 8x better fatigue resistance, superior performance under HGV turning shear, 90%+ resistance to fuel/hydraulic spills. Costs 10-15% more upfront but recovers premium within 8-10 years through extended life and reduced maintenance.
How do you handle drainage during resurfacing?
Assess existing drainage during survey – measure falls, check gully positions, identify pooling zones. Solutions: improve surface falls (minimum 1:80 gradient), add gullies where needed, install slot drains in high-stress areas, integrate SuDS where required. All coordinated with asphalt installation – ironwork adjusted to match new levels.
Can you work with Section 38 adoption requirements?
Yes. This is core work for us. We design to DMRB standards, specify to SHW clauses 900-950, provide full compaction testing (minimum 6 cores per 1,000sqm), deliver as-built surveys, manage the 12-month maintenance period, and coordinate inspector sign-off. Our Backlog Defect Resolution service also clears existing adoption barriers.
What testing do you provide?
Nuclear density gauge verification during laying (targets ≥98% compaction, ≤3% voids above spec). Core sampling for density, voids, and binder content (6+ cores per 1,000sqm). Layer thickness verification. CE certification for all materials. Marshall stability testing for designed mixes. Full documentation package at handover.
How quickly can you mobilise?
Standard commercial projects: 10-14 days from order to start (allows approvals, traffic management, stakeholder notifications). Emergency repairs: on site within 24 hours, permanent repairs within 48 where safety-critical. Large projects requiring Section 278 approvals: 6-8 weeks (approval timelines set by highway authority).
What if ground conditions are worse than expected?
Our site investigation minimises surprises – CBR testing, trial pits, utility scans. If genuine unforeseen conditions emerge (contamination, unmarked services, structural voids), we stop, inform you immediately, assess implications, provide options with cost and programme impacts. No additional work without your written approval.
Need to understand your site's condition and options?
Book a Free, no-obligation Commercial tarmac surfacing assessment
We’ll inspect it, test the existing surface, assess traffic loading, identify defects, and provide a written engineering specification with fixed-fee pricing.
No obligation. No sales pressure. Just expert technical advice from NHSS-accredited specialists who’ve engineered hundreds of commercial surfaces.
Call or fill out our form and we'll be in touch within 24 hours.
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