Microsurfacing: A Cost-Competitive Alternative to Traditional Mill and Resurfacing Methods

 Using the International Slurry Surfacing Association (ISSA) guidelines, the group established best practices and guidelines for a 2021 pilot project. This included a change in criteria for project selection, using two layers, called a double lift application, and established skid factor requirements. The results of the pilot program were positive, with both skid values and rideability improved.

At the end of the pilot project, the group discussed successes and areas for improvement. It was determined that there is no single solution. Instead, the correct combination of product identification, project selection, and design must be determined for each roadway project. 

Yearly reviews from this group continue to provide improved methods to address new concerns that arise, such as stone whip-off, which occurred in 2024. A stone whip-off occurs when loose aggregate is displaced from a road surface treatment, such as chip seal or oil and chip. To address this concern, the double lift application was adjusted by placing a Type B application on the bottom to fill ruts and a Type A application on top, allowing for a smoother ride. This adjustment addressed the material whip-off and improved rideability, while ensuring acceptable skid resistance results. 

This PennDOT and industry partnership, led by PennDOT Engineering District 3 employees Jeff Kerr, Andrew Poploskie, Isaac Bragunier, and Steve Tokarz, has continued to improve the microsurfacing program throughout the district. This cost-competitive alternative to traditional mill and resurfacing methods has assisted the district in preserving more than 229 miles of roadway throughout the nine-county region between 2020 and 2024. 

“The department and industry representatives used a data-driven approach to modify a specification to improve the performance of microsurfacing for the benefit of all parties,” said Assistant District Executive for Construction Justin Blakeney. 

In March 2025, District 3 was awarded the International Slurry Surfacing Association Excellence in Pavement Preservation Award for their commitment to pavement preservation by working with industry partners to improve the overall quality of the microsurfacing treatment program in the district.