Our Paving Process: How Cojo Delivers Quality Results

How We Build Driveways and Parking Lots That Last

Every paving project we complete follows the same disciplined process, whether it is a 500-square-foot residential driveway or a 50,000-square-foot commercial parking lot. The steps do not change because the fundamentals of quality paving do not change.

Here is exactly what happens from the moment you contact us to the day we finish your project.

Step 1: Initial Contact and Site Assessment

Every project begins with a conversation. You call or submit a request, and we schedule a site visit within 1 to 3 business days. There is no charge for the assessment.

What Happens During the Assessment

One of our project managers visits your property and evaluates:

• Existing surface condition - What is there now, and what state is it in?
• Base and subgrade indicators - Are there signs of base failure, drainage issues, or soil problems?
• Access and logistics - Can our equipment reach the work area? Are there utilities, trees, or structures to work around?
• Drainage patterns - Where does water go now, and where should it go?
• Scope of work - What exactly needs to happen to give you a quality result?

We take measurements, photograph the existing conditions, and ask you about your goals for the project. A driveway designed for two passenger cars has different specifications than one that needs to handle an RV or work truck.

The Estimate

Within 2 to 3 business days after the site visit, you receive a detailed written estimate that includes:

• Scope of work broken down by phase
• Material specifications (asphalt type, base material, thickness)
• Timeline for completion
• Total cost with no hidden fees
• Warranty terms

We explain every line item and answer questions. If you want to compare our approach, our guide on how to compare paving estimates walks you through what to look for.

Step 2: Scheduling and Preparation

Once you approve the estimate, we schedule your project based on weather forecasts and our current workload. We aim to start within 1 to 2 weeks during peak season (May through October) and can often start sooner during shoulder months.

Before We Arrive

We will ask you to:

• Move vehicles off the driveway or out of the paving area
• Relocate any items near the work zone (planters, trash bins, basketball hoops)
• Arrange alternative parking for the duration of the project
• Note any underground utilities, sprinkler lines, or irrigation near the work area

We call 811 to have utility locates marked before excavation. This is required by Oregon law and protects both you and our crew.

Step 3: Demolition and Removal

If there is existing pavement, the first day of work usually involves removing it.

For Full Removal Projects

Our crew arrives with excavators, loaders, and dump trucks. We saw-cut clean edges at the project boundary, then break up and load the old asphalt and damaged base material. All demolished material is hauled to a recycling facility where the asphalt is processed into reclaimed material for future use.

For Mill and Overlay Projects

When the existing base is sound, we use a milling machine to grind off the top layer of deteriorated asphalt. This is faster, less disruptive, and less expensive than full removal. The milled material is recycled just like demolished asphalt.

Our milling versus removal guide explains how we determine which approach is right for your project.

Step 4: Base Preparation

This is the most important step in the entire process. A beautiful asphalt surface over a weak base will fail within a few years. A properly built base under average asphalt will last decades.

Subgrade Work

After removing the old pavement, we evaluate the exposed subgrade:

• Soft spots are excavated and replaced with compactable material
• Wet areas receive drainage solutions (French drains, grading corrections)
• Clay soils may get a geotextile fabric layer to prevent migration into the base
• The entire subgrade is compacted with a vibratory roller and proof-rolled to verify stability

Proof-rolling means driving a loaded truck across the prepared subgrade. If the surface deflects under the truck's weight, we know there is a weak spot that needs attention before base material goes down.

Base Material Installation

We install crushed aggregate base material in lifts (layers), typically 6 to 8 inches total for residential projects and 8 to 12 inches for commercial. Each lift is:

1. Spread to uniform thickness with a motor grader or skid steer
2. Moisture conditioned to optimal compaction range
3. Compacted with a vibratory roller in multiple passes
4. Tested for density to confirm proper compaction

The finished base must meet grade specifications within a quarter inch. This precision ensures the asphalt layer has uniform thickness and the surface drains correctly.

Step 5: Paving

Paving day is when the project comes together visually, but it is only possible because of the preparation that preceded it.

Tack Coat

Before asphalt is placed, we apply a tack coat, a thin layer of liquid asphalt that acts as a bonding agent between the base (or milled surface) and the new asphalt. This prevents layers from separating over time.

Asphalt Delivery and Placement

Hot mix asphalt arrives from the plant at 275 to 325 degrees Fahrenheit. It must be placed and compacted before it cools below about 185 degrees, which gives us a working window that varies by air temperature and wind conditions.

Our paving crew coordinates delivery trucks to ensure a continuous supply of material. Interruptions in material delivery can create cold joints, which are seams that become weak points in the finished surface.

The asphalt is placed using a paver that spreads it to a uniform depth and provides initial compaction through a vibrating screed. For most residential driveways, we place asphalt in a single 2.5 to 3 inch lift. Commercial projects may require two lifts totaling 4 to 6 inches.

Compaction

Immediately behind the paver, our roller operators compact the asphalt using steel drum and pneumatic tire rollers. Proper compaction is the single most critical factor in asphalt longevity.

Under-compacted asphalt allows water and air to penetrate, accelerating deterioration. Over-compacted asphalt can crack. We target 92 to 96 percent density, verified by checking against the mix design specifications.

Detail Work

After the main surface is placed, our crew handles the details:

• Hand work around utility covers, curbs, and garage aprons
• Feathering transitions where new asphalt meets existing surfaces
• Edge compaction along borders
• Joint treatment where sections meet

These details separate professional paving from average work. A smooth transition at your garage door and clean edges along your lawn are signs of a crew that takes pride in their work.

Step 6: Final Inspection and Walkthrough

After paving is complete and the surface has cooled enough to walk on (typically by the next morning), we schedule a walkthrough with you.

What We Check Together

• Surface smoothness and uniformity
• Drainage patterns (water should sheet off, not pool)
• Edge quality and transitions
• Match to agreed specifications
• Any areas that need touch-up

We document the finished condition with photographs for our records and yours. If anything does not meet our standards or your expectations, we address it before closing the project.

After the Project

Curing Period

New asphalt needs time to fully harden. During the first 6 to 12 months:

• Avoid parking heavy vehicles in the same spot repeatedly
• Do not turn steering wheels while stationary (this scuffs soft asphalt)
• Keep sharp objects off the surface (jack stands, kickstands, lawn chair legs)
• The surface will be more susceptible to scuffing in hot weather

Maintenance Guidance

We provide written maintenance guidelines with every project, including when to apply the first sealcoat (typically 6 to 12 months after paving), how to handle minor cracks, and what to watch for as the driveway ages.

For detailed maintenance scheduling, our asphalt maintenance calendar covers seasonal care specific to Oregon conditions.

Warranty

Every project includes our warranty coverage. We stand behind our work because we build every project the same way, with the same materials, to the same standards. Our warranty guide explains exactly what is covered and for how long.

Why Process Matters

Any company can lay asphalt on your property. The difference between a driveway that lasts 10 years and one that lasts 25 is the process underneath the asphalt: the assessment, the base preparation, the compaction, and the attention to detail.

Learn more about who we are and how we operate on our about page, or explore our full range of services.