On Asphalt Base

Start milling off existing pavement in thickness corresponding to the Confalt® layer. However minimum 5 cm.  Reason for milling would be cracks, rutting or destroyed surface in general. Often the wearing course has high content of bitumen and is suffering on hot summer days. In this case the complete wearing course must be milled off too.

If necessary the base is milled further down – in situations with severe rutting or very uneven surface. Then a leveling layer of polymer modified well compacted asphalt in 3-5 cm is installed as a base for Confalt®. A Confalt® layer of 5-7 cm thick is suggested as new wearing course.

On Concrete Base

Concrete based pavements are more challenging to refurbish due to the joints. Some movements in the concrete base can be obtained by the flexibility of the Confalt® but not all. In this situation we have good experience with a fibretex net placed on the concrete base with emulsion. It is our experience that about 50% of cracks are eliminated by this method.

In order to achieve a surface completely free of cracks penetrating from below, a complete demolishing is necessary. With a concrete breaker or guillotine breaker the concrete tensions are released and the movements will then be so small that the Confalt® system can obtain the movements without cracking.

The design values of the concrete will be changed and a new design should be recalculated.


On flexible or semi-flexible pavement the patching is not complicated. It can be a challenge however is to make it last. MonoConfalt is a perfect material to avoid this situation. The setting time can be adjusted down to 1 hour for the critical taxi way or a bottle neck area.

Full depth repair

On concrete pavements it can sometimes be necessary to repair in full depth. Contec has an extensive experience with these types of repairs from our involvement in highway road repairs from South Africa.

In process in brief: The destroyed area is cut out in full depth. Ø16 mm holes are drilled horizontally into the concrete for every 50 mm. The holes are filled with fast setting injection adhesive before inserting the bars. A 50 x 50 x 10 mm mesh is welded onto the bars and the hole is ready for casting.

With fast setting HPC the opening time is 2-4 hours depending on temperatures.

Photo series: Before and after...