Asphalt Driveway Calculator
Asphalt tonnage + stone base + sealer for new install, overlay, or patch — with crew-hour labor and price-per-sq-ft summary.
Confirm morning of pour — oil-priced
New install only. 4–6 in #57 standard.
Result
- Area
- 800 sq ft
- Asphalt tonnage
- 14.5 tons
- Stone base tonnage
- 13.3 tons
- Asphalt cost
- $1,885
- Stone base cost
- $427
- Sealer
- —
- Labor
- 18.6 hr · $1,392
- Total (material + labor)
- $3,703
- Effective $ / sq ft
- $5
This estimate is based on national average costs and may vary by region, project specifics, and market conditions. Use as a starting point for your bids.
How to estimate an asphalt driveway
Tonnage is the line item that matters. Volume in cubic feet × 145 lb/ft³ (compacted hot-mix density) ÷ 2000 = tons of asphalt. A typical 20 × 40 ft residential driveway at 3 in compacted is about 14 tons. At $130/ton delivered, that's $1,820 in hot-mix material before stone base, labor, or overhead.
Standard depths
| Use | Asphalt depth | Stone base |
|---|---|---|
| Residential driveway | 3 in compacted | 4–6 in #57 stone |
| Heavy-vehicle residential | 4 in compacted | 6 in |
| Commercial apron | 5–6 in compacted | 6–8 in |
| Overlay (existing asphalt) | 1.5–2 in compacted | None (existing base) |
Pricing benchmarks
- Hot-mix asphalt: $100–160/ton delivered
- Crushed stone base (#57): $28–40/ton delivered
- Asphalt sealer: $30–50 per 5-gal pail, ~250 sf/gal
- Crack-fill (rubber): $4–6 per LF
Installed price for a typical 20 × 40 ft residential new install: $4,500–7,000 in most US markets. Overlay on the same footprint: $2,200–3,500.
Weather window
Asphalt cures by cooling, so ambient temp above 50°F is the functional minimum (some specs say 40°F with extra blanket protection). Below 50°F, the mix cools before compaction completes and you get poor density. Avoid rain in the first 24 hours after pour — water in uncured asphalt causes raveling. Most northern markets shut down asphalt work November through March.
Frequently asked questions
How is asphalt measured and priced?
By the ton, delivered hot. Volume (length × width × depth in feet) × density 145 lb/ft³, divided by 2000 = tons. Hot-mix asphalt runs $100–160 per ton delivered in most US markets. A 20×40 ft driveway at 3 in compacted needs about 14 tons. Always confirm pricing the morning of pour — asphalt is petroleum-based and prices swing with oil markets.
How thick should a residential asphalt driveway be?
3 inches compacted is the residential minimum on a properly prepared stone base. 4 inches if you have heavy vehicles (RV, work truck). Commercial driveways and aprons run 5–6 in. Going below 3 in saves a few tons but the driveway cracks within 5–8 years. The stone base under it should be 4–6 in of compacted #57 stone for residential.
Overlay vs new install — when does overlay make sense?
Overlay (1.5–2 in over existing) works when the underlying asphalt has no major cracks, no heave, and the edges are sound. It runs about half the cost of a new install. If the existing has alligator cracking, depressions, or edge failure, overlay just delays the inevitable — full mill-and-fill or remove-and-replace is the right call. Most reputable contractors won't overlay over visibly failing asphalt.
When should I seal the driveway?
First sealcoat 12 months after new install (let it cure). Then every 3–5 years thereafter, depending on UV exposure and traffic. Sealer is $30–50 per 5-gal pail and covers ~250 sq ft per gallon at 0.10 gal/sq ft. DIY sealcoating is feasible — the prep (clean and crack-fill) takes longer than the application itself.
How fast can a crew install asphalt?
A 3-person crew with a paver and roller installs about 1.5–2 tons per crew-hour. That's roughly 1 driveway per day for a 20×40 ft residential at 3 in. Add a half-day for stone base prep on a new install. Weather matters — asphalt needs ambient temp above 50°F and dry conditions for proper compaction.
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