Newport Revitalizes 60 Blocks With Cost-Effective Full Depth Reclamation and Chip Seal

Years of deferred maintenance, limited funding and harsh winter conditions left many of Newport, Washington’s roads in poor condition. By 2025, approximately 60 city blocks were experiencing base failure, potholes and cracking up to 8 inches deep, creating a pressing need for rehabilitation.  

After receiving a grant from the Washington Transportation Improvement Board and acquiring specialized equipment, Newport selected a full depth reclamation strategy that allowed the City to rebuild failing roads while reusing up to 100% of existing pavement materials. The reclaimed base was then finished with a prime coat, chip seal and specialty fog seal, creating a durable driving surface and protecting the rehabilitated roadway.  

Restoring Roads With Limited Resources 

Repeated freezing and thawing caused the underlying soils to expand and contract, weakening the subgrade and allowing moisture to penetrate the pavement. Spring snowmelt further compounded the damage, accelerating deterioration across the City’s streets.  

Approximately 60 blocks of Newport’s streets were failing from the bottom up, leaving residents with crumbling roads. Newport needed a solution as budget friendly as it was effective.  

“If we had contracted this project out for grinding and paving, the cost would have exceeded $60,000 per block,” said Dave North, Newport Public Works Director. “For us, it’s the difference between doing it and not doing it, and we do not have the money to do that process.”   

With only a $30,000 annual maintenance budget, Newport looked for a way to maximize its available resources. The City pursued an in-house full depth reclamation program and secured a $170,00 grant from the Washington Transportation Improvement Board to purchase the necessary equipment.  

Rebuilding Roads From the Ground Up 

Newport’s aging roads required a multistep strategy. The City began with a 6- to 8-inch mechanical full depth reclamation using equipment purchased with the grant. Then they applied the PEP-C conventional prime coat at 0.25 gallons per square yard over the reclaimed base and let it cure for 48 hours, while leaving the lanes open to traffic. From there, North’s team applied the HFE-150 chip seal at 0.40 to 0.45 gallons per square yard and covered the surface with a full graded maintenance rock at 28 to 32 pounds per square yard.  

After a few weeks, the City applied Quickseal — a rapid-setting fog seal — at 0.08 to 0.12 gallons per square yard. Once the streets were swept, traffic returned to the surface within a mere two hours.  

Turning Finite Funding Into Lasting Roads 

By leveraging grant-funded equipment, existing staff and in-house capabilities, Newport transformed a project that would have required an estimated $2.4 million into a $240,000 rehabilitation effort. 

“It’s exciting to see what Newport has accomplished. Every agency has different resources and project delivery needs, and Newport found an approach that allowed them to make the most of available funding and in-house capabilities,” said Evan Henninger, Regional Sales Director for Ergon A&E. “If funding is limited and you want to cover more miles while addressing severe deterioration, full depth reclamation with a chip seal is one of the most cost-effective options available.” 

“This town is really taking the initiative, putting in the energy and effort to preserve their road system and improve it over time,” said Henninger. “They will no longer be chasing potholes and filling cracks. Instead, they will see drastic improvements in road quality and eventually be able to focus on other projects that have been previously neglected.” 

Overall, the project resulted in enhanced performance and durability in the treated blocks, along with reduced water penetration, cracking and pothole development. Newport expects a roadway life extension of 10+ years.  

“I think other cities with the right resources could consider a similar approach. It can be an effective way to stretch limited budgets while improving their roadways,” said North. “We saved $56,000 per block. This process has made it possible for us to repair our streets.” 

To learn more about Ergon Asphalt & Emulsions and how we can enhance your project, contact your Ergon A&E representative.