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Across the country, counties are finding that it pays off to be proactive with pavement preservation. In Greene County, Indiana, a recent project serves as a powerful example of how chip seal and fog seal treatments can extend the life of rural roads, deliver significant cost savings and maintain safe, reliable travel for local communities.
In early June, a seasoned team from Evergreen Roadworks completed 163,382 square yards of a single-layer chip seal, followed by a protective fog seal, across ten different local roads* in Greene County. Thanks to experienced crew members like Ryan Ackerman and Joey Hannah, the entire project was completed in just three days—an impressive display of both logistical coordination and field expertise.
*Treated Roads: Lawrence Hollow Drive, Bruce Drive, Raines Road, Legion Road. And portions of: American Bottoms Road, Sharkey Road, Britton Road, Fellows Ridge Road, Sylvania Road, CR 500N.
Chip sealing (sometimes known as oil and chip) is one of the most cost-effective pavement preservation tools available, especially for lower-volume, rural roads. It is ideal for roads in generally good condition (Pavement Condition Index, or PCI, of 60–90), with adequate structural capacity. It can also be used if the pavement is beginning to show minor issues like surface cracking (less than ¼”), friction loss or minor oxidation.
Fog seal is a light application of diluted asphalt emulsion added to roads in good condition, in this case, over the chip seal. It helps lock in aggregate, reduces dust and adds protection from moisture and oxidation. Used together, these treatments slow deterioration and extend pavement life for a fraction of the cost of traditional resurfacing.
Rather than waiting for more advanced deterioration that requires costly rehabilitation, counties like Greene are investing early. The result: longer-lasting roads, improved safety and a significantly lower cost per mile of maintenance over time.
1. The chip seal process begins with sweeping the road to ensure a clean surface.
2. Next, a liquid asphalt binder is sprayed using a distributor truck, followed by a layer of aggregate chips.
3. Pneumatic tire rollers then embed the chips into the binder.
4. Finally, a fog seal is applied over the stone to help lock in the chips, reduce dust and give the surface a rich, black finish.
Oil Distributor Applies Liquid Asphalt Binder, Chip Spreader Follows Behind
Completed Chip Seal, Fog Seal Applied on Top
Not only is the process quick, allowing traffic to resume within an hour of chip seal and just 1–3 hours after fog sealing, but it is also highly effective. When timed correctly, chip seal can extend a road’s life by 7–10 years (for PCI 80 roads) or 3–5 years (for PCI 60 roads). The fog seal can add another 2–4 years by protecting the pavement from moisture and oxidation.
RoadResource.org illustrates the financial benefit of preserving pavement while it is still in good to fair condition.
Chip sealing offers a 45–50% reduction in life-cycle costs, compared to traditional mill and fill resurfacing with hot mix asphalt. For tight budgets, that kind of saving is not just appealing, it is essential. More importantly, these treatments allow road managers to take a preventive, rather than reactive approach, keeping good roads good for longer.
As Greene County’s recent work illustrates, successful chip seal projects depend on careful site selection, experienced crews and timely treatment. But when those factors align, the results speak for themselves: stronger roads, lower costs and a community that benefits from safe, well-maintained infrastructure.
