Asphalt Tonnage Calculator, Surface Paving and Haul Roads

How many tons of asphalt a paved section takes, from its length, width and compacted thickness. Then how fast your paver lays it, how many hours and truckloads that is, and what paver speed keeps up with the plant. Surface paving only: site roads, haul roads, pads and yards. The density and the paver arithmetic come off the Caterpillar Performance Handbook's paving pages, every step shown.

An asphalt paver and a drum roller laying a hot mat on a mine site road at dusk, dust in the air

Step 1 - The section you are paving

Measure these off your drawings or your site. The numbers in the boxes are an example, not a standard: a 1,000 ft run of 24 ft road at 3 in.

Step 2 - The mix density

Density is the number that decides the tonnage, and it is the one most people guess. The best number is yours: the compacted density on your supplier's mix design or your core results. If you do not have it, pick one of Cat's printed figures below. Cat prints more than one, and they disagree.

Step 3 - The paver and the trucks

Optional for the tonnage, needed for the hours. Cat's paver chart is worked at 100% efficiency and says to multiply by your own. These are yours.

compacted asphalt, at your density
at Cat's 145 and 155 lb/ft³
truckloads
paver laying rate
paver hours
paver speed to keep up with the plant
StepValueWhere it comes from

The mat, in section

What the density does to the order

What this does not know. It gives the tons of compacted mat in place and adds nothing to them. None of the 22 handbooks behind this site prints a waste or overrun allowance for asphalt, so there is none here: how much extra you order for an uneven base, edges, joints and the last truck is your call, and the page will not make one up. It does not convert loose mat to compacted, because no roll-down figure is printed either. It is not a mix design and not a pavement design: it does not tell you what thickness a haul road needs. Paver hours cover laying only, at the efficiency you give it, and say nothing about the rollers keeping up.
Cat's asphalt densities, and where each one is printed
Materiallb/ft³kg/m³ as printed What Cat uses it forPage
Asphalt1452,322Cold planer production chart, "as referenced on AsphaltPavement.org, the website of NAPA"10‑2
Hot mix asphalt1552,483Double drum and combi vibratory compactor production, assumed condition10‑20
Hot mix asphalt1552,486Pneumatic tire compactor production, assumed condition (printed as kg/cm³)10‑22
Cold in-place recycled asphalt1402,246Pneumatic tire compactor production, assumed condition (printed as kg/cm³)10‑22

Caterpillar Performance Handbook, edition 50, Paving Products. None of these is offered as a standard. Each is the density Cat assumed to build one of its own tables, and the book does not say which mix any of them is. 145 sits under the cold planer chart on p. 10-2, "as referenced on AsphaltPavement.org, the website of NAPA". 155 is the assumed condition on both compactor tables, pp. 10-20 and 10-22. They are 6.9% apart. Cat's paver production chart on p. 10-12 prints no density at all, but working its own cells backwards gives about 146 lb/ft³, which is why 145 is the default here: it is the density Cat's own paving chart is built on. On p. 10-22 Cat prints the metric figures as "kg/cm³", a unit misprint for kg/m³, and reads 2486 where 155 lb/ft³ converts to 2483, the figure p. 10-20 prints. This page works in lb/ft³ and converts exactly, so those 3 kg/m³ never reach the answer.

Cat's asphalt paver production chart, tons per hour at 100% efficiency
Compacted matSpeed, ft/min6 ft7 ft 8 ft9 ft10 ft11 ft 12 ft
1 in.1022262933374044
1 in.2044515866738088
1 in.3066778799110120131
1 in.4088102116131146161175
1 in.50110129145164183201219
2 in.1044525866748088
2 in.2088176*116132146160176
2 in.30132154174198220240262
2 in.40176204232262292322350
2 in.50220258290328366402438
3 in.1066788799111120132
3 in.20132153174198219240284*
3 in.30198231261297330360393
3 in.40264306348393438483525
3 in.50330387435492549603657
4 in.1088104116132148160176
4 in.20176204232264292320352
4 in.30264308348396440480524
4 in.40352408464524584644700
4 in.50440516580656732804876

Caterpillar Performance Handbook, edition 50, p. 10-12, "Asphalt Paving Charts". Cat: "These charts will assist you when trying to match plant output with paving speeds. Keep in mind when using these charts, it will be at 100% efficiency. If you know efficiency, multiply T.P. hour × efficiency." This page does not look numbers up in the chart; it works the arithmetic the chart is built on (width × speed × 60 min × compacted thickness × density ÷ 2,000 lb), so it answers for any width, speed and thickness, and the chart is kept here to check it against. Every cell agrees with that arithmetic at about 146 lb/ft³ to within 2%, except two marked *, which are misprints: the 2 in. and 3 in. charts are each the 1 in. chart multiplied up, and those two cells are not. The 2 in. cell at 20 ft/min and 7 ft should read 102, not 176, and the 3 in. cell at 20 ft/min and 12 ft should read 264, not 284.

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Worked example

Worked with the values this page loads with, so the method can be checked against the cited source without entering anything. Change any input above and the calculator recomputes; the numbers below stay as a fixed reference case.

Area: 1,000 ft × 24.0 ft24,000 ft² (2,667 yd²)your section
Compacted volume: area × 3.00 in6,000 ft³thickness after rolling
Compacted density145.0 lb/ft³Cat Performance Handbook ed. 50, p. 10-2
Weight: volume × density870,000 lbarithmetic
= tonnage: weight ÷ 2,000 lb per short ton435 tonsthe headline number, compacted mat in place, nothing added
Spread rate at 3.00 in: density × thickness326 lb/yd²what each square yard takes
Per 100 ft of road at 24.0 ft wide43.5 tonsfor pricing by the station
Same mat at 145.0 lb/ft³435 tonsCat cold planer chart, after NAPA, p. 10-2
Same mat at 155.0 lb/ft³465 tonsCat compactor tables, pp. 10-20 and 10-22
Gap between Cat's two hot mix figures+30.0 tons (6.9%)neither is wrong; your mix design settles it
Passes across 24.0 ft at 12.0 ft a pass, rounded up2arithmetic
Paver at 100%: 12.0 ft × 30 ft/min × 60 min × 3.00 in × density392 tons/hrCat asphalt paver chart method, p. 10-12
× job efficiency 75%294 tons/hrCat: "multiply T.P. hour × efficiency", p. 10-12; your efficiency
Paver hours: tonnage ÷ laying rate1.5 hlaying only, at your efficiency
Truckloads: tonnage ÷ 20.0 tons, rounded up22your trucks
Paver speed to keep up with 300 tons/hr: plant ÷ (rate per ft/min × 75%)31 ft/minthe p. 10-12 chart worked backwards; your plant

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