Asphalt tonnage comes from volume multiplied by density. The standard compacted hot mix asphalt (HMA) density is 145 lbs per cubic foot, the figure used by paving contractors and asphalt suppliers for estimating orders. Simplified: multiply your area in square feet by your depth in inches, then divide by 166 to get tons at HMA density.
Worked example: A two-car driveway, 20 ft x 20 ft at 3 inches deep.
Parking lot example: 100 ft x 50 ft at 4 inches deep.
To find the area of an irregular driveway shape before calculating tonnage, the Square Footage Calculator handles rectangles, L-shapes, circles, and triangles with unit conversion built in.
An asphalt driveway project has three cost components. The material cost (what this calculator estimates) is only one part. Full installed cost ranges from $3-$7 per square foot for most residential driveways:
| Cost Component | Typical Cost | Notes |
|---|---|---|
| Hot mix asphalt (material) | $80-$150 per ton | Varies by region and oil prices |
| Gravel base (4-6 in) | $15-$30 per ton | Crushed stone or compacted aggregate |
| Labor (lay and compact) | $1-$3 per sq ft | Depends on job size and access |
| Equipment (roller, paver) | Included in labor rate | For large jobs, may be quoted separately |
| Total installed (all-in) | $3-$7 per sq ft | Standard residential driveway |
| Driveway resurfacing | $1-$3 per sq ft | Overlay on existing sound base |
Example total cost: A 400 sq ft driveway (20 x 20 ft) at 3 inches asphalt over a 4-inch base:
For the gravel base calculation, the Concrete Bag Calculator handles material quantities for any base or foundation work alongside your asphalt project.
Asphalt millings (also called reclaimed asphalt pavement or RAP) are the ground-up material from old asphalt surfaces. They are significantly cheaper than new hot mix and work well for driveways, farm lanes, parking areas, and utility paths. Millings have a lower density than new HMA, so the tonnage formula uses a different density factor.
| Factor | New Hot Mix Asphalt | Asphalt Millings (RAP) |
|---|---|---|
| Material cost | $80-$150 per ton | $10-$20 per ton |
| Density | 145 lbs/cu ft | 110-125 lbs/cu ft (avg 117.5) |
| Durability | 20-30 year lifespan | 5-15 years depending on use |
| Surface quality | Smooth, professional finish | Rougher, gravel-like appearance |
| Best use | Driveways, roads, parking lots | Farm lanes, utility paths, low-traffic driveways |
| Requires roller? | Yes, required | Yes, recommended for best result |
Millings can be used as a temporary or permanent driveway surface. Over time, the asphalt binder in the millings re-bonds under heat and traffic, creating a harder surface. For topsoil, gravel, or sod calculations for areas adjacent to your paved surface, use the Topsoil Calculator which converts square footage and depth to cubic yards for bulk material orders.
Asphalt is cheaper upfront but requires maintenance every 3-5 years. Concrete costs more initially but typically lasts 25-50 years with minimal upkeep. The right choice depends on climate, traffic, and budget:
| Factor | Asphalt | Concrete |
|---|---|---|
| Installed cost (per sq ft) | $3-$7 | $6-$12 |
| Material lifespan | 20-30 years | 25-50 years |
| Maintenance frequency | Seal every 3-5 years | Minimal, occasional crack fill |
| Repair cost | Lower (patching) | Higher (concrete section removal) |
| Winter performance | Better (heat absorption) | Can crack in freeze-thaw cycles |
| Summer performance | Can soften in extreme heat | More stable in high heat |
| Resale impact | Functional, expected | Premium appearance |
For a 400 sq ft driveway over 30 years: asphalt installed at $1,800 + 6 sealcoating treatments at $250 each = $3,300. Concrete installed at $3,200 + minimal maintenance = $3,500-$4,000. Over a long time horizon, costs are comparable.