Asphalt Jointless Paving Explained: Highway Paving with 4 Pavers in Echelon

One of the most important specifications for highway paving is to avoid cold joints. A cold joint forms when asphalt from one paving pass cools before the next pass is laid alongside it.

What is cold joint in asphalt paving?

We've applied this method a couple of times before, during phases 2 and 4, and each time the echelon formation of four pavers has produced strong, consistent mats.

One of the most important specifications for highway paving is to avoid cold joints. A cold joint forms when asphalt from one paving pass cools before the next pass is laid alongside it. This happens when a single paver lays one lane, then returns later to pave the adjacent lane. By that time, the edge of the first pass has cooled, making it harder to bond with the new hot asphalt. Over time, these joints can become weak spots, leading to cracks and reduced pavement life.

To solve this, we use multiple pavers in echelon formation. This means several pavers work side-by-side, laying fresh asphalt in unison. The hot edges bond seamlessly, creating one continuous, jointless pavement — no matter how wide the roadway. The result is a stronger, smoother surface that lasts longer and requires less maintenance.

How many balloon lights can you count on the main photo above? :-)

Currently, All Roads is completing Phase 5 of the Highway 1 paving project for the Ministry of Transportation and Infrastructure of British Columbia and here, we're operating four pavers in echelon. The precision and coordination required are immense, but the reward is a truly seamless asphalt mat that will serve travelers for years to come.

"Cold joints are the weak points in the asphalt mat," explains Russell Johnston, Paving Superintendent. "The fewer we have, the better—and with our approach, we have none at all."

"That's why we roll out four pavers side by side. If we tried to cover the same width and volume with just one paver, it would take much longer, leave multiple cold joints, and greatly increase the risk of premature failure. Our method don't just reduce cold joints—we eliminate them and it delivers a seamless mat built to last."

We've applied this method a couple of times before, during phases 2 and 4, and each time the echelon formation of four pavers has produced strong, consistent mats. Because of these results, we've come to view it as a standard, as well as practical, approach to delivering quality and durability in highway paving.