Transforming a Failing Industrial Lot into a Durable, High-Traffic Asphalt Surface
Client: GreenCore Manufacturing Ltd.
Location: Houston, Texas
Project Type: Industrial Pavement Rehabilitation
Duration: 6 Weeks
Background
GreenCore Manufacturing operates a 24/7 facility that handles heavy freight trucks, forklifts, and constant employee traffic. Their existing pavement was over 18 years old and showing severe signs of distress—deep cracks, potholes, drainage problems, and dangerous uneven surfaces. These issues weren’t just aesthetic; they were impacting vehicle maintenance costs and posing safety risks for drivers and workers.
Challenge
The client’s goals were clear but demanding:
- Replace failing pavement without halting production.
- Ensure the new surface could withstand continuous heavy loads.
- Solve drainage issues that were leading to water pooling and base erosion.
- Deliver a solution that would reduce maintenance needs for at least the next decade.
Our Approach
Asphalt Roadway’s engineering team began with a full site assessment, including core sampling to evaluate subgrade conditions. We discovered that years of water damage had weakened the base layer significantly.
Our solution plan included:
- Phased Construction Scheduling – We divided the lot into work zones to keep traffic flowing while repairs were underway.
- Base Reconstruction – Removed 12 inches of compromised aggregate and replaced it with a stabilized, load-bearing base.
- Heavy-Duty Asphalt Mix – Designed a high-performance asphalt blend with polymer-modified binders for maximum durability.
- Improved Drainage System – Installed new sub-surface drains and adjusted surface grading to eliminate water pooling.
- Final Sealcoating – Applied an industrial-grade sealcoat to enhance weather resistance.
Execution
Work was conducted in night shifts to avoid disrupting daytime operations. Advanced paving equipment ensured a precise surface finish, while quality checks were conducted after each phase.
Results
- 60,000 sq. ft. of asphalt laid with zero production downtime.
- Load-bearing capacity improved by 40%.
- Drainage issues completely resolved, preventing future base failures.
- Maintenance costs expected to drop by over 50% annually.
- Client reported improved safety and smoother operations within the first week.
Client Feedback
“The Asphalt Roadway team went above and beyond. They understood our time-sensitive needs and delivered a surface that’s built to last. We’ve seen a huge difference in both vehicle performance and safety.”
— Operations Manager, GreenCore Manufacturing
Key Takeaways
This project demonstrates Asphalt Roadway’s expertise in industrial pavement solutions, combining smart scheduling, advanced materials, and engineering precision to deliver results that last.