Transforming a High-Traffic Industrial Roadway with Durable Asphalt Solutions
Client: City Infrastructure Department – Industrial District
Location: Midwestern United States
Project Duration: 6 Months
Scope: 4.2 miles of industrial roadway resurfacing and structural rehabilitation
The Challenge
The Industrial District’s main freight corridor was showing severe signs of deterioration. Years of exposure to heavy truckloads, fluctuating temperatures, and inadequate drainage had caused deep potholes, rutting, and surface cracking. This roadway wasn’t just a local street—it was a critical supply chain route connecting distribution centers, warehouses, and manufacturing facilities to the interstate.
The City Infrastructure Department needed a fast, cost-effective, and long-lasting asphalt solution that could withstand constant heavy traffic without frequent maintenance shutdowns. A complete concrete rebuild was considered, but it was deemed too costly and time-consuming.
The Solution
Asphalt Roadway was brought in to deliver an engineered pavement system built for performance. The approach included:
- Comprehensive Site Assessment
- Core sampling and pavement structure analysis to determine subsurface strength.
- Laser scanning for grading and slope accuracy to improve water runoff.
- Custom Asphalt Mix Design
- High-performance polymer-modified asphalt (PMA) designed for heavy loads.
- Incorporation of recycled asphalt pavement (RAP) to enhance sustainability and cost efficiency.
- Drainage & Base Reinforcement
- Installation of sub-surface drainage systems to prevent water infiltration.
- Cement-treated base layer to distribute weight evenly and minimize deformation.
- Efficient Construction Phasing
- Work scheduled in night shifts to minimize daytime freight disruptions.
- Use of warm-mix asphalt technology for faster compaction and extended working time in cooler conditions.
The Results
- Project Completion: Finished 3 weeks ahead of schedule.
- Load-Bearing Capacity: Increased by 40% to handle heavy truck traffic.
- Maintenance Reduction: Projected to extend the pavement life by 12–15 years before major repairs are needed.
- Cost Savings: $1.3M saved compared to a full concrete reconstruction.
- Sustainability Impact: 22% reduction in greenhouse gas emissions through RAP usage and warm-mix technology.
Client Testimonial
“Asphalt Roadway delivered a solution that not only solved our immediate road safety concerns but also ensured we won’t be facing the same issues for many years. Their engineering expertise and ability to work within our time constraints made a significant difference for our freight operations.”
– Director of Infrastructure, Industrial District
This project showcases Asphalt Roadway’s ability to combine engineering precision, sustainable practices, and efficient project execution to meet the toughest roadway challenges. Whether it’s a busy freight corridor or a rural access road, Asphalt Roadway delivers results built to last.