Before work began

into this driveway:

After Completion

By doing this to the driveway:

During Construction

and this to the driveway:

Back Dragging Cement Treated Base Stone

This driveway is a perfect example of what Phaltless, Inc. can do for you to renovate and repair your driveway or parking lot. This particular job required us to excavate the entire area in front of the garage doors to ensure proper drainage away from the house after paving; and to repair the base that had deteriorated over time. The base was replaced with cement treated base. Cement treated base is pug mix base stone that is mixed with 5% cement dust. The material achieves 800 psi during hydration and not only stands up to heavy weight loads; but also cures quicker than the pug mix that does not have cement mixed in with it. This ensures that your job will get done in a timely manner, less wait time for the asphalt to be installed. The cement base is graded and rolled to compaction just like the regular pug mix. Once it is compacted it is there to stay. Finally the driveway was leveled up with a leveling run of asphalt topping and then over laid with a new layer of asphalt topping at one and a half (1 1/2) inches thick. All asphalt was machine laid and rolled to compaction.

All in all another fine project that the homeowner was pleased with.

At this particular job, Phaltless was contracted to renovate the driveway. Prior to starting the work on the driveway, the customer mentioned that he would like a paved surface for his HVAC unit and aluminum boat to sit on. He thought concrete would be the best application and we agreed. Due to the elevation change from the yard to the driveway, there were some drainage issues that needed to be considered. The finished elevation of the concrete patio was going to be higher than the finished driveway elevation after both jobs were completed. It was going to be necessary to either install a step, or slope the concrete down to the driveway. After a brief consultation with the owner, we decided to slope the concrete down to the driveway.

The topsoil in the proposed patio area was removed and stockpiled on site so that it could be used to back-fill around the patio after completion of the flat-work. The perimeter of the proposed patio was then formed. We then spread a layer of base stone in the area prior to pouring the concrete. Finally, our finishing crew poured and broom finished 4,000lb fiber mesh concrete for the new patio. The job turned out very nice after completion and the customer was very happy with the result.

Below are a couple of photos of the area before the work was started and after completion.

Photo showing the job prior to paving the driveway and pouring the concrete patio next to the house

Newly poured concrete pad

Concrete patio after backfill around edges

That is how Phaltless, Inc. recently repaired an area that was failing due to root damage for a residential customer.  The entire area was first milled with a milling machine attachment that is attached to our Bobcat Skid Steer Track Loader. After the area was milled, the millings were removed and the area was thoroughly cleaned with a broom attachment that is attached to our Bobcat Skid Steer Track Loader. This was followed with two (2) inches of asphalt topping, machine compacted. An asphalt curb was hand formed on one side of the asphalt patch to retain the dirt.

Below are a couple of pictures showing the process.

Before

Tamping the 1st Layer of Asphalt

Tamping the 2nd Layer of Asphalt and Hand-forming the Asphalt Curb

The finished product

Phaltless also provides concrete bollard repairs and installations.

In many cases, when bollards are installed the first time, they are not installed in a manner that they will last a long time. The reason for this is because they are not footed deep enough under the surface of the asphalt to withstand the abuse of cars and trucks running into them. That is why when Phaltless, Inc. installs them, we take care to auger a hole deep enough to sink the bollard 3′ under the surface of the asphalt. This insures that they will “stand-up” a long time.

In most cases we start by purchasing pipe bollards cut in 7′ sections. This way after installation is complete, there will be 3′ of the pipe under ground, and 4′ of the pipe above ground. A hole is then augured with an auger attachment on our skid steer loader that is wide enough to accommodate the pipe and the concrete that will need to surround the pipe under ground to make it sturdy enough to standup to cars and trucks running into it. The pipe is then installed and filled with concrete. Concrete is also poured at the base of the pipe and up to the level of the pavement on grade. The pipe is leveled to make sure that it is straight. Finally, after the concrete is fully cured, the pipe bollard is painted. The color is usually safety yellow

Below are a couple of photos showing a set of bollards around a fire hydrant that we had to repair becasue they were failing.

Before

After

After negotiating a price that the church was happy with, Phaltless scheduled the work to start as soon as possible.

The job began with demoing the extruded concrete curbing that was on each side of the road. Phaltless, Inc. then used a reclaimer machine to pulverize the existing asphalt and mix it with the base stone. After the asphalt was pulverized, portland cement dust was spread over the road with a cement spreader truck which evenly distributes the specified amount of cement over the particular area that needs repair. Once the cement was evenly spread over the road, we came back over it with the reclaimer machine and a water truck that mixes all of the materials together. The cement is mixed at a rate of 6% with water. This achieves a cement treated base that is an excellent surface to pave on; and that will provide many years of service. The mixture was allowed to hydrate and then paved with 2 layers of asphalt. The first layer of asphalt was 1 1/2 inches of asphalt binder. The second layer was 1 1/2 inches of asphalt topping. All asphalt was machine laid and rolled to compaction. Finally, extruded concrete curbing was installed on each side of the road to finish the job.

Below are some photos that will take you through the construction process.

Bottom of Road Before Work Began

Pulverizing the old asphalt

Road after old asphalt is pulverized

Cement Spreader Truck spreading cement

Cement evenly spread on road

Mixing the cement with the reclaimer machine

Grading the mixture

During the hydration process

During the hydration process

After paving and curbing

After paving and curbing

The amount of tractor trailer traffic and fork lift traffic that is present in a Shaw Industries Plant requires a pavement schedule that is specified to standup to some heavy duty weight loads. Therefore, they call Phaltless, because we are equipped to provide a pavement section that incorporates full depth reclamation, and/or soil cement. These processes both use cement dust as a key component to the base material that will be heavy duty and stand up to these weight loads.

Plant 3 had multiple parking lot maintenance issues that were beginning to surface and they needed to be addressed. The scope of work involved using full depth reclamation in the entrance to the plant because the heavy tractor trailers were deteriorating the asphalt enough to require full depth maintenance. Additionally, the employee parking lots were very old and needed a new layer of asphalt. Because the employee parking lots had an old asphalt curb around the perimeter, a representative from Phaltless, Inc. suggested removing that old asphalt curb and replacing it with new extruded concrete curb. This would give the parking lot a lot better “finished” look. Phaltless installed speed humps after paving and of course striped the parking spaces too.

In order to keep the plant operating at full capacity, Phaltless worked closely with the management at Shaw Industries to devise a plan that would keep the only way in and out of the plant fully functional. We were able to do this by working on one side of the entrance/exit at a time and taking down a fence next to the entrance/exit so that traffic could navigate around the construction area when necessary. Because the entrance was where the full depth reclamation was taking place, this was extra tricky. The cement needs time to hydrate before paving so we had to get all the cement mixed in before we began paving the entrance/exit. This takes some time; especially when we are mixing at the depth we were at this job. The depth of construction was 12 inches. We pulverized the existing asphalt with a reclaimer machine. After pulverization, we spread cement on top of the existing material. The cement was then mixed with the existing materials and water at a rate of 6% by weight with the reclaimer machine. The mixture was then graded with a motor grader and rolled to compaction with a smooth drum vibratory roller.

The next phase of construction involved stripping the asphalt curbs and cleaning all of the existing asphalt that we were going to overlay. The existing asphalt was sprayed with tack coat to help adhesion between the old asphalt and the new. This was followed with (2) inches of asphalt topping on the existing asphalt. The cemented areas were paved with (2 1/2) inches of asphalt binder and (1 1/2) inches of asphalt topping. The asphalt binder will add extra stability to the entrance to standup to all the heavy traffic coming in and out of the plant. All asphalt was machine laid and rolled to compaction.

Below are pictures of the Entrance/Exit before construction began.

Entrance/Exit before construction

Reclaimer pulverizing asphalt in Entrance/Exit

Motor grader grading the Entrance/Exit after cement mixed with existing materials

Below are pictures showing the Entrance/Exit after paving was completed.

After the Entrance/Exit was paved

After the Entrance/Exit was paved

After the Entrance/Exit was paved

Below are pictures before the employee parking was overlaid with a new layer of asphalt.

Before the new layer of asphalt was laid

Before the new layer of asphalt was laid

Before the new layer of asphalt was laid

After the employee parking lot(s) were overlaid with the new layer of asphalt, striped, and curbed.

After the new layer of asphalt was placed

After the new layer of asphalt was placed

After the new layer of asphalt was placed

The property manager at Georgetown Bay Subdivision in Ooltewah, TN called on Phaltless, Inc. when there was major pavement failure in the exit drive of the subdivision. Traffic flow was a concern because this was the only way in and out of the subdivision. Not only did the residents need to come in and out but there was also construction traffic from new houses being built that needed to come in and out of this entrance/exit. Phaltless came up with a plan that would not impede traffic flow coming in and out of the subdivision.

The area was laid out and saw cut. Spoiled materials were than dug down to a depth of ten (10) inches and loaded in a dump truck, and hauled off site. The patch was then back filled with eight (8) inches of cement fortified base stone and rolled to compaction. The cement base was allowed to hydrate. This was followed with two (2) inches of asphalt topping. All asphalt was machine compacted.

The end result was a smooth, symmetrical patch that will provide many years of service.

Below are some photos before, during, and after the job was completed.

Before repairs began

Georgetwon Bay (after)

Georgetown Bay (after)

This particular project involved some full depth repair, filling potholes, and base stone installation.

The full depth repair area was out in the middle of the parking lot. Therefore, there is a great deal of traffic that drives over it on a daily basis. We needed to make sure that there was a solid foundation underneath the surface of the new layer of asphalt so that there would not be any future cracking in the area.

To achieve this, we used six (6) inches of cement treated base stone as the foundation. The limits of the area was first laid out and then saw cut. The spoiled material was dug down to a depth of eight (8) inches and hauled off of the property. We then installed six (6) inches of cement treated base and rolled it to compaction. This was followed with two (2) inches of asphalt topping. All asphalt was machine laid and rolled to compaction.

The finished product is a nice symmetrical patch that is smooth and will give years of service.

Below are some photos walking you through the asphalt repair process.

Repair area being sawcut after layout

After the cement treated base was installed

After asphalt was installed

To achieve the desired grade, a portion of the existing materiel was hauled off site. Once the desired grade was achieved,  the job called for cement to be mixed with the existing materials, with water, at a rate of 6% by weight at twelve (12) inches thick. The raw cement dust was spread over the existing materials. A water truck was then hooked up to the reclaimer machine that mixed all of the materials together at a depth of twelve (12) inches.

Below are photos that show Phaltless in action.

Pulverizing the existing asphalt

Loading the pulverized asphalt in dump trucks ready for haul off

Phaltless mobilized a grader and roller on site and clipped the existing base stone to get it on grade and compacted so that it would be ready for the layer of asphalt. The next day, Phaltless mobilized an asphalt paving machine and smooth drum vibratory roller on site to place the asphalt topping. The compacted thickness of the layer of asphalt topping was determined to be two (2) inches.

Phaltless, Inc. turned the job around very quickly which made the customer very happy. The finished product turned out to be a beautifully paved driveway.

Below are a couple of photos of the job before, during, and after.

Before Grading and Asphalt Paving

Driveway Before Grading and Asphalt Paving

After the driveway was graded and rolled to compaction

During Asphalt Paving

On grade

Paving the driveway down the hill

Rolling the asphalt to compaction

Dropping the asphalt in the paving machine

Checking the depth of asphalt and raking the edges

After Grading and Asphalt Paving