Phaltless, Inc. has been hired to do multiple jobs for Shaw Industries over the course of the last 2 years. By using different processes and techniques, we have been able to differentiate ourselves from the competition. These processes and techniques not only save the customer money; but they also provide a finished product that will provide many years of service. Phaltless, Inc. does it right the 1st time so you do not have to come back a short time later and spend more money.
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