This project completed in June, 2011 required milling a large section of existing parking lot (approx. 10,000 square yards) to a depth of 2 1/2 inches, haul off all material, clean and prep, then pave with 1 1/2 inches (compacted) of Perma-Flex asphalt, and 1 inch of 9.5 mm asphalt topping, then re-stripe all lines and pavement markings.
What is unique about this project is the thickness of the Perma-Flex layer. Under normal conditions a one inch layer of Perma-Flex is standard for most parking lots receiving light car and truck traffic loads. However the owner wanted a heavier duty pavement so that the life of the existing pavement could be extended even further. So we recommended milling the asphalt down 2 1/2 inches (after core sampling to make sure there is plenty of depth to support a 2 1/2 inch mill), then pave with the 1 1/2 inches of Perma-Flex, and the one inch of topping. As you can see by the pictures, we use depth probes to assure that the thickness of the asphalt being laid is consistent with the specifications for the job. In this case, in order to achieve 1 1/2 inches of Perma-Flex COMPACTED, we had to lay the Perma-Flex at a depth of 1 7/8 inches. In the case where the Perma-Flex specifications call for 1 inch COMPACTED, then we will lay the Perma-Flex at a thickness of 1 1/4 inches. This same principle applies to asphalt topping, as well as other types of asphalt. It is imperative that Perma-Flex is laid at the correct thickness in order for the rocks to form a matrix when rolled to help prevent cracking from migrating up into the final layer of topping. Unfortunately, many contractors are not laying the Perma-Flex at the correct thicknesses, and this will lead to premature reflective cracking.
On this project we completed the job in 4 days, 2 sections in total, whereby, we milled and prepped a section in one day, then paved and striped the section the following day. Because of our equipment capabilities and experienced crew, we were finished with the paving around 2:30 p.m. each day, which allowed our striping crew to immediately lay out and stripe the lot, having it opened to traffic by 5:30 p.m. With such a busy and high profile shopping center, it was paramount that we kept traffic disruption to a minimum. One of our representatives, along with an owner's rep met with each tenant individually and explained the paving process and what to expect, along with a color coded map showing the areas to be paved (see map in photo gallery).