Benchmark Service: Construction Phase Services
Issue: The existing concrete pavement at a Fulfillment Center, designed for heavy commercial vehicles, began showing signs of failure less than 10 years after installation. The distress was attributed to insufficient structural integrity and subgrade support, which could not withstand the prolonged stress from slow-moving and stationary heavy truck traffic. These failures presented significant risks, including reduced operational efficiency and increased maintenance costs.
Solution: Benchmark, Inc. provided onsite construction observation services to ensure the roadway's reconstruction met the required specifications for durability and longevity. The process involved the following key steps:
-
Subgrade Preparation: The existing pavement was excavated down to the subgrade, followed by a proof roll to confirm stability. Fortunately, no undercutting was required to improve subgrade strength.
-
Geogrid Fabric Installation: A geogrid fabric was installed with a two-foot overlap to prevent subgrade materials from mixing with the aggregate base and to enhance pavement structure stability.
-
Aggregate Base Placement: New stone aggregate was placed, compacted, and fine-graded to meet the proposed grades, forming the foundation for the pavement.
-
Steel Reinforcement: Dowel bar baskets were installed at control joints, and steel mesh was added between joints. The steel reinforcement was wire-tied to maintain alignment during concrete placement.
-
Concrete Installation: Heavy-duty concrete was pumped into place and underwent Quality Control testing to verify strength, ensuring the finished roadway met designated performance standards.
These methods ensured the roadway was rebuilt with a focus on structural integrity and long-term functionality
Possible Impact: The improved design and precise construction methods will significantly enhance the pavement's lifespan, reducing the likelihood of future failures caused by subgrade instability or insufficient reinforcement. Although concrete roadways involve higher initial costs, their durability in handling heavy truck traffic makes them a cost-effective choice over time. With proper preventive maintenance, such as joint and crack sealing, the roadway's condition will remain stable for many years, minimizing operational disruptions and maintenance expenses.
By employing robust construction practices and quality materials, the newly rebuilt roadway will support the heavy operational demands of the Fulfillment Center, providing the client with a reliable and sustainable infrastructure solution.
