Project Overview

Civils and Environmental Ltd were commissioned to undertake tarmac resurfacing and trench reinstatement works within an operational industrial yard. The scope focused on planing out and relaying previously installed road trenches, restoring structural integrity and providing a long-lasting, smooth, traffic-ready surface.

The works were designed to reinstate the yard following underground service works, ensuring the surface could withstand HGV movements, plant traffic, and daily operational loads.

Initial Site Inspection & Assessment

Following a detailed site inspection of the yard, it was identified that:

• Existing reinstated trenches required upgrading

• Surface levels needed correction

• The finished surface required improved durability

• Proper bonding between existing and new asphalt was essential

The reinstatement was specified to a depth of approximately 80mm, ensuring adequate structural strength and longevity in a heavy-duty environment.

Phase 1: Planing & Surface Preparation

Mechanical Planing (Approx. 80mm Depth)

The first stage involved mechanical planing (milling) of the trench sections to remove the existing surfacing material to the required depth.

This process:

✔ Removes compromised or uneven material
✔ Creates clean vertical edges for bonding
✔ Ensures consistent reinstatement depth
✔ Prevents reflective cracking

All arising materials were removed from site and disposed of via licensed waste channels or recycled where appropriate.

Phase 2: Binder Course Installation

60mm AC20 Binder Course

Following preparation, a 60mm layer of AC20 dense binder course asphalt was laid.

AC20 binder course is designed to:

• Provide structural strength

• Distribute vehicle loads

• Act as the primary load-bearing asphalt layer

• Resist deformation under heavy traffic

The material was machine-laid and compacted using vibrating rollers to achieve correct density and compaction values in line with industry best practice.

Phase 3: Surface Preparation & Bonding

Thorough Mechanical Sweep

Before laying the surface course, the area was:

• Thoroughly brushed and mechanically swept

• Cleared of debris, dust, and loose aggregate

• Inspected to ensure optimal adhesion conditions

Proper cleaning is critical to prevent delamination between asphalt layers.

Application of K1-40 Tack Coat

A K1-40 bitumen emulsion tack coat was evenly applied across the binder layer.

Tack coating ensures:

✔ Strong interlayer bonding
✔ Reduced risk of slippage or separation
✔ Long-term durability of the asphalt system
✔ Enhanced structural performance

This stage is essential for maintaining pavement integrity under heavy traffic conditions.

Phase 4: Surface Course Installation

40mm SMA10 Surface Course

The final running surface consisted of 40mm Stone Mastic Asphalt (SMA10).

SMA10 is selected for:

• High durability in commercial and industrial yards

• Excellent rut resistance

• Improved skid resistance

• Smooth, uniform finish

• Enhanced long-term wear performance

The material was laid to level tolerance and compacted to achieve a consistent finish, ensuring proper surface water runoff and safe vehicle operation.

Quality Assurance & Finishing

Upon completion:

• All reinstated areas were checked for level consistency

• Edges were sealed where required

• Surface tolerances were visually and physically inspected

• Site left clean and operationally ready

The finished surface provides a durable, heavy-duty reinstatement designed to perform under frequent industrial traffic.

Outcome & Client Benefits

✔ Structural reinstatement of road trenches
✔ Improved surface durability and lifespan
✔ High-performance AC20 binder and SMA10 wearing course
✔ Strong interlayer adhesion via K1-40 tack coat
✔ Smooth, compliant and professional yard finish
✔ Reduced risk of water ingress and future failure