How To Plan and Install Paving Over a Larger Site

As a self-performing paving contractor that completes demolition, erosion control, underground utility installation, and subgrade and base work, Tucker Paving Inc. is well aware of the complexities associated with sizeable, full-blown paving projects. “[A paving job] is run like a train: you don’t get completely done with one step before you start another,” says Larry Tucker, the president of the Winter Haven, Florida-based contractor. “The process is the same on every job, but sometimes the rules and the players change.” In September, Tucker Paving conducted full-site paving work for Legoland, one of the newest theme parks in Central Florida. The yearlong project was completed under two contracts, and the steps involved—and presented here—exemplify the work the firm typically undertakes on its larger jobs.

By Erik Pisor

1. Control erosion

Because the Legoland project bordered Lake Eloise, the largest of a chain of lakes in Winter Haven, Florida, Tucker Paving first built a storm-water system, installing storm pipes to manage any potential damage to the lake and to protect cypress trees along the shoreline. To control rainfall during the project, the firm also installed retention ponds. Such precautions are usually necessary in Central Florida because projects are commonly located near the edge of a lake.

2. Demolish the existing site

Prior to subgrade and paving operations, demolition work is often required because projects are commonly located on existing vacant properties. The site for the new Legoland was previously home to another amusement park, Cypress Gardens.

To clear the site, Tucker Paving used tractor hoes and various loaders to demolish the existing buildings, ride foundations, and sidewalks of the old park. The contractor also demolished the park’s existing hardscape. Concrete generated from demolition activity was crushed on-site by a screening-crushing system and reused for Legoland’s base, and in total nearly 24,000 tons of concrete was recycled.

3. Balance the site

In preparation for subgrade work, Tucker Paving balances a site by cutting areas of dirt and filling in other areas using scrapers and road trucks. Part of site balancing also includes the installation of underground utilities including water, sewer, and sanitary-sewer systems.

For Legoland, the firm installed more than five miles of such systems. Once in place, the underground utilities are covered with backfill, and the site is balanced a second time by road trucks and scrapers. “We get the grade to a point where we’re ready to starting putting in our subgrade,” Tucker says.

4. Mix the subgrade

To obtain the necessary subgrade, Tucker Paving often has to import different materials to mix with the existing soil at a project site. During the Legoland project, the firm imported clay and mixed it with the soil to get the appropriate methylene blue valves (MBVs) for subgrade approval—MBVs being an important indication of asphalt-concrete performance in pavements. Once the subgrade is mixed, it is density-tested and inspected by an independent party.

5. Install the crushed-concrete base

Subgrade approval paves the way for asphalt-base installation. The 24,000 tons of crushed concrete recycled from demolition and 26,000 tons of imported lime rock composed the base material used for Legoland. “We had more than 2,500 deliveries for our scope of work,” Tucker says, adding that the majority of deliveries were asphalt-, base-material-, and pipe-related.

To install and place the base, Tucker Paving wetted the ground and then used Komatsu loaders and John Deere and CAT motor graders. During asphalt-paving operations, which included the installation of two asphalt layers, the contractor used two Modoc PF 150s and ran two paving crews that consisted of up to 16 workers total. To avoid issues associated with common afternoon storms, Tucker Paving conducted all concrete pours between 1 a.m. and 2 a.m.

6. Put on the finishes

Following paving operations, Tucker Paving cuts the asphalt using diamond blades attached to various machines. The asphalt is typically cut to install drainage channels, plumbing, and power and communication cables. At Legoland, the firm installed more than 25,000 linear feet of curbs as well as parking-lot lighting and landscaping. ABQ