Dig out existing concrete and replace with binder and top project
Project Type: Dig out existing concrete and replace with binder and top
Project Address: Gibsonia, PA
Project Description:
Our team recently completed a major concrete-to-asphalt conversion and heavy-duty paving project for a property in Gibsonia, Pennsylvania. This full-depth restoration involved removing compromised, cracking concrete and installing a complete, multi-layered asphalt system designed for long-term structural strength and smooth functionality.
The project began with the complete excavation and removal of the existing concrete slab. Once the old material was hauled away, our crew inspected and prepared the exposed sub-base. We graded and thoroughly compacted the underlying stone foundation to eliminate soft spots and establish a solid base. To achieve a perfectly level foundation, we added 2A modified stone where needed, performing a comprehensive rolling pass across the entire surface to guarantee maximum load-bearing density prior to paving.
With the base stabilized, we executed a two-stage paving process. First, we paved a 2-inch binder layer—a heavy-aggregate asphalt base engineered to provide core structural strength and flexural durability. This binder layer was thoroughly rolled and compacted. Next, we applied a 1.5-inch wearing surface of 9.5mm fine-aggregate top-coat asphalt over the binder. This final layer was compacted with precision to deliver a dense, smooth finish that minimizes surface porosity.
To complete the project, our technicians ensured all outer edges and transition seams were cut in clean, straight lines and meticulously sealed to prevent water infiltration—a critical defense against Western Pennsylvania's damaging winter freeze-thaw cycles.
By combining rigorous multi-stage compaction with a dual-layer asphalt design, we delivered a durable, high-capacity pavement built to withstand heavy traffic and severe weather. This project showcases our technical expertise in full-depth excavation, sub-base stabilization, and precision asphalt paving.
