Semi-rigid surface layers – high-performance coverings

Areas of heavy traffic, such as bus stations, motorway service stations, intersections, airports, transhipment centres, warehouses and industrial areas are particularly exposed to wear and deformation. Semi-rigid surface layers are suited to such areas of application in particular. The two-component coverings consist of a cavity-rich asphalt frame and a thin fluid filling mortar. They combine the flexibility of the asphalt with the load-bearing capacity and the sealing strength of concrete. A high load capacity and a long lifespan are guaranteed.

Because of the many positive features, Otto Bößl KG, in constructing a warehouse for pallets and adjacent industrial areas, decided on the installation of a semi-rigid layer and commissioned Rädlinger Asphaltbau GmbH with the project. The areas to be created had to stand high point and wheel loads and constant forklift movement.

After creating a bedding layer, the asphalt frame was initially applied to a layer thickness of 5 cm, using a conventional road paver. The asphalt mix used for this purpose was first subject to an initial inspection prior to installation. The bituminous framework contains a mix of coarse aggregates, fillers and other additives and includes 25-30% cavities.

Unlike previous orders where the asphalt supporting frame was done by subcontractors, the Rädlinger Asphaltbau team performed this step itself for the first time. During the work, the supporting frame had to be absolutely protected against the ingress of liquids and precipitation, so as to prevent water entering it. In addition, special attention was paid to a uniform installation, as the installation method used does not allow for subsequent correction.

The second step involved the cavities in the asphalt frame being filled with a high-strength mortar. The high-performance liquid mortar was inserted with a hose, distributed with sliders and thus filled in. A final stripping action revealed a homogeneous, flat surface. The delivery of the flowable mortar and the filling was performed by one of Rädlinger Asphaltbau GmbH subcontractors.

After three days of curing, 1,500 m² of warehouse space and 2,000 m² of outdoor area had a durable finish supremely suitable for its intended use as storage and transhipment site and which will withstand the respective loads.


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