The construction of a sports track tends to be more challenging than your typical parking lot paving jobs. Asphalt Contractors Inc. (ACI), located in Union Grove, WI, knows this to be all too true after working on the Union Grove High School running track in their hometown.
The initial project was a result of a $3 million dollar referendum to upgrade the athletic facilities. ACI was hired as a subcontractor to provide the stone base and asphalt paving on the running track. The project began in early spring with the target completion date prior to the first day of school in the fall semester.
In addition to the running track, the football field was to be regraded and synthetic turf installed. ACI was to then pave both ends of the field along with a long jump and pole vault area.
Overcoming Sub Problems
The design specifications called for a drainage system that ran around the inside perimeter of the running track. The existing track was removed and the grade on the football field was changed to accommodate the less than 1% inward drainage specification.
ACI came in and began with proof rolling the sub-base provided by the excavating contractor.
“The entire track area failed,” ACI owner Bob Kordus says. “So our first step was to stabilize the surface. We used a Portand stabilization method where we spread Portland cement on the subgrade, added water and pulverized the surface to mix in the cement with the subgrade. The sub-base was then fine graded and compacted.”
This process provided a stable surface that passed proof roll and enabled ACI to place the stone base. 3,700 tons of 1-1/4-in. dense graded base was placed in two days. Throughout this process, ACI had to work around and with the sub-contractors installing the artificial turf, bleachers and score board.
“We are a local contractor to this area and I am a school board president at one of the feeder schools to the high school,” Kordus says. “We were also the only local contractor used on project. Our work progressed on schedule, but I had a sense that the other subs had pressure to perform at other districts and could fall behind, this caused me to check their progress on an almost daily basis.”
It was because of this constant monitoring that on one day Kordus observed the turf contractor and general contractor arguing at mid-field. Evidently the base was too dry and the turf contractor was telling the general contractor to expect a delay.
“I approached them because their language was not acceptable in the school environment,” Kordus says. “When I found out what the problem was, I simply got some sprinklers and garden hose from our shop and turned on the water. Fifteen minutes later the turf contractor was turning them off because the base was to wet. Problem solved.”
Adding More Work
Due to the topography and proximity of the running track to the tennis courts and school, the construction of the new track would prohibit any future repairs to the tennis courts.
“The courts were in average to poor condition,” Kordus says. “I approached the school about the problem and was told there was no money in the budget to repair the courts."
ACI elected to repave all four courts, including cracksealing, petro-mat, net post replacement, paving and color coating as a donation in honor of Kordus’s mother S.M. Kordus.
“My mother is a very avid tennis enthusiast, subscribes to the tennis channel and watches tennis everyday,” Kordus says. “She has been with our company from the beginning and is still active in our business at 95 years young.”
In honor of ACI’s generosity to the school and the project, a memorial plaque was placed in the tennis court area with S.M. Kordus’s name.
Paving to Perfection
With the tennis courts paved, bleachers, electrical and turf installed, ACI was able to begin the paving process on the running track. ACI was extremely conscious of every detail to make sure the highest level of utilization was in store for this space. The track circles the football field and needed to look and function at a professional sports level.
“Obviously the track was to remain an oval – however there was no reason it couldn’t be as wide as possible and have more that four lanes,” Kordus says. “Running tracks also present a unique challenge because a track is a circle with no specific start or stop area. The work at the start and stop must be provided by hand which leaves no room for error. We used a Caterpillar AP1055B Paver with Topcon Grade & Slope controls to achieve the desired grade control.”
ACI owns an 8000-lb Astec Batch Plant capable of producing 240 tons per hour. Approximately 1,800 tons of E mix asphalt was placed in two layers. ACI laid the base course, placed tack and then placed the surface course.
ACI used three rollers, a Hypac roller for initial knock down and compaction, then Hamm and Wacker Neuson rollers for finishing.
The paving was completed before to the first week of August so the surface would cure prior to color coating and be ready for the first day of school.
The school was so appreciative of ACI’s assistance in completing the project on time and aiding other contractors to ensure the field was ready for football season, that ACI was invited to the dedication ceremony where the school revealed an ACI sign installed permanently on the bleachers.
“Union Grove is our home,” Kordus says. “Our communities children go to this school, our employee’s kids go this school. We had a high level of passion entering into this project and were determined to finish with perfection. Schools are important no matter what village, town or city they are located – these kids are our future and deserve the best resources we can offer.
“Because of my involvement as a school board member and local contractor I wanted this project to be perfect and run smoothly,” Kordus finishes. “Due to the dedication of our employees, using the proper equipment and using consistent standard construction practices we delivered a first quality product that I am proud of.”
