Aggregate Industries’ SuperCurve resurfaces at Port of Liverpool

As a vital dock system for the transportation of goods entering the port, high volumes of heavy goods vehicles (HGVs) going in and out of the port every day had in recent years taken a toll on the existing carriageway’s hot-rolled asphalt (HRA) surface, causing deteriorating longitudinal joints.

Sefton Council proposed renovating the area around Princess Way Roundabout/Crosby Road South highway at the Seaforth end of the docks, and the carriageway from the port exit to the roundabout under the A565 flyover. This included identifying two running lanes into the Port Entrance and adding a newly constructed third lane to accommodate traffic to Crosby.

Having previously worked successfully with Dowhigh and Sefton Council on a number of local resurfacing projects, Aggregate Industries were once again called in to offer their expertise in traffic management and associated vehicular issues. For Dowhigh, in particular, it was important to find an alternative to hot-rolled asphalt (HRA) that would prove both durable and long-lasting, capable of withstanding the high levels of HGV traffic on this busy route.

As such, Aggregate Industries’ suggested the use of its new SuperCurve product, a high performance 10mm polymer modified asphalt designed and engineered to provide an enhanced surface course for higher stressed areas.

During the project, Dowhigh’s surfacing gang and Aggregate Industries plant staff faced incredible time restraints from Sefton Council, Highways England and Liverpool Port as the main road needed to be operational as quickly as possible.

For work to take place on the busy route, overnight road closures and traffic diversions would need to be put in place, which was agreed upon by Highways England, Sefton MBC, Port of Liverpool and Merseyside Police.

Living up to its reputation for working quickly and efficiently, meticulous planning by the Aggregate Industries team saw Phase 1 completed between 10am and 3pm in 2017, and Phase 2 finished between 8pm and 2am in 2018, causing minimal disruptions and meeting the client’s limited timeframe. The process involved Dowhigh laying SuperCurve using two of its pavers working in echelon, which minimised the longitudinal and cross joints where HGVs would travel into the port.

In addition, the carbon footprint of the project was significantly reduced due to Aggregate Industries’ tailored delivery strategy. Delivered straight from the firm’s asphalt plant in Bootle, it took a seven mile round trip to supply 1,022 tonnes of SuperCurve. Excavated materials that weren’t needed were transported to Dowhigh’s recycling depot, which entailed just a four-mile round trip. Highways England also agreed to amend their working times from their usual 10pm to 5am hours, mindful of the residential housing close by.

Charlotte O’Connell, Territory Sales Manager at Aggregate Industries, said: “As a busy main route in and out of the Seaforth Docks at the Port of Liverpool, this stretch of carriageway sees large volumes of HGVs passing through day after day, which unsurprisingly led to the rapid deterioration of the existing surface. “With extensive industry knowledge and expertise in creating bespoke asphalt solutions, we’re delighted our pioneering new SuperCurve has succeeded in creating a durable and long-lasting surface, as well as being able to successfully meet the client’s ambitious surfacing schedule.”

Peter Allard, Director at Dowhigh, said: “Having worked with Aggregate Industries on a number of other local road surfacing projects, we were really impressed by their exceptional customer service and innovative asphalt solutions. When it came to the Port of Liverpool, we were keen to use a material offering enhanced strength and longevity, and SuperCurve didn’t disappoint. I’d like to thank Aggregate Industries for delivering a for delivering a first class service throughout, including fast and efficient surfacing as well as taking care of recycling the materials used in the project.”