Inlay Crack Repair System

Our stress absorbing inlay crack repair system is designed to repair reflective fatigue cracking in rigid and flexible highway surfaces. Our blended modified bitumen compound has excellent adhesive and compressive properties for improved resistance to wheel track deformation over a wide range of temperatures.

Inlay

Key Benefits

Prevents further deterioration.
Increases the pavements’ effective life.
Suitable for both asphalt and concrete surfaces.
Fast and effective installation minimises traffic disruption.
Suitable for application throughout the year.
Cost effective.

Uses

Inlay repair system.
Concrete repair system.
Stress absorbing membrane interlayer.
Kerb sealing work.

Key Benefits

Case Studies

Park Lane Central London

Kingsmead Avenue, Kingston Upon Thames

Wirtgen UK Headquarters, Lincoln

Kingsmead Avenue, Kingston Upon Thames

Construction value: Circa £6.5k

Client: Royal Borough of Kingston Upon Thames

Key dates: August 2011

Background/Overview

Kingsmead Avenue is a post-war residential development in the Royal Borough of Kingston Upon Thames, London. As in many developments of the period within London, construction comprised of a concrete carriageway that subsequently received a thin asphalt overlay.

The joints to the concrete were showing signs of failure with the risk of water ingress to the sub-base adding to the problems. The Council had also received complaints of traffic noise. A solution was required that would solve both issues.

Project Overview

Taylor Woodrow trading as ESM were contracted to undertake repairs to the joints to eradicate the risk of water ingress and reduce the traffic noise.

Recessed joint repairs were selected as the best value solution and carried out using the Armour-screed material. By planing out either side of the joint and infilling with this flexible material, this treatment not only sealed the joint from further water penetration but also provided a smoother running surface for traffic and extended the life of the concrete pavement.

Key Benefits

Extending the life of the concrete pavement.
Reflective crack prevention if the concrete is overlayed with asphalt or other thin surface treatments.
This method of repair prolongs the life of the asphalt layer, helping to significantly reduce the maintenance costs and efficiently target the defective area of the carriageway.
Armour-screed is a fast-curing material which ensured that we were able to maintain access for residents at all times. Works were completed by our dedicated Joint Sealing Division with minimal disruption and in full consultation with local residents.

Park Lane Central London

Construction value: Circa £22k

Client: Ringway Jacobs working on behalf of Transport for London

Key dates: September 2011

Background/Overview

Park Lane is a busy route through Central London, home to many world-renowned hotels, and is flanked to the West by Hyde Park.

The construction of the carriageway on Park Lane comprised of a concrete sub-base with asphalt overlay. Extensive reflective cracking was evident throughout this section of highway caused by the differential movement of this concrete sub-base.

The carriageway surface was showing severe signs of stress and with the risk of extensive potholes. This, along with residential complaints regarding road surface noise, meant Transport for London decided something had to be done to rectify the problem.

The client and designer opted to treat the cracks at the planed binder course level, above the concrete joints with a recessed inlay treatment using the Armour-screed material. This treatment absorbs the movement from the concrete and prevents the onset of reflective cracking in the overlaying asphalt surface.

With the high-profile location of this site and the significant disruption that any works cause to road users, an ‘insurance policy’ was added to this treatment.

Project Overview

Taylor Woodrow trading as ESM through our dedicated Joint Sealing Division undertook the works under nighttime closures to minimise disruption to road users. The joint sealing works had no impact on overall programme duration.

Induced cuts to the asphalt surface directly over the treated joints were installed and sealed with an N2 material that ensured any possible risk of future reflective cracking was eliminated.

Key Benefits

Reflective crack prevention.
Significant cost and time savings.
The joints and cracks to the concrete sub-base were treated without affecting or extending the resurfacing programme.
The scheme was completed by utilising integrated Eurovia divisions, allowing more control to ensure a smooth and efficient programme.
Works were completed overnight, minimising disruption to road users.

Wirtgen UK Headquarters, Lincoln

Construction value: £42k

Client: Wirtgen Group

Key dates: March 2024

Project Overview

In 2017, the worldwide operating company Wirtgen Group built a new 90,000sq.ft. UK head office, vehicle workshop, parts storage, and external hardstanding for their plant in Newark. Wirtgen, whose core business is the development and production of machinery for road construction, maintenance and mineral processing, had a base in North Hykeham and a depot site at Leicester which were brought together into this one new purpose-built site. As some of their equipment weighs up to 80 tonnes, which when loaded on lorries for delivery can be up to 120 tonnes, there was an effect on the external hardstanding areas where lorries and plant had been turning.

In 2017, internationally operating company Wirtgen Group, built a new 90,000sq.ft. UK head office in Newark which is also utilised as a vehicle workshop, for parts storage, and as an external hardstanding construction. Wirtgen’s base in North Hykeham and depot site in Leicester were brought together to create this new purpose-build headquarters site in Newark.

Wirtgen – whose core business is the development and production of machinery for road construction, maintenance, and mineral processing – has equipment that weighs up to 80 tonnes which, when loaded on lorries for delivery, increases to 120 tonnes. This has influenced the external hardstanding areas where lorries and plant had been turning, hence the need for an updated site.

Project Specifics

Taylor Woodrow trading as ESM worked with the Wirtgen Group for concrete repairs and joint sealing around the hardstanding areas of the Newark complex. The concrete slabs were breaking up in locations of heavy movement. The team used Maxi-Crete F20 (an inlaid crack repair asphalt) and concrete to repair the patches greatly prolong the service life and enhance ride quality. This was laid in a buff colour to be sympathetic to the adjacent surface colour.

The team also repaired 1500m of joint sealing around the slabs. Works were required in a busy yard with which access was maintained. Coordination was required with the VINCI Facilities team. Diversion route was agreed on to the site and all deliveries where informed of changes ahead of entering the site.

Due to the size of the equipment that Wirtgen moved around the site, if any significant movements where required, these were coordinated with the site team. Everyone working in the hardstanding areas underwent a site induction before being allowed on site due to the plant people interface required.

Richard Allsopp, Sales Director Wirtgen said “I just wanted to drop you a short note to thank you both for the excellent job your team has turned out repairing the concrete joints in our yard at Newark. The whole process has been seamless from start to finish. Your team have worked in a very professional, safe, and tidy manner carrying out everything we requested.”