The Retreat - Asphalt Reclamation

San Marcos, Texas

Project Description

132,000 SF surface reclamation at a 285-unit, multi-family complex in San Marcos, Texas near the Texas State University campus.

The surface was significantly compromised with visible pavement distress due to ground swell from an existing water problem.

Industry / Sector

Asphalt reclamation of the access road and parking area at The Retreat apartment complex.

Key Challenges

• Sub-grade comprised of clay, limestone, and unknown material
• 20-30’ elevation change across the project creating complex drainage issues
• Complex was at full occupancy during the entire project

Project Duration

21 days

Key Project Objectives

• Create a viable, low-maintenance surface with minimal interruptions to owners, staff, and tenants
• Meet strict budget considerations
• Complete the project within tight time constraints

Solution & Method

Lab testing determined that infusing the existing sub-base to a depth of 6 inches was optimal — avoiding 18 inches of excavation and Geo-grid installation.

A Wirtgen 200 series machine was used to apply the precise dose of T-PRO® polymer based on on-site material testing. The base was allowed to cure for 12–24 hours before the final topcoat application.

The job-site was completed in 3 phases (approximately 1 week per phase). This approach eliminated the need for approximately 1,000 truckloads of material transport.

The stabilized base was then topped with 1.5 inches of asphalt.

Before Reclamation

Significantly distressed asphalt surface due to ground swell and water issues.

During Stabilization Infusion Process

Top-Coat Application

New Cured Polymer Sub-Base

Expect a flexible 800-1200 PSI dry climate & 350-450 wet PSI

After with 1.5” Asphalt Overlay

Final Result: A smooth, durable, and long-lasting surface.

Results & Achievements

• $450,000 saved in project costs
• Eliminated approximately 1,000 truckloads of material haul-off and import
• Significant reduction in environmental impact and liability
• Completed in just 21 working days
• Delivered a sustainable, durable surface for all users