Ports of Indiana: Asphalt Milling & Paving During Live Operations

Challenges & Solutions

The Challenge:

Managing traffic during reconstruction across critical access points.

The warehouse relied on both entrances for daily operations. Extensive patching across the entrances complicated the work, but operations couldn’t stop—trucks needed continuous access for loading and unloading throughout the project.

Our Solution:

Strategic traffic management and phased construction.

Site Services built temporary stone ramps to reroute traffic around open pavement cuts. This proactive approach maintained safe vehicle access throughout the milling and paving process.

Our team coordinated work schedules to minimize disruption while completing the full-depth removal and replacement efficiently.

Clear communication and flexible planning kept operations running smoothly during construction.

The Asphalt Milling & Paving Process

Site Services executed a systematic approach to transform the steel warehouse’s failing surfaces:

Phase 1: Asphalt Milling & Removal

Our crew removed the deteriorated asphalt completely, eliminating damaged layers that had compromised structural integrity. This full-depth removal created a stable foundation for the new pavement system.

Phase 2: Heavy-Duty Commercial Paving

Six inches of fresh asphalt was installed using proper compaction techniques designed for industrial loads. This substantial thickness ensures long-term durability under the constant heavy truck traffic typical at port facilities.

Phase 3: Stone Parking Restoration

The stone parking area along the road was repaired and leveled, eliminating large holes that had prevented safe truck parking. This restored full functionality to the facility’s staging areas.

The Result

The project was completed with zero business interruption – a testament to Site Services’ planning and execution. The customer was thrilled with the smooth new asphalt surfaces and restored parking functionality.

Project Outcomes:

• Durable 6-inch asphalt surface built to withstand heavy industrial traffic for years

• Smooth, safe driving and parking surfaces throughout the facility

• Restored stone parking area allows trucks to stage safely along the road

• Continuous operational access maintained throughout construction

The steel warehouse now operates with reliable pavement infrastructure that supports the demanding logistics requirements of port operations in Portage, Indiana.