Pavement rehabilitation is rarely a simple task, but the complexity spikes significantly when the job site is a 24/7 major food manufacturing facility. This wasn't just a matter of laying fresh asphalt. This project presented a "perfect storm" of logistical constraints. For the facility managers, the pavement construction posed a severe operational risk. Any misstep could halt production lines, delay shipments, and impact the bottom line.
CLIENT Challenge
This food manufacturing facility is a 24/7 operation with narrow, one-way roadways, limited access points, and time-sensitive dock operations. Pavement construction posed a high operational risk due to:
- Directional traffic constraints that limit how vehicles can move through the site
- Continuous truck traffic and active dock operations throughout the day and night
- A single product delivery port critical to maintaining production
- Waste management infrastructure essential to keeping the production floor clean and compliant
Any disruption to access, deliveries, or waste removal could have directly impacted daily operations, production schedules, and overall facility efficiency.
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Fine Grading Aggregate |
Benchmark’s Role
Benchmark provided Construction Phase Services (CPS), serving as the owner’s eyes and ears on site. The team managed daily coordination between the facility, contractor, and operations staff to ensure construction progressed smoothly while keeping the plant fully operational.
Key CPS Actions
- Coordinated the opening of a second site gate to maintain consistent inbound and outbound truck flow
- Adjusted construction phasing to preserve dock access and align with delivery schedules
- Sequenced work at the site’s sole product delivery port during a one-week operational window with no deliveries
- Optimized dock door phasing, reducing disruption from four weeks to two weeks
- Carefully sequenced concrete work to keep a critical compactor dumpster operational throughout construction
- Maintained 24/7 traffic control, clear signage, and communication across all work zones
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Fabric, Grid and Base Installation
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Concrete Pour
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Project Oversight
Benchmark provided continuous quality control to ensure work met design intent and specifications, while also helping non-technical stakeholders understand progress and quality. This included:
- Verification of excavation depths, subgrade conditions, and undercutting
- Oversight of fabric, geogrid, aggregate placement, compaction, and testing
- Drainage structure inspection and final grade verification
- Concrete reinforcement, mix consistency, sawcut timing, and joint sealing
- Asphalt mix verification, placement, compaction, density testing, and yield checks
Outcome
- Plant operations were maintained without interruption
- Critical deliveries were completed as scheduled
- Operational disruption was reduced through optimized phasing
- High-quality pavement was installed as designed
- Continued multi-year partnership with successful project delivery
Why CPS Matters
Benchmark complements facility operations teams by managing the complexity of pavement construction in active environments. By coordinating people, processes, and timing, CPS helps protect safety, maintain production, and ensure long-term pavement performance—without putting day-to-day operations at risk.
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