Semi-rigid wearing courses combine the advantages of an asphalt-based pavement skeleton with the high compressive strength, abrasion resistance and chemical resistance of a cement-bound high-performance grout. The technology is based on an open-graded asphalt or bituminous support structure with a high void content. After installation and compaction, this void system is completely filled with a highly flowable UHPC or high-performance cementitious grout. The result is a composite wearing course that is more elastic than pure concrete, but significantly more dimensionally stable, denser and more fuel-resistant than standard asphalt.
Installation is carried out in several steps. First, the load-bearing base or existing asphalt surface is inspected, cleaned and, if necessary, re-profiled. Then an open-graded asphalt skeleton is installed in a defined layer thickness and compacted. After sufficient cooling, the UHPC grout is applied and worked into the pore structure using rubber squeegees, screeds or suitable spreading equipment. Complete filling without voids and dry zones is essential. After surface finishing, curing follows in order to prevent early drying, shrinkage stresses and loss of strength. Depending on the mix design, temperature and load requirements, the surface can be reopened to traffic after a defined hardening period.
For new military construction projects, this technology offers significant advantages. Tank parking areas, heavy-duty access roads, aircraft aprons, refuelling zones, container handling areas, military ports and logistics depots are frequently exposed to extreme wheel loads, slow turning movements, shear forces, fuels, hydraulic oils, salts and mechanical abrasion. A semi-rigid UHPC wearing course significantly reduces rutting, surface deformation and fuel-related damage. At the same time, it can be installed with fewer joints and faster than conventional concrete pavements.
The benefits are also substantial for rehabilitation projects. Existing military asphalt surfaces often still have a load-bearing substructure, while the surface itself is damaged by heat, heavy-duty traffic or operational fluids. A semi-rigid UHPC wearing course can technically upgrade such surfaces without requiring complete reconstruction of the entire pavement structure. This reduces closure times, construction costs and operational interruptions.
Another advantage is its adaptability to different temperature zones. In hot climates, such as the Middle East, Africa or Australia, the high dimensional stability improves resistance to deformation and softening. In cold and frost-exposed regions, a dense UHPC matrix can reduce the ingress of water and de-icing salts. In maritime or tropical climates, the low permeability supports protection against chlorides, moisture and chemical exposure.
This makes the semi-rigid UHPC wearing course a strategic surface technology for military infrastructure: robust, load-resistant, repair-friendly and designed for high operational readiness.
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