Case Reference: Port of Virginia, USA
The Port of Virginia is one of the largest and strategically most important port facilities on the East Coast of the United States. Its terminal infrastructure includes high-intensity operational zones for container handling, RO/RO cargo and breakbulk logistics. These areas are exposed to extreme mechanical loads, concentrated wheel pressures, fuel and oil contamination, frequent traffic movements and short maintenance windows.
At the Portsmouth Marine Terminal, a parking area for straddle carriers required a more durable pavement solution after the existing asphalt surface showed progressive deterioration. The main damage mechanisms were fuel and oil leakage from the parked straddle carriers, deformation of the asphalt surface and rutting caused by high point loads from heavy equipment. These conditions increased maintenance demand, reduced pavement reliability and created the need for a more robust surface system.
In 2000, an area of approximately 11,271 square feet was upgraded with UHPC Phalt. The system was selected because it combines the advantages of asphalt-based flexibility with the dense, mineral performance profile of an ultra-high-performance cementitious matrix. This makes UHPC Phalt suitable for industrial pavement zones where conventional asphalt is often too sensitive to fuel, oil, static loads and surface deformation.
The technical objective was to create a jointless, wear-resistant and largely impermeable pavement surface with high load-bearing capacity. UHPC Phalt provides improved resistance against fuel and oil exposure, reduces rutting under parked heavy vehicles and supports long service life in port logistics environments. The dense surface structure also contributes to lower water ingress and reduced degradation of the pavement system.
A key operational advantage was the short construction and curing period. Compared with conventional concrete pavement systems, UHPC Phalt allowed a significantly faster return to service. After only 24 hours of curing, the pavement area was put back into operation by the port. This rapid reopening is particularly relevant for port terminals, logistics hubs, industrial plants and military transport areas, where long shutdown periods are economically and operationally critical.
Pavement Design
The pavement build-up used for the straddle carrier parking area was structured as follows:
| Layer | Thickness |
|---|---|
| UHPC Phalt surface layer | 2" |
| Asphalt base layer | 8" |
| Aggregate base course | 11"–15" |
| Sand layer, CBR = 10 | 3'–4' |
| Sand subgrade | 3'–4' |
This structure demonstrates how UHPC Phalt can be integrated as a high-performance surface layer above a conventional pavement foundation. The system is particularly relevant for container terminals, port yards, RO/RO handling zones, heavy-duty parking areas, airport logistics zones, industrial yards and military loading areas.
From a technical perspective, UHPC Phalt offers a modern solution for pavement areas where asphalt alone may not provide sufficient resistance against concentrated loads, chemical exposure and continuous operational stress. For infrastructure owners, the main benefit is not only higher mechanical performance but also reduced maintenance frequency, faster repair cycles and improved long-term availability of critical operating surfaces.
WPE-DK positions UHPC Phalt as a heavy-duty pavement technology for demanding infrastructure environments requiring durability, fast installation and reliable resistance against load, fuel, oil, abrasion and moisture. The Port of Virginia case demonstrates the relevance of such systems for high-value logistics infrastructure exposed to continuous heavy-duty use.
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