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“It looks like a brick road and it wears like a brick road -- but it installs like the asphalt it is. The asphalt is applied in normal fashion and grooved into brick shapes using a template pressed into the finished surface. The 'magic' happens with the finish application. Then, viola!... A brick paved street in any color combination imaginable.”

The StreetPrint process and emulsions have been in use for more than five years. Though extensive product testing has been done, the real test has been the test of time. Five years has shown that the product has durability beyond standard asphalt. It is virtually stain-proof and impervious to damage from salt, petroleum distillates, and other corrosives known to reduce the life and luster of asphalt. Unlike standard brick, StreetPrint has 'grout lines' that encourage both water run-off and improved traction, thus offering safety features previously unavailable with standard asphalt. StreetPrint also eliminates the problem of weed growth so often seen in hand laid brick. It is highly suitable for state or municipal roadways, and is also perfect for cross walks and mall situations and all residential uses. With all these advantages, StreetPrint was the perfect choice for installation on a residential street in the quaint city of Boyertown, Pennsylvania.

My company, Gable Enterprises, is an authorized applicator of StreetPrint, under license from Integrated Paving Concepts Inc., Victoria, British Columbia, Canada, the developer of the process. Although our project began on a bright summer day in 1995, the process really begins at the asphalt plant where a special hardening modifier was added to a Department of Transportation approved wearing surface. It was then thoroughly blended into the primary mix. This product assisted environmental integrity from the very beginning as hauling vehicles no longer had to use diesel fuel before loading. Crews simply coated the hauling surface with soapy water, pulled under the fill bin, and loaded the material. Unloading was a breeze.

The on-site process began with sweeping the existing street to eliminate any loose debris such as dirt, leaves, or twigs. Once completed, a tack coat was applied. We have found this step to be very important as it ensures quality adhesion of the new product to the existing material.

The next step was to apply a leveling course. This step provided for recrowning and eliminated any voids that may have been present in the existing surface, thus providing a consistent surface to work on. We have found that failure in this area will often result in loss of quality when imprinting begins. Consistent depth and compaction eliminates unnecessary labor and provides the required base for clear print definition.
Important Considerations

After applying the leveling course, the wearing course was installed. We have also found that it is important to use ID-2 wearing course with modifier added and maintain the necessary 1.5 in. compacted depth. To achieve a quality print, it is important to complete 90 percent of the rolling/compacting before imprinting begins. Because there is a variety of imprint templates available, we select a pattern before the date of installation. There are different sizes and shapes for different areas. For this project we chose a standard brick pattern. The basic template is 6 ft 6 in. deep x 12 ft. wide. The templates are easily overlapped to achieve any desired width.

Once placed, the process of compacting the templates began. As with any project, having the right tools for the job reduces the potential for error and delay. Our situation revolved around the fact that the added asphalt modifier allows early use of the material, but reduces the amount of time it is workable. We have found that by using a series of standard Dynapac (Schertz, Texas) vibratory plate compactors, a smaller Dynapac 3- to 5-ton roller, and a large vibrating plate we can comfortably meet the required time frames. However, use of the larger plate compactor is essential. The unit itself weighs about 1,100 pounds and it applies 13,000 lbs. psi. This combination achieved the Department of Transportation approved compaction factor of 92 percent in minimum time. To set the templates, we use standard compactor plates. To achieve consistent depth of print, we followed up with the roller and the large vibrating Dynapac plate compactor, at a dead slow speed. Removing the templates was simple. Again, we did not have to use diesel fuel. A mild soapy solution worked very well.

By the time we began removing the first set of templates the crowd was gathering. Everyone was clearly impressed with the brick design edge that was so clearly established. Officials from all over the area were comparing notes along with the 'oohs' and 'aahs' that this process generates. It was particularly interesting for the crowd because to achieve this objective, all steps in the process must be happening simultaneously as the project moves along.

Initial material was continually laid out in front, with the rolling compaction process following in-line. The printing stage worked forward third in line. Masking techniques were used to protect the integrity of the product. Special hand printing tools were used for hard to print areas. The same installation techniques were used to install a beautiful intersection radius. When the second pass was required, we just interlocked the templates and, presto, we had correct alignment. We used a series of seven or eight templates simultaneously in this manner.
Perfect Match

Using a paver equipped with a joint matcher was essential. The matcher rides on the in-place surface and assured a perfect match, every time. We were able to complete 60 to 70 ft of paving before stopping to evaluate and catch up on hand finishing. However, we did find that we had to have 90 percent of the compaction work completed before printing to achieve these results. For corners or curves, there are several template patterns available. A 'soldier' course can be very effective in this application. Hand printing tools can also be used. For this project, we chose a combination of hand tools and templates. Although labor intensive, it allowed us to ensure continued integrity of pattern after the corner or curve surface was installed. We are fortunate to have a staff of skilled craftsman who take extraordinary pride in their work. Still, the cost remains less when compared to hand laid brick.

As we placed the initial wearing course, luting was done as usual, followed by brooming to assure a nice tight pinched joint.

After printing was completed we allowed the road to cure for several days before beginning the coating process. Once cured, the area was washed down with a high-pressure system to eliminate all dirt, debris, and loose asphalt from the printed surface. Washing ensured that the printed surface would bond properly with the finish coatings. Now it was time to pull the final rabbit out of the hat. The color went on. Two coats of epoxy-fortified acrylic emulsion were used. A special additive was used to ensure durability in a high traffic area. Special sprayers were used to accommodate the viscosity of the coating and large, hard bristled brooms helped to guarantee even distribution of the coating material.

These coatings are really unique. Not only are they salt, gas, and oil resistant, they also allow the asphalt to breathe and continue to cure. There are six standard colors, with many others to chose from. Extra-cost custom colors can also be mixed.

Regulation makes it imperative that state and municipal authorities be made aware of product integrity. PennDOT was present during the project and conducted a number of tests. The first area examined was compaction. PennDOT randomly picked three spots and removed four-in. core sections. The test results from all three samples were then averaged. The goal of a 92 percent compaction rate was achieved. In addition, the police department performed skid-resistance tests before and after the application of coatings. This is a standard test commonly used to evaluate accident scenes. We are proud to say that the results were highly satisfactory. For those wheelchair access areas, StreetPrint meets criteria as established by the Americans with Disabilities Act.

The completed project is proof that the cost-effectiveness of StreetPrint does not sacrifice the beauty and charm of the desired hand laid brick effect. It is also the only decorative paving technique that can be installed over existing asphalt paving. The potential is virtually endless.

StreetPrint was developed and originally tested in Vancouver, B.C., a beautiful area subject to environmental conditions similar to those found in Pennsylvania. StreetPrint has stood up under the test of time in Vancouver, and we are confident that it will continue to do so here in Pennsylvania.