Asphalt in a large enclosed area

[David in Texas]

Hello,
I have a 10,000 s.f. horse riding arena that I want a hard floor for. Concrete would be a minimum of $65,000 and hot mix asphalt has been quoted at $3.25 per s.f. ($32,500.00). Unfortunately, both are out of my budget.
Context:
There would be no driving on this. It will be used for some sports (basketball, pickleball and ********) as well as small concerts up to 500 people.
The arena would be enclosed, spray foamed and have HVAC so weather would not be the issue that it usually is on asphalt.
I was thinking of putting down a crushed concrete base followed by asphalt millings. Compact them down with a roller and then seal it with a sealer I can buy at Grainger in 55 gallon drums.
Total cost of this method appears to be about $14,000.00.
It is either this or I would have to scrap the whole idea.

 

[FJ4FUN]

Sounds like a solid plan given the intended use.
Check out Wolverine Coatings' RestoraSeal 3515 as well.

 

[David in Texas]

Thank you FJ4FUN. I will check that out now.

 

[Ole Slewfoot]

Check with your local hot plant on sealer.

 

[Xti04]

What about just haevily compacted crush and run? That way you dont have to seal it.

 

[Rusted Nut]

I’ve used asphalt millings to build temp roads/lay down storage area on construction sites. It’s OK for temp use to get you out of the mud, but the surface is uneven and pretty porous, and this is after being graded and rolled with a 50 ton roller. It would not take an asphalt sealer very well at all, too porous. You may not be happy with the end result, especially for pickle ball and the like.

 

[FJ4FUN]

I’ve used asphalt millings to build temp roads/lay down storage area on construction sites. It’s OK for temp use to get you out of the mud, but the surface is uneven and pretty porous, and this is after being graded and rolled with a 50 ton roller. It would not take an asphalt sealer very well at all, too porous. You may not be happy with the end result, especially for pickle ball and the like.

You make a good point re: too porous for a sealer.

 

[Dozerhand]

I don't think I would use milling and then try to spray something on it. You will end up with a sticky mess. Kinda the same for hot mix. I've done some big jobs inside but none came out that good. Without the hot sun to bake it it seems like asphalt under roof never really sets up. You get a 300 pound guy sitting in a folding chair for a concert and you're going to have 4 holes in your floor. I say bite the bullet for concrete or go with the tried and true dirt floor and just deal with the dust. How about some type of astroturf product?

 

[David in Texas]

I don't think I would use milling and then try to spray something on it. You will end up with a sticky mess. Kinda the same for hot mix. I've done some big jobs inside but none came out that good. Without the hot sun to bake it it seems like asphalt under roof never really sets up. You get a 300 pound guy sitting in a folding chair for a concert and you're going to have 4 holes in your floor. I say bite the bullet for concrete or go with the tried and true dirt floor and just deal with the dust. How about some type of astroturf product?

Thanks for the advice. I can't just bite a $60,000.00 bullet though. I have looked at astroturf and may go that route or even put it on top of the asphalt.

 

[FJ4FUN]

Decomposed granite???

 

[rsanter]

What about compacting the exsisting soil, then top with DG or smaller gravel and compact again.
A gravel road base that is compacted to 98% is as hard and solid as concrete.
You won’t be as thick but I think it can be done so work well and you could even do it yourself

 

[Jbullfrog]

I would spread rock in the entire arena to hold the dust down, then split it up and pour concrete in sections. You could ask your local concrete companies to let you know if they have reject loads and have them dump them in your building. Keep a section formed and ready for them to come. The salvage yard I worked at 20 years ago poured 100's of yards this way.

 

[Youngandfree]

What kind of income are you getting from the concerts and sports?