Originally constructed in 1974, the Valley Preferred Cycling Center (formerly known as the Lehigh Valley Velodrome) has long drawn the world's top cyclists and has provided an economic boom to Lehigh County, PA. As such, it was extremely important to the county that the facility be properly maintained so that they could continue to draw premier talent to the track. This track is one of only a handful of certified outdoor 333-meter tracks in the country. After receiving feedback from several cyclists, the owners recognized that the concrete track was in need of resurfacing.
Run by a former Olympic medalist, all repair work had to be completed on the track during the winter months so that racing and training schedules would not be affected. Structural Preservation Systems (SPS) was contacted to perform the repairs for this project. According to specifications from the Union Cycliste Internationale (UCI), (which call for flatness to within four millimeters in two meters) the track was out of spec. Because funds for the project were limited, SPS worked with cyclists to identify both the problem and most highly trafficked areas of the track. Taking these factors into account, the final repair addressed nearly 40 percent of the track in terms of flatness, along with a full placement of new overlay.
To begin the repair process, crews ground the high areas of the track to decrease the rise, eliminating bumps. After crews had ground a portion of the track, cyclists would then ride on the track again to determine if that amount of grinding alleviated the problem. This task was extremely challenging because the team was repairing for feel rather than a quantifiable specification. There were five to six iterations of obtaining rider feedback, so it was critical to have the same riders on the track each time. Baker Concrete Construction developed an innovative method for the grinding process. An A-beam strut with an electric winch was used to convey the grinder up and down the 30-degree bank with a cable. Typical concrete repairs to distressed areas were also completed. Once the grinding and repair processes were complete, crews resurfaced the track using multiple coats of a polymer-modified Portland cement material.
A cross-hatch placement pattern (alternating application directions) was used to achieve complete coverage and provide a uniform finished color. Next, all joints across the track surface and the top and bottom were sealed with a traffic grade sealant. New racing and time trial lines were painted, and eight feet of the existing asphalt apron was removed and replaced with a road super-pave mixture.
Open in time for the cycling season, the project began in late October 2007 and was completed in early May 2008. The completed work has increased the safety and smoothness of the track and also eliminated the majority of bumps and all delaminations.