When you see our asphalt paving crews diligently working on major road projects or our plants operating at peak capacity, it’s easy to focus solely on the impressive volume of materials flowing through our network. However, behind every ton of asphalt we or our customers lay down lies a meticulous, scientific process that underscores our unwavering commitment to quality control.

At The Gerken Companies, the creation of roads that stand the test of time is a carefully synchronized effort. Our robust quality control (QC) loop begins in a controlled laboratory environment and culminates behind a roaring paving train.

Here is a look at how our QC teams facilitate the vital link between our manufacturing plants and active field projects, and why their work contributes to our reputation.

A Coordinated Effort

Building a reliable road presents a two-part challenge: the precision manufacturing of the material, followed by its flawless installation. If either aspect falters, we risk issues like premature cracking or rutting.

Fortunately, at The Gerken Companies, our asphalt operations seamlessly bridge these two distinct environments through our comprehensive QC program. This process ensures that the asphalt produced at our plants is identical to the asphalt we install in the field, maintaining the highest possible quality standards.

Perfecting the Recipe

Our laboratory testing is very precise. Operating out of an advanced central laboratory in Napoleon, Ohio, and our 14 plant-specific labs, our technicians expertly manage the chemistry behind our mixes. Using their training, they painstakingly verify the job mix formula to ensure the liquid binder content is on target and the aggregate blends are correct.

In the lab, technicians burn off liquid bitumen in ignition ovens to achieve the ideal asphalt binder percentage. It’s a delicate balance—too much liquid can lead to road bleeding, while too little can result in brittleness. Additionally, they employ mechanical sieves to prevent aggregates from segregating and use gyratory compactors to simulate how the mix will perform under decades of heavy traffic.

Managing the Real World

Once the asphalt leaves the plant, the dynamics shift entirely. Field quality control faces the unpredictability of weather, fluctuating temperatures, and the hustle of active traffic.

This is where our extraordinary field technicians shine—they expertly manage real-world conditions. They monitor mat temperatures in real time and utilize density gauges behind the rollers to ensure that compaction meets targets before the mix cools. By taking core samples from the finished pavement and returning them to the lab, they complete the quality loop, verifying that the actual installation aligns with the laboratory’s ideal specifications.

Science on the Move

Every department at Gerken plays a critical role in our overarching success, but it is our QC team that provides the technical insurance policy for our work. They represent the analytical backbone of our infrastructure production. By striking the ideal balance between the rigorous precision of the lab and the complex variables of the field, our QC teams work tirelessly to uphold quality, safety, and excellence in every project we undertake.

With such passionate and diligent efforts from our entire team, we confidently create roads that not only endure but also serve our communities with pride for generations to come.