Our Major Resurfacing Project at The Co-op Academy, Manchester

The Co-op Academy approached us with the challenge of revitalizing their playgrounds, seeking a durable and safe solution to enhance the outdoor play experience for their students.

To kick off the project at The Co-op Academy, we first had to create a temporary roadway to ensure smooth access to the tennis courts for our equipment and materials. This involved excavating the ground on either side of the existing path, widening it to accommodate wagons and allow for the transportation of materials to the work area. In addition to this, we addressed an already damaged pathway that led up to the tennis courts. Rather than opting for a quick fix, we decided to fully renovate the path by excavating the old surface and reinstalling it with concrete edgings and a durable tarmac finish, ensuring a long-lasting, high-quality solution for the school.

Next, we moved on to the resurfacing of the tennis courts, starting by removing the old ACO drains and concrete footings. After clearing the area, we installed new ACO drains equipped with cast iron heel guards, ensuring improved drainage and durability. To achieve a smooth, flush finish, we then planed off the perimeter of the area, about 1 meter wide, to align with the new edging. Any existing cracks in the surface were also planed out to a depth of 75mm, and a 75mm thick binder course of 20mm dense bituminous tarmac was applied directly to these planed cracks, ensuring a stable and solid foundation. The binder course was carefully rolled to ensure proper compaction. To enhance adhesion, we sprayed the entire 2170m² area with Bitumen Emulsion, preparing the surface for the final layer. The finishing touch was the application of an Ulticourt tarmac surface, chosen for its durability and suitability for high-performance sports.

The next part of the project involved creating a tarmac area next to the school’s car park. We began by excavating the area down to a depth of 275mm to prepare for the new surface. Following this, we excavated a trench to install 6mm concrete edgings around the perimeter, providing a clear boundary for the new tarmac area. To prevent weeds from growing through to the surface, we laid a layer of Terram Construction Fabric. We then imported and compacted MOT Type 1 Stone at a depth of 200mm, creating a solid base for the surface. Once the base was in place, we applied a 50mm thick tarmac binder course with a 20mm bituminous layer, which was carefully rolled to ensure a polished and long-lasting surface. To complete the project, the team supplied and installed the final finishing layer of Ulticolour Tarmac, providing a high-quality, long-lasting surface that perfectly complemented the surrounding area. We then repeated this process for the new surfacing for their football pitch.

In addition to the main areas of the project, we also carried out some work at the car park entrance. This involved removing the existing road kerb at the gateway entrance and replacing it with a new drop kerb formation to improve access. We carried out all necessary groundworks to form the new entrance, ensuring the area was properly prepared for the new surface, including the installation of all required edging details. Once the groundwork was completed, we finished the area with a high-quality road-spec tarmac surface, providing a durable and smooth entrance that seamlessly blended with the rest of the site.

The completion of this major resurfacing project at The Co-op Academy has significantly enhanced the school’s outdoor spaces, providing safe, durable, and high-quality surfaces for both play and practical use. Every aspect of the project was designed to meet the school’s needs while ensuring longevity and performance. We are proud to have delivered a solution that not only improves the aesthetics and functionality of the site but also offers lasting value for the school and its students for years to come.