Echelon Paving Powers APEX Motor Club Expansion
BY Immanuel Martinez
Sunland Adds to APEX Motor Club with Quality Echelon Asphalt Paving
The high-speed world of motorsports demands world class precision, performance and durability. At Sunland Asphalt & Construction, LLC, Phoenix, we embraced these principles when we took on the development of the second circuit at the APEX Motor Club track in Maricopa. Spanning from August 2024 to February 2025, this project represents an incredible milestone in Arizona’s racing landscape.
The transformation of undeveloped farmland into a high-performance racetrack required extensive engineering and meticulous attention to detail in planning. Phase two took place from August 2024 to February 2025.
Transforming Dream Into Reality
The transformation of undeveloped farmland into a high-performance racetrack required extensive engineering and meticulous attention to detail in our planning. Grading was a critical component, with 138,960 cubic yards of material cut and 121,163 cubic yards of fill placed to shape the building pads, retention basins, multiple track sections, runoff areas and paddocks.
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For the track’s foundation, an 8-inch layer of Aggregate Base Course (ABC) was placed and finish graded before receiving a 2.5-inch application of ½-inch asphalt—meaning ½-inch nominal maximum aggregate size (NMAS). The track itself was surfaced with 1.5 inches of a 3/8-inch Special Mix for the wearing course, ensuring superior grip and durability. Our use of echelon paving—simultaneously running three pavers—was key to achieving a seamless, high-quality racing surface.
A binder course of 2.5 inches of ½-inch material required 100% of the aggregate should pass through the ¾-inch sieve. The surface course of 1.5 inches of 3/8-inch Special Mix required 100% should pass through the ½-inch sieve.
“During echelon paving, we utilized three material transfer vehicles (MTVs): two Weilers and one Roadtec Shuttle Buggy,” said Greg Hughes, our project manager – Public Works. “Paving operations were carried out using three Vogele Super 2000-3i pavers. Paving this way almost eliminates any joint and acts as one continuous mat. The slope of the track was minimal, so additional support equipment was not required during rolling operations.”
“At the transverse joints, we used a 12-foot straightedge to check for flatness and made necessary adjustments to maintain levelness. Along the outer edge tie-ins, we aligned the screed to match the elevation of the existing asphalt for a seamless transition.”—Greg Hughes
A Track Built for Enthusiasts
APEX Motor Club, now owned by RJT Capital, is more than just a racetrack; it’s a haven for speed enthusiasts. Strategically located to serve Phoenix, Tucson, and even cities like Los Angeles and Albuquerque, this circuit caters to drivers who demand the best. Every detail, from the material selection to the construction techniques, was geared toward delivering a world-class racing experience.
The two sections of the track Sunland has now completed can be run independently or combined into a single 4.7-mile configuration for racing.
The track’s continuity with Phase 1, which we paved in 2018, was another highlight of this project. Ensuring seamless integration required exceptional precision in tie-in joints and elevations. The result is Arizona’s longest motorsports track—a continuous circuit designed to push limits and set new standards in high-performance driving.
“The original track measured 2.27 miles, while Phase 2 added an additional 2.43 miles,” Hughes shared. “These two sections can be run independently or combined into a single 4.7-mile configuration.”
Precision Paving at it’s Best
One of the most demanding aspects of this project was achieving the track’s stringent surface tolerance. That quality started at the base.
“To ensure grade tolerance, our blade utilized GPS technology to follow the project-specific model accurately,” Hughes explained. “At the transverse joints, we used a 12-foot straightedge to check for flatness and made necessary adjustments to maintain levelness. Along the outer edge tie-ins, we aligned the screed to match the elevation of the existing asphalt for a seamless transition.”
Echelon paving, which was crucial to ensuring consistent quality across the track’s 42- to 50-foot width, can have many complex logistical challenges in coordinating multiple paving machines and maintaining uniform asphalt application.
Project Foreman Isidro Lopez was one of the key figures in bringing the project to life. He stated, “Spending time with family is my favorite way to unwind,” but on the job, he played a vital role in delivering the precision the track required.
“Since GPS technology was used to establish the desired grade during preparation, we paved using a 2D control system,” Hughes explained. “Each paver was equipped with 30-foot paving skis, which helped maintain consistent depth and alignment. The skis function as a leveling system by averaging the surface over their full length, effectively smoothing out minor grade variations. Additionally, the second lift served as a corrective layer, addressing any imperfections remaining in the base course.”
Additionally, Sunland installed 4,850 feet of concrete curbing designed specifically for APEX, improving both functionality and aesthetics. Our team also constructed a 100-foot by 85-foot box culvert and 1,020 feet of cut-off walls to manage water flow and enhance track stability, ensuring optimal performance under diverse conditions.
A binder course of 2.5 inches of ½-inch material required 100% of the aggregate should pass through the ¾-inch sieve. The surface course of 1.5 inches of 3/8-inch Special Mix required 100% should pass through the ½-inch sieve.
Key Partners
This project was a collaborative effort, made possible by our trusted subcontractors:
- Solterra Materials supplied the high-performance, polymer-modified asphalt, ensuring superior grip, durability, and smoothness. Led by Michael Thompson, Solterra’s expertise in asphalt production and logistics was instrumental in maintaining project timelines and quality.
- Vital Contracting, under the leadership of Stephen Boyd, executed all earthwork operations, delivering near-perfect tolerances essential for racetrack construction.
- CMT Technical Services, headed by DJ Peters, ensured compliance with rigorous material testing standards, performing geotechnical evaluations, density testing, and asphalt mix verification.
A truck has completed loadout at the Solterra Materials plant and is ready to take a load of mix to the APEX Motor Club track project.
Spotlight on Isidro Lopez
One of the key figures in bringing this project to life was Isidro Lopez, project foreman at Sunland Asphalt. With years of experience in the industry, Lopez played a vital role in delivering the precision required for a world-class track. He stated his favorite aspect of this job was, “Seeing the owner’s excitement when we finished—it was like kids opening Christmas gifts.”
Project Foreman Isidro Lopez was one of the key figures in bringing the project to life. He stated, “Spending time with family is my favorite way to unwind,” but on the job, he played a vital role in delivering the precision the track required.
The most memorable day for Lopez was, “Reaching the end of the track on that final day of paving—everyone was thrilled to achieve the end goal.”
“Seeing the owner’s excitement when we finished—it was like kids opening Christmas gifts.”—Isidro Lopez
A Legacy of Excellence
On this issue’s front cover, from left to right, Will Morrison is the asphalt plant operator for the Coolidge site and Matt King is an asphalt plant foreman for Solterra Materials, the company that supplied the high-performance, polymer-modified asphalt for Sunland’s APEX project.
Sunland Asphalt & Construction’s commitment to precision and innovation continues to drive our success. The completion of APEX Motor Club Phase 2 marks yet another milestone in our legacy of delivering top-tier asphalt solutions. From engineering complexities to flawless execution, this project exemplifies our expertise in high-performance paving—ensuring that APEX remains the premier destination for automotive enthusiasts across the Southwest.
For those who live life in the fast lane, APEX Motor Club is ready. And Sunland Asphalt & Construction is proud to have paved the way.
Immanuel Martinez brings 20+ years of experience managing complex construction projects, pioneering 3D paving innovations, and leading high-performing teams across public and private sectors. To learn more about Sunland, visit sunlandasphalt.com and check out past articles on TheAsphaltPro.com.