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  • Roadstone, a CRH Company, has developed an innovative, scalable solution that sets a new benchmark in high-performance roads
  • A groundbreaking asphalt mix featuring an ultra-high percentage (70%) of reclaimed asphalt pavement was made possible through the use of a novel rejuvenator
  • Multiple other technologies, including the integration of bio-binders contributed to a high-performance and durable mix
Division(s)
CRH International
Product Type(s)
Asphalt
Paving & Construction

CRH Company Roadstone has leveraged their extensive technical expertise to develop a groundbreaking asphalt mix for the resurfacing and improvement of one of Ireland’s National Road projects.

The asphalt mixture featured a multi-component rejuvenator which was developed in house and a bio-binder system to achieve an ultra-high percentage of reclaimed asphalt in the pavement. A tailored blend of innovative additives enabled the use of 70% reclaimed asphalt pavement (RAP), while still meeting all performance requirements.

The innovative solution integrated multiple advanced technologies including:

  • Replacing 10% of the total binder with lignin, derived from waste wood, which served as a partial bio-binder replacement for bitumen;
  • The lignin also served as a component of the rejuvenation strategy; designed to restore the mechanical and chemical properties of aged RAP binder and enable the use of ultra-high RAP content, while also improving performance.
  • The use of HVO (Hydrotreated Vegetable Oil) and Renewable electricity (38.8% CO2 reduction) in the asphalt plant and in all transport and paving equipment, replacing diesel and fuel oil, to reduce carbon emissions;
  • Warm Mix Asphalt (WMA) which is produced at lower temperatures to traditional asphalt mixes and helped minimize fuel usage and emissions, and
  • Intelligent compaction technology, which created efficiencies in quality control, contributed to reduced carbon emissions.

Roadstone carried out extensive laboratory testing to validate the mixture’s ability to meet specified requirements for durability and functionality under high traffic conditions. The results demonstrated clear performance improvements in key properties such as stiffness, and fatigue resistance, as well as excellent water sensitivity (up to 98.4%) and high stiffness (>4300 MPa) which are indicators of a durable, high-performing mix.

100% of the reclaimed material was processed and reused, eliminating asphalt waste to landfill. Additionally, the mix achieved a 94% reduction in CO₂ when compared to a conventional asphalt mixi.

The project which was supported by CRH’s Innovation Fund was deemed a successful trial and sets a new benchmark for high performance, circular road construction in Ireland, with a scalable, repeatable formula for other CRH markets.

i using 100% virgin aggregates and bitumen, produced with fossil fuel and hot mix asphalt