Road Recycling

Solutions
Three processes designed to reduce
your carbon footprint and cost

Colas
Our road recycling processes
Colas Limited operate throughout the UK as a service
provider to the highway and airfield sectors. As a part of
the International Colas Group, Colas can draw upon the
resources and expertise of one of the worlds leading
organisations, for construction and maintenance within
the roads and airfields industry.
Colas are at the forefront of developing and mastering road recycling techniques and
have a number of sustainable surfacing options within our portfolio, providing long
term preventative maintenance.
Our expertise within the road recycling market have been long established and
carried out for over the past 50 years.
These processes re-use existing materials, reduce waste and consequently avoid
unnecessary lorry movements and landfill. During consultation, our team of experts
are able to independently advise clients on the ideal solution, depending on the
current site conditions.

1. Repave
New Surface Course
Surface Course

20 - 25mm

30mm

2. Retread
As required

3. Deep Recycling
As required

75mm

Binder Course

150mm to
350mm

Road base

Sub-base

A hot recycled surface

course process, which
can be applied throughout
the year in most weather
conditions. Repave can
be combined with any
surface course currently
available and with Colas
proprietary surface
course, Colrug.

A cold process used on

both carriageways and
footways that saves
energy and reduces
hydrocarbon emissions,
while reconstructing the
surface layers faster and
more economically than
conventional surfacing
processes.

A fast and economical

cold reconstruction
process for the complete
road surface or for
haunches. This process
may also be completed
ex-situ and material may
be mixed off site, with
no waste, ensuring
controlled quality and
the opportunity to include
other re-usable materials
such as glass, china clay
and crumbed rubber.

Deep Recycling
Deep recycling is a fast and
economical cold reconstruction
process which reconstructs
the entire road surface or
haunches to a depth of 150mm
to 350mm and is mixed with
new binders to form a uniform
and strengthened structure.

Rather than removing the existing material, this process

recycles the existing material in-situ. This rapid process
has the advantage of reducing lorry movements and
minimising disruption to both road users and residents.
Up to 1500m2 can be treated per day depending on
site conditions. Leaving the material in place during
operations means that local and emergency access
can be maintained.
After initial pulverisation, the surface is compacted
and trimmed. Excess material is removed before
recycling the existing pavements, after which emulsion
and hydraulic binders are then added to the existing
material. Fuel ash or cement may be added according
to TRL 611 creating FABM, HBM or CBM mixes. During
which time the sub-grade is not exposed, reducing the
risk of soft spots.

Once the recycling is complete,

the material is again compacted
and the surface shaped by a
grader to the required levels.
Finally the surface is coated
with bituminous emulsion
and sealing grit after which
it can be subjected to traffic
if necessary.
Depending on design
requirements, a final surface is
laid appropriate to site conditions.
The process is specified
according to TRL 611 and is
approved under clause 947 of the
Specification for Highway Works.
Reduced time on site by
up to 60% means less road
space occupation and minimal
traffic requirements
In-situ benefits result in
reduced lorry movements
and disruption to local
communities
Reduced energy consumption
by up to 60% in the total
construction cycle when
compared to conventional
road surfacing treatments
Conserves natural resources
through recycling materials
such as glass and china clay
Great efficiency and
ultimately cost savings
Treats tar-bound layers
in-situ according to EU
regulations without the
need of costly disposal.

Retread
Carriageway and footway in-situ recycling

Retread is a cold in-situ recycling

process, with over 30 years
proven performance on UK
carriageways and footways.

With increasing focus on sustainable procurement, Colas Retread

process offers a low CO2 emission alternative. By reducing the output of
energy, emissions and waste, Colas are able to aid clients in significantly
lowering their carbon footprint.
Carriageway Retread
Carriageway Retread recycles the
existing pavement in-situ to form
a durable reprofiled carriageway
rather than planing off and
discarding the old material as in
traditional methods. Specialist
plant is used to breakdown the
surface of the carriageway to a
depth of 75mm. This material is
graded to form the new profile.
Retread emulsion is thoroughly
mixed into the existing road
pavement to ensure uniform
distribution and penetration of
the binder.

The surface is compacted and an

application of binder and 14mm
chippings are rolled in to close
surface voids. A double 6mm
surface dressing finishes the
process, on which any choice of
surface material can be applied
if deemed necessary.

Before

Retread can work to existing

levels leaving kerbs and iron
work undisturbed, thus reducing
costs. Time required on site
is significantly reduced in
comparison to conventional
road surfacing treatments,
reducing overall disruption to the
community and road users.

After

Footway Retread
During the process specially designed
equipment is used to breakdown the
surface of footpaths to a depth of
75mm, new Retread binder is added
and thoroughly mixed with the old
material, rejuvenating it. The level of
the completed Retread can be suited
to accept a new asphalt surface
course or Slurry Seal.

Any surplus materials can be used

to treat soft spots or where levels
are low, the remainder is suitable
to use as a sub-base elsewhere.
Colas uses a footway paver to
ensure that our footway work has
a superior finish when compared
with traditional hand lay methods.

Case Study for

Carriageway
Retread in
KIRKLEES

Total Energy Consumption, GJ

UPSTREAM
DOWN STREAM
REPAVE
STRUCTURE BINDER AGGREGATES TRANSPORT MANUFACTURE TRANSPORT LAYING MACHINE
CONVENTIONAL 3,142.6
REPAVE 1,770.7

Repave:
Pulverise 75mm
and Retread

TOTAL

771.3

259.2

4,550.6

1,571.7

631.2

1,270

10,926.5

119

13.2

243.4

454.2

301.5

1,270

4,171.6

Saving in energy consumption

Area:
77,442m2
Conventional:
Plane out 75mm and
replace with HDM
binder course

Colas can work in partnership

with existing Service Providers
for the delivery of this process.
Surface course and iron works
adjustment can be provided by
the client, bringing the benefits
of recycling while still supporting
existing arrangements.

61.8%

GHG Emission in Equivalent CO2 tonnes

UPSTREAM
DOWN STREAM
REPAVE
STRUCTURE BINDER AGGREGATES TRANSPORT MANUFACTURE TRANSPORT LAYING MACHINE

TOTAL

CONVENTIONAL

184.8

27.9

19.1

294.6

115.7

48.5

95.3

758.1

REPAVE

103.7

4.3

5.9

35.4

3.2

95.3

448.6

Saving in CO2 EMISSIONS

61.4%

Repave
A greener road network
Repave is a hot in-situ recycling process which can take place
throughout the year in most weather conditions and on any
class of road or airfield pavement. It involves the recycling of
existing asphalt road material in-situ, reducing traffic disruption,
lorry movement, the demand for new aggregate and cost.
Repave can be combined with
any type of surface course
including HRA.
The site is assessed to determine
suitability. If necessary, core
samples are taken to confirm
the construction and binder
penetration value.
The road surface is heated to
150oC forming a plasticised asphalt
layer, and the materials are then
scarified to a depth of 30mm.
This is completed using a two
stage passive scarifier with spring
loaded tines to avoid damage to
street furniture. A vibrating screed
reprofiles and corrects levels for
the required crown or crossfall.

A new thinner asphalt layer is then super imposed, thereby providing

a homogenous asphaltic layer up to 50mm.
Heat from the Repave process penetrates 25-30mm deep into
the surface of the road, allowing the final layer to be laid even
during wet, cold weather.
The surface to be treated can be either HRA, SMA or bituminous
macadam. Gullies may not need to be adjusted saving time and
money, Repave can provide a faster and more economical alternative.
The Repave process is approved under clause 926 of the Specification
for Highway Works.

 50% Increased recycled content

Reduced time on site means less road
space occupation and minimal traffic
management requirements
Recycling materials conserves natural
resources and extends the life of the
existing infrastructure. Reduced use of
virgin materials promotes retention of
habitat and green spaces
Reduced Green House Gas and
CO2 emissions
Reduced energy consumption in the total
construction cycle when compared to
conventional road surfacing treatments.
Waste reduction - The percentage of
waste produced is negligible, avoiding
unnecessary landfill
Cost savings due to shorter construction
period and reduction in the use of
new materials.

Project A64 Malton Bypass March 2011

Achieved savings
compared to
conventional
Conventional:
Plane out 50mm
and replace with
50mm SMA
Repave:
Plane out 25mm,
repave and
replace with 25mm
Masterphalt-P

UNIT

CONVENTIONAL

REPAVE

SAVINGS

PLANINGS OFF SITE

Ton

3,099

1,549

1,549

50

MATERIAL TO SITE

Ton

3,507

1,712

1,794

51

LORRY MOVEMENTS

No

331

164

167

51

Nights

10

10

CO2 EMISSIONS

Ton

275.2

173.7

101.5

37

ENERGY

GJ

4,226.7

2,589.1

1,637.6

39

705,562

440,992

264,570

37

DURATION

COST

Total resurfaced Area westbound

& Eastbound using repave

32,696m2

Our approach to sustainability

Research, development and innovation are firmly embedded within the
Colas culture and have proven to be an integral part of Colas growth
strategy. Development of our products and operational processes are
tailored towards meeting the changing needs of our clients.
We recognise the importance of safe guarding our environment and
conserving natural resources, Colas is at the forefront of developing and
road recycling processes providing sustainable highway maintenance
solutions for our clients.

Environmental Calculator
Our environmental calculator software allows us to measure
the carbon footprint of our processes through measuring
energy consumption and greenhouse gas emissions.

T
 he calculator allows us
to measure the footprint
of any of our products
and processes
Accurately assessing their
impact in terms of energy
use and emissions
P
 rovides unique statistical
comparison between
alternative techniques

The calculator achieves this through

including details such as aggregate
type, laying process and transport
distances. The software allows
alternative processes or methods
to be displayed alongside each
other, providing a quick and easy
comparison tool for designers
and project managers.
The introduction of this calculator
allows us to offer clients tangible
and numerical data on the energy
consumption and emission savings
made, when using our road
recycling processes.

Furthermore the analysis allows

for accurate assessment of
environmental impact and these
savings maybe used towards
sustainability targets.
Customers who choose our road
recycling processes receive a
complimentary report on the
savings made towards energy
consumption and emissions.
Typical savings achieved
can be up to 60% for energy
consumption and greenhouse
gas emissions.

 esults reveal great variations

R
in the environmental impact
of differing construction
techniques
T
 he calculator enables
us to determine the most
sustainable method of
working for any project.

Regional Office
Cakemore Road
Rowley Regis
Warley
West Midlands
B65 0QU
T: 0121 561 5561
F: 0121 561 4364
E: recycling@colas.co.uk
Part of the International Colas Group

Colas Limited
Wallage Lane
Rowfant, Crawley
West Sussex RH10 4NF
T: 01342 711000
F: 01342 711199
E: info@colas.co.uk

www.colas.co.uk