Boral has launched an innovative asphalt product incorporating crumbed rubber derived from end-of-life Off the Road (OTR) tyres, typically used for heavy-duty industrial vehicles.
This Australian-first initiative promises enhanced road durability and a more sustainable approach to road construction.
The new high-binder crumbed rubber asphalt surfacing utilises OTR tyres sourced directly from Boral’s own sites, including front-end loaders and quarry haul dump trucks.
By replacing common crumbed rubber with this alternative, Boral’s asphalt mix boasts superior cracking resistance, potentially doubling the lifespan of pavements compared to conventional road treatments.
OTR tyres are engineered to withstand the rigours of demanding environments, supporting heavy machinery across various sectors such as construction, manufacturing, mining, agriculture, and aviation.
These tyres can range from under 20 cm for forklift tyres to nearly two metres for those used on mining dump trucks.
Boral’s process recovers approximately two-thirds of each OTR tyre for use in the crumbed rubber mix, equating to roughly 400 kilograms per tyre.
The launch follows Boral’s participation in an Australian Flexible Pavement Association (AfPA)-funded project with Tyre Stewardship Australia six months prior.
This collaborative effort aimed to identify the optimal OTR-derived asphalt mix for creating more sustainable and resilient roads.
Boral then partnered with the Sunshine Coast Council to conduct real-world road demonstrations across three locations: Railway Parade in Glass House Mountains, Spalls Road in Diddillibah, and Perlan Street in Nambour.
These trials allowed for performance measurement under varying traffic conditions.
In total, Boral paved 7,000 square metres of local roads using 10,000 kilograms of OTR-derived crumbed rubber, equivalent to 25 large earthmover tyres, sourced from Boral’s West Burleigh Quarry.
This marked the first known use of OTR tyres in asphalt mix within Australia.
Boral’s OTR-derived crumbed rubber asphalt offers increased road performance and longevity, reducing the need for frequent maintenance like crack sealing and patching, ultimately minimising costs and community disruption.
Furthermore, the product provides substantial sustainability and emission-reduction benefits.
Richard Pearson, Executive General Manager Asphalt at Boral, stated: “We are pleased to be leaders in construction material innovation and bring to market our high-binder crumb rubber asphalt surfacing derived from Off the Road tyres.
“Finding ways to be more sustainable and drive a more circular economy is central to what we do at Boral.”
Pearson further added: “Our successful engagement with Sunshine Coast Council, AfPA and Tyre Stewardship Australia led to the creation of this new product that will provide increased circularity benefits to the community — diverting tyres away from landfill and into new recycled products.
“Our operations will also benefit from reduced emissions from asphalt manufacturing and the reuse of end-of-life OTR and truck tyres from Boral sites.”
Boral encourages further innovation within the building and construction industry and invites councils and government bodies to integrate recycled materials, including crumbed rubber asphalt, into their projects.
