Boral Limited has unveiled a groundbreaking innovation in road construction, launching Australia’s first proprietary crumbed rubber asphalt bitumen that utilizes end-of-life Off the Road (OTR) tyres. This revolutionary asphalt mix, derived from the robust tyres of heavy-duty industrial vehicles, promises to significantly enhance road durability and sustainability.

OTR tyres, designed to withstand the rigors of demanding industries like construction, mining, and agriculture, are now finding a second life in Boral’s high-binder crumbed rubber asphalt surfacing. These tyres, ranging from small forklift tyres to massive mining dump truck tyres nearly two meters in diameter, are processed to create crumbed rubber, a key component in extending pavement lifespan.

Boral sources end-of-life OTR tyres from its own sites, specifically from front-end loaders and quarry haul dump truck vehicles. Approximately two-thirds of each OTR tyre is recovered, translating to roughly 400 kilograms of rubber per tyre, for use in the asphalt mix.

The incorporation of crumbed rubber provides significant anti-oxidation properties, effectively combating the primary cause of residential road deterioration: UV-induced oxidation. This translates to an estimated doubling of pavement lifespan compared to conventional road treatments, offering long-term cost savings and reduced maintenance.

This innovative product is the culmination of extensive research and collaboration. Six months prior, Boral participated in an Australian Flexible Pavement Association (AfPA)-funded project, in partnership with Tyre Stewardship Australia, aimed at determining the optimal OTR-derived asphalt mix for sustainable and resilient roads. Building on this research, Boral partnered with Sunshine Coast Council to conduct a real-world road demonstration across three sites: Railway Parade in Glass House Mountains, Spalls Road in Diddillibah, and Perlan Street in Nambour.

The demonstration involved paving 7,000 square meters of local roads using 10,000 kilograms of OTR-derived crumbed rubber, sourced from vehicles at Boral’s West Burleigh Quarry. This equates to the equivalent of 25 large earthmover tyres, marking the first known use of OTR tyres in asphalt mix in Australia. The demonstration sites were strategically chosen to assess the asphalt’s performance under varying traffic conditions.

Richard Pearson, Executive General Manager Asphalt at Boral, emphasized the company’s commitment to innovation and sustainability. “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 stated.

He further highlighted the collaborative effort that led to this breakthrough: “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.”