Sustainable Asphalt Mixtures for Road Repair

At Sacyr Maintenance, we seek innovative solutions that represent an advancement not only in the management of our infrastructure to prevent accidents due to poor road surfaces but also in the use of materials that are increasingly environmentally friendly.

In 2022, we began using the innovative product ‘Reparabache’ in the MASAI mixtures for road pavement, a mixture with the same performance as conventional asphalt, but applied cold, quickly, simply, and cleanly, with immediate traffic reopening.

Among its innovations is the incorporation of rubber powder. Typically, two used tires are recycled per ton of mixture. 

This European Commission-approved product is 100% ecofriendly and fully reusable, as the surplus can be stored again. It also incorporates graphene in its manufacturing, which doubles its durability and improves its elastic recovery. Its demand is increasing, as it can be applied in adverse weather conditions. Additionally, it contributes to the reduction of noise pollution.

Its most common uses include asphalt spraying on supports for paving, priming in waterproofing systems, crack sealing, and making asphalt mortar.

On the other hand, among the MASAI mixtures is Bioroad, another additive that has received many accolades. It is a truly unique additive for asphalt mixtures, based on recycled vegetable oils and waste from olive oil processing.

With this additive, the need to use standard petrochemical melting agents is eliminated, as its composition includes 30-50% recycled vegetable oils and 20-30% other waste such as olive mill wastewater (residue from pressing olives).

The functionality of these by-products has been achieved through nanotechnology using graphene.

Thanks to Bioroad, asphalt mixtures can be manufactured at lower temperatures, reducing energy consumption and the carbon footprint generated by traditional hot manufacturing processes.

These asphalt mixtures are produced between 120-140 degrees Celsius (40 degrees less than traditional methods).

Additionally, recently on the Turia Highway (CV-35), currently managed by Sacyr Concesiones, pothole repair and crack sealing operations have been carried out using a variant of Bioroad, called Lazarus. It is a modified petrochemical compound containing bituminous binders with graphene-based nanomaterials, improving the life and resistance to fatigue cycles of the pavement.

2% of this mixture is added to milling remnants (asphalt removed from damaged roads). Lázaro is an additive designed to manufacture mixtures with 100% milled material. It is composed of vegetable oils and other products, enriched with graphene.

On the same road, we have also used AC 11 Surf, a cold mix asphalt, consisting of a bituminous emulsion. The bags are of AC11 SURF bituminous mixture type with more than 20% RAP (recycled asphalt pavement).

It is produced semi-hot (approximately 30ºC less than a conventional mixture) thanks to ecological additives that also allow it to be stored in bags and applied cold.

We have also used 'Repara Sellagrietas', an anionic bituminous emulsion (mineral-based, with a negative electrical charge, enriched with graphene, of viscous consistency, and applied cold), which is applied directly to the crack without any other additive for repair.

  • Road maintenance
  • Innovation

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