A190 Foam Mix Resurfacing, Seghill


Northumberland County Council




March 2022

The Project

The scheme involved the cold milling and resurfacing of 11,000m2 of the A190 through Seghill and involved the recycling of a significant amount of tar bound road planings from across Northumberland using an off-site foamed bitumen process (Foambase) provided by our partner, OCL Regeneration Ltd. This is part of a series of projects to recycle historic stockpiles of tar bound road planings for Northumberland County Council.

The work was completed using our 2m wide planer over 9 night shifts and involved:

  • Cold milling and removal of 150mm depth of existing road surface
  • Off-site production of recycled tar bound planings to produce a foam mix binder course at the OCL recycling facility at Bedlington
  • Reinstatement of 100mm depth using the foam mix binder course
  • Laying of 50mm depth Armaflex surface course.

The Foambase cold-lay surfacing material incorporated 94% recycled tar planings which was bound with foamed bitumen and other hydraulic binders, using 80% less energy and 50% less CO2 than traditional materials.

Working at night on a congested site, we safely managed the removal and reinstatement of 3,700 Tonnes of material.

Key Quantities:

0 m2
Road Surface Replaced
0 Te
Recycled Planings Foam Mix Binder Course
0 Te
10mm Armaflex Surface Course

Challenges and Successes

The project posed a number of challenges, including delivering all works at night whilst safely reopening the road each morning at 6am; planing out and re-laying significant quantities of material each night before the reopening deadline; laying new products at significant depth to the required specification while working to tight deadlines; coordinating mixing operations and Foambase deliveries from the mixing plant 10 miles away and managing a very busy and constrained site at night whilst coordinating planing operations, surfacing, material removal and multiple Foambase binder and Armaflex material deliveries from different suppliers in the required sequence through a narrow site. The work was delivered safely to a very high quality and the road was reopened on time each day.

Client Benefits:

By reincorporating the tar bound road planings into the new road surface material, Northumberland County Council was able to safely dispose of previously accumulated hazardous waste without sending to landfill, which would have cost a significant amount of money. Additionally, the reuse of the tar bound road planings by the Foambase process used 80% less energy and saved 50% CO2 when compared to newly supplied material.

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