A46 road rebuild recycles 17,432 tonnes of old asphalt, cuts carbon footprint 23%

National Highways says contractors reused 17,432 tonnes of material from the old A46 Warwick Bypass while resurfacing 3.5 miles of northbound carriageway. Kier and Aggregate Industries recycled 56% of the existing road back into the new surface, cutting the project's carbon footprint by 23%. The work also avoided around 82,000 road miles of vehicle movements. The key is Foamix, a cold-mix asphalt process that avoids heating tar-bound material and reduces fumes on site. Old layers containing tar were processed and encapsulated back into the pavement instead of going to landfill. That matters because tar-bound road waste is hazardous and expensive to dispose of at licensed facilities. The project fits National Highways' wider target of net zero maintenance and construction by 2040. It is a practical example of how road resurfacing can lower emissions without waiting for new materials or major technology shifts.