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This study aimed to rehabilitate a distressed road pavement using cold in-plant recycling with foamed bitumen, a sustainable technique that enables full reuse of existing materials while minimizing energy consumption. This method offers a cost-effective, environmentally friendly alternative to conventional reconstruction. The pavement design incorporated a 100% cold in-plant recycled base course optimized through laboratory investigations to determine the ideal binder content—2.6% foamed bitumen (70/100 pen) and 2.0% cement. Following laboratory validation, the mixture was applied in a full-scale experimental section in Riachos, Portugal, with rigorous quality control and performance assessment. Results confirmed its excellent performance under actual conditions, demonstrating its viability for large-scale infrastructure projects. This study highlights the environmental benefits of using 100% reclaimed asphalt, supporting circular economy goals and significantly reducing road construction’s environmental impact. The findings validate the proposed binder proportions and reinforce cold recycling with foamed bitumen as an effective, resource-efficient solution for durable and sustainable road rehabilitation.

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Sustainable Pavement Rehabilitation Using Cold In-Plant Recycling with Foamed Bitumen: The Portuguese ER243 Case Study

  • 会议论文

  • 发表日期：

    2026年

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  • Joel Oliveira,
  • Hugo Silva,
  • Caroline Moura,
  • Francisco Castro,
  • Gonçalo Henriques,
  • João Carvalho,
  • Anabela Martins,
  • José Santos,
  • José Almeida

摘要

This study aimed to rehabilitate a distressed road pavement using cold in-plant recycling with foamed bitumen, a sustainable technique that enables full reuse of existing materials while minimizing energy consumption. This method offers a cost-effective, environmentally friendly alternative to conventional reconstruction. The pavement design incorporated a 100% cold in-plant recycled base course optimized through laboratory investigations to determine the ideal binder content—2.6% foamed bitumen (70/100 pen) and 2.0% cement. Following laboratory validation, the mixture was applied in a full-scale experimental section in Riachos, Portugal, with rigorous quality control and performance assessment. Results confirmed its excellent performance under actual conditions, demonstrating its viability for large-scale infrastructure projects. This study highlights the environmental benefits of using 100% reclaimed asphalt, supporting circular economy goals and significantly reducing road construction’s environmental impact. The findings validate the proposed binder proportions and reinforce cold recycling with foamed bitumen as an effective, resource-efficient solution for durable and sustainable road rehabilitation.