Asphalt solutions including recycled & structural solutions
As a leading asphalt manufacturer, Downer operates and manages one of the largest networks of fixed and mobile asphalt plants across Australia and New Zealand. Meaningful improvements in road construction outcomes are achieved through our advanced asphalt products, cutting-edge technologies, precision laying techniques and robust manufacturing capabilities.
Our asphalt solutions are serving the needs of urban roads, airport runways, ports and motor-racing tracks, delivering on sustainability, durability and resiliency. Designed to withstand high volumes of traffic, minimise rutting, and maintain performance in challenging weather conditions, Downer’s asphalt solutions deliver robust structural integrity for a wide range of applications.
In Australia
Downer’s asphalt solutions are backed by thorough research and development which create and validate custom and standard mixes e.g., AC14, AC20, SMA10, OGPA, to suit traffic, climate, and project needs. Our laboratories have the capacity to conduct different accredited tests on aggregates, asphalt, concrete, and soil, to meet the Australian Standards, Austroads, State Road Authorities’ specifications, and Downer specifications. Our experts conduct real-time testing during production and paving, checking binder content, aggregate grading, and mix density. We follow Inspection and Test Plans (ITPs) that meet the relevant standards. In the field, we perform compaction checks, monitor temperatures, and evaluate surfaces to ensure quality across applications.
Our fixed asphalt plants include the advanced High Recycling Technology (HRT) Series capable of producing up to 100 percent recycled asphalt, using waste materials such as soft plastics, glass, toner cartridges, and reclaimed asphalt pavement (RAP). Our asphalt production is also backed by an Environmental Product Declaration (EPD) verifying the sustainability of our products and reinforces our commitment to providing customers with innovative sustainable asphalt solutions.
Our sustainable flagship asphalt products in Australia include:
Reconophalt™
- Incorporates recycled soft plastics, toner, and reclaimed asphalt pavement (RAP), helping customers and contractors reduce landfill and carbon emissions, while delivering superior rut and fatigue resistance. It’s approved by the NSW EPA and Victorian Department of Transport and has been used in major projects like the M80 and Monash Freeway.
High RAP Mixes
Asphalt blends with up to 100 percent recycled content, reducing reliance on virgin materials and lowering carbon emissions without compromising performance.
Armourpave
A high-performance asphalt mix developed by Downer’s Road Science AU team. It’s engineered specifically for heavy-duty environments such as container and intermodal terminals, hardstands and industrial yards, docksides and heavy-trafficked intersections.
Tack Coats
- CRS60 – is a Cationic Rapid Set bitumen emulsion developed by Downer for use in road construction and maintenance. It contains 60 percent bitumen and 40 percent water plus emulsifier, making it ideal for spray sealing, asphalt tack coating, patching and surface enrichment, and two-coat spray seal applications.
- Track guard (AU) – is a proprietary cationic bitumen emulsion developed by Downer, designed specifically as a trackless tack coat for road construction. It is engineered to prevent binder tracking across paving sites, improve shear resistance between pavement layers and enhance bond strength between asphalt courses.
- BridgeBond – BridgeBond is a polymer-modified anionic bond coat emulsion developed for use in bridge construction. Its primary purpose is to enhance the bond strength between concrete surfaces and the next pavement layer, ensuring structural integrity and durability under high-stress conditions.
In New Zealand
Road Science provides asphalt binder solutions that are backed by thorough research and development within their four IANZ-accredited New Zealand laboratories. Our asphalt plants across the country manufacture, supply and deliver quality, reliable product to meet our customer needs.
View all Road Science asphalt binders here: Asphalt Products | Asphalt Manufacturer | Road Science NZ – Road Science
Sustainable product features include:
EME2
- A high-modulus asphalt designed for thinner, stronger pavements. It enables up to 30 percent reduction in thickness, accelerates construction, and supports the use of recycled materials like RAP.
BioBind
An innovative low-carbon bitumen alternative, made from renewable resources that matches the durability and performance of conventional bitumen. BioBind not only reduces the environmental footprint associated with traditional fossil fuel-based bitumen, but its cutting-edge formulation also boasts significantly lower embodied carbon.
Downer’s asphalt strategy incorporates scientific approaches and sustainability by implementing circular economy principles, investing in low-carbon technologies, and working with councils and contractors. With an increasing demand for sustainable infrastructure, Downer provides asphalt solutions aimed at supporting communities in developing infrastructure that is efficient, safe, and resilient.
