The St Austell A391 NEDR resurfacing scheme set out to enhance the performance and resilience of a major bypass route while embedding sustainability at the heart of the project. Working in collaboration with Cormac and Cornwall Council, the project focused on innovative material selection and efficient delivery methods to meet both performance and environmental goals.
To achieve a long-lasting, high-performance finish, two specialist surfacing materials were selected: Milepave™ PMB and Hardipave™.
Milepave™ PMB was applied across the A391 carriageway, offering enhanced durability and a surface reinforced finish – ideal for heavily trafficked roads. Hardipave™ covered the roundabouts, providing a jointless, high-strength, deformation-resistant surface capable of withstanding constant turning movements and heavy loads.
Milepave™ contributed to a significant reduction in the carbon footprint of the scheme compared to conventional surfacing materials. By using fewer resources overall, including a lower bitumen content and reduced aggregate, Milepave™ minimises the carbon typically associated with traditional asphalt materials. Its lower mixing and laying temperatures further decrease energy consumption during production, delivering immediate carbon savings. This considerable environmental benefit supports Cornwall Council’s carbon reduction strategies and given the scheme’s length of nearly 3km, selecting a lower-carbon material provided substantial environmental benefits across the project’s lifecycle.
To minimise disruption on this busy route, the project employed Echelon paving with a power feeder, operating two pavers in tandem. This approach allowed surfacing gangs to work simultaneously, ensuring timely delivery while maintaining high-quality standards, maximising operational efficiency and crucially achieving a seamless finish across all 3 lanes of the carriageway.
The St Austell A391 NEDR resurfacing project showcases how innovative material choices and advanced delivery methods can combine to deliver durable, sustainable highways. By integrating low-carbon materials and efficient paving techniques, the scheme sets a benchmark for future road construction projects across the UK.
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