How to build a stronger, longer lasting carbon negative road

Start by identifying the underlying cause of the pavement damages/distresses

There are many different reasons for a road to be experiencing problems that can lead to a reduction in service lifetime. The underlying cause of the pavement distresses are reflected in the pavement, and can often be identified by identifying type of pavement damage and assessing your drainage situation, climate factors, traffic volume, etc. In Carbon Crusher we use SkyRoads AI our own pavement distress software to do this.

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Start With the Right Foundation: Rehabilitate Instead of Replacing

Traditional road-refurbishment involves tearing up old roads and sending the debris to landfills, which generates massive CO₂ emissions. Instead, use Full-Depth Reclamation (FDR), a process where the existing road materials are recycled on-site.

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What It Entails:

• Mill up the road (HMA Pavement + base-layer) to a depth of around 25 cm using specialized equipment, such as Carbon Crusher’s Carbon Rover (TBA), which crushes the old road materials into a reusable base.

• Avoid the need for transporting and dumping materials, this drastically reduce emissions.

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Benefits:

• Keeps the existing road foundation in place.

• Eliminates the carbon cost of quarrying new aggregate and manufacturing asphalt.

• Reduces construction time and minimizes disruption.

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Use sustainable binder in the stabilizing Layers

By incorporating a stabilizing layer with a sustainable binder in your roads, you can create a more durable, carbon-negative road structure that binds carbon in the road.

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What Is a Stabilizing Layer?

A stabilizing layer is a foundational component of the road that ensures structural integrity and distributes the weight of traffic evenly. It works in tandem with the asphalt layer to enhance the road’s strength and longevity.
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Purpose of the Stabilizing Layer:

• Reinforces the base material to prevent deformation under heavy traffic.

• Reduces reliance on asphalt by minimizing its thickness, lowering overall emissions.

• Enhances durability in roads prone to water damage, frost damage or high loads.

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How to Build the Stabilizing Layer:

• After the old road material is crushed and mixed, we apply a layer of Biobinder-treated aggregate to create a solid, flexible base.

• Compact the layer to ensure it provides a strong, even surface for the upper layers.

• Optional: Incorporate carbon-sequestering additives, such as biochar, to further increase sustainability.

Benefits of Combining Stabilizing Layers With BioBinder

Our Biobinder is a biogenic that is non-toxic. dependent on local factors, we customize the binder to meet the needs of every unique road. This black box is what we call “mix design”. With the right mix design we optimize for:

• Enhanced Durability: The stabilizing layer prevents rutting, cracking, and other road failures, extending the road’s lifespan.

• Lower Carbon Footprint: Reduces the need for thick asphalt layers, lowering overall material consumption and emissions.

• Cost Efficiency: A well-stabilized base cuts down on repair and maintenance costs over time.

• Flexibility for Heavy Loads: Ideal for roads in high-stress areas, such as mining, logging, and agriculture routes.

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Use Machinery Designed for Efficiency and Sustainability

Construction machinery can be a significant source of CO2 emissions. Opt for equipment designed to optimize fuel use and integrate processes.

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The Crusher.

• The modified crusher combines multiple steps—crushing, mixing, and road laying—into one efficient process, reducing fuel consumption and emissions.

• Its cutting-edge design minimizes the use of diesel while ensuring precision in applying materials like Biobinder.

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Plan for Longevity and Durability

The carbon footprint of road maintenance is often overlooked. Building roads that last longer reduces repair frequency and associated emissions.

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Use AI Tools for Predictive Maintenance:

• Tools like SkyRoads, an AI-powered pavement management system, help road owners predict when maintenance is needed.

• Preventing deterioration before it becomes critical saves costs, materials, and emissions.

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Integrate Vegetation and Carbon-Sequestering Additives

Green Shoulders and Roadside Vegetation:

• Planting vegetation along roadways can sequester additional carbon while improving stormwater management and reducing heat island effects.

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Carbon-Sequestering Additives:

• Explore the use of additives like biochar or other carbon-negative materials within the road layers to further enhance sequestration.

Monitor and Improve Over Time

Building carbon-negative roads is not just about the initial construction but also about maintaining and improving the process over time.

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Why Carbon-Negative Roads Matter

Every kilometer of carbon-negative road not only reduces CO₂ emissions but actively removes carbon from the atmosphere. When scaled globally, this innovation can turn roads from a source of harm into a critical part of the solution to the climate crisis.

By following the steps outlined above—rehabilitating instead of replacing, utilizing sustainable binders, incorporating AI for predictive maintenance, and designing for durability—you can build roads that are better for the planet and better for communities. Together, we can transform the world’s infrastructure from grey to green, one road at a time.