Reducing emissions
Country road surrounded by greenery with a blue sky.

How can we reduce emissions in the road rehabilitation process chain?

Transparent facts and figures for sustainable effects in road rehabilitation. As obvious as it sounds, only what can be measured can be controlled.

What emissions are produced in the road rehabilitation process chain?

If we want to reduce emissions, we first need transparency on where they occur and how they contribute across the entire process. In road rehabilitation, emissions arise throughout a chain of activities — from aggregate extraction and asphalt production at the mixing plant, to transport logistics (on- and off-site) as well as asphalt milling and paving. The largest share of emissions across this process is generated during asphalt production. By comparison, emissions from on-site construction machinery are significantly lower. Nonetheless, they should be assessed in context, as on-site operations are critical for delivering the work and achieving the required quality.

Using a conventional road rehabilitation process as our baseline, we varied key parameters in a model-based scenario analysis to estimate the emissions reduction potential.

Baseline scenario - Conventional road rehabilitation with Wirtgen Group equipment

Parameters, assumptions and machines considered in the Baseline Scenario:

Length: 1,000 m
Width: 7.5 m (common for two lanes)
Courses: Surface course (40 mm), Binder course (80 mm), Base course (100 mm)
Mobile equipment fuel: Diesel (B7)
Asphalt mixing plant: Lignite dust, 0% RAP, Asphalt temperature 160°C
-> Construction site parameters in detail

Emissions shares¹

Transportation: 15%¹ for transportation of aggregates, asphalt, and milled material
Mobile machines: 4%¹ for cold milling machine, road paver, and rollers/compactors
Raw materials: 6%¹ for mining/quarrying, 28% for bitumen for asphalt production + bitumen emulsion
Materials processing: 43%¹ for asphalt mixing plant (fuel + electricity), 4% for mobile equipment, e.g. mobile crushing plants, mobile screening plants, excavators, and wheel loaders (fuel)

Enlarge pie chart

The result:

Even small changes can make a difference. We show you how efficiency and decarbonization can be meaningfully combined – practically and effectively.

Where is potential for reducing emissions in the road rehabilitation process chain?

The following options can be used to reduce emissions

Pie chart for emission reduction through dry storage of materials

Scenario 1: Dry storage of materials

Emission reduction through warm mix asphalt paving, with emission figures

Scenario 2: Paving warm mix asphalt

Emission reduction through hot recycling with 90% RAP in the asphalt mixing plant, with emission figures

Scenario 3: Hot recycling in the asphalt mixing plant with 90% RAP*

Emission reduction by the use of green hydrogen as a fuel in the asphalt mixing plant, with emission figures

Scenario 4: Green hydrogen* as fuel in the asphalt mixing plant

Pie chart showing the reduction of emissions through the combined use of green hydrogen and 90% RAP, with emission figures

Scenario 5: Green hydrogen* and 90% RAP***

Pie chart showing emission reduction through the use of the in-situ cold recycling method, with emission figures

Scenario 6: Using in-situ cold recycling*/**

Disclaimer

¹ All results are estimates and may vary depending on all assumed parameters (in particular, without limitation, Length, Width, Courses, Bitumen content in asphalt, Burner Fuel type, distances and used machines). Our estimates are based on a model-based scenario analysis performed internally at the WIRTGEN GROUP that has not been independently verified. For our estimates we compared performance data of WIRTGEN GROUP equipment, computed from the results of our studies, in the various scenarios indicated above. CO₂e emissions values were based on data originating from various industry sources and may vary according to the source, year, and region:

  • Aggregate extraction emission value: Based on the emission value of final aggregates from Probas (German Environment Agency (UBA)) and internal calculations of the manufacturing process based on Kleemann crusher consumption values.
  • Bitumen emission value: Probas Database (German Environment Agency (UBA))
  • Lignite Dust emission value: CO₂ emission factors for fossil fuels Update 2022 (German Environment Agency (UBA))
  • Green Hydrogen emission value: JEC Well-To-Wheels Report v5 (European Commission’s science and knowledge service)
  • Cement Emission Factor: International Energy Agency (IEA) 2022
  • Truck Diesel consumption: ICCT Fuel efficiency Technology in European heavy-duty vehicles (state: +moderate engine technology)
  • Diesel (7% Biodiesel, common in Germany) emission value: DIN EN 16258 (WTW)