The problem with traditional asphalt renovation

Conventional road renovation is straightforward but heavy:

• The original asphalt pavement needs to be removed
• A rebuild from the base up is needed
• A fresh asphalt layer has to be added

This approach consumes large volumes of materials, generates significant waste, and increases CO₂ emissions.

In the following project, you'll see how Mesh Track® on the other hand, outperformed traditional reinforcement by reducing material consumption, minimizing waste, and lowering the environmental impact of construction.

For this 1.000 m² road project, renovating in the traditional way would mean:

• Thick asphalt layers (7 cm of base- and binder course + 4 cm of wearing course)
• Full excavation (in this case 18 cm of asphalt)
• Higher transport and production impact

The result?

A carbon-intensive process that’s increasingly hard to justify in sustainable construction projects.

A smarter alternative: Reinforce instead of replace

Mesh Track® flips the logic: don’t rebuild everything but reinforce what’s already there!

Instead of full removal, the process is leaner:

• Profile milling only 5 cm of the existing asphalt (so no full excavation needed)
• Apply reinforcement (Bitufor = Mesh Track® steel interlayer + slurry)
• Add a thinner new asphalt layer (4 cm of binder course + 3 cm of wearing course)

That’s it, so no deep excavation, nor full reconstruction needed.

Let the numbers do the talking

Staying with the same example, we get the following outcomes:

CO₂ emissions

• Traditional solution: 20.418 kg CO₂
• Mesh Track® solution: 11.417 kg CO₂

(Amounting in a 49% reduction!)

Material use

• Asphalt thickness reduced by 11 cm
• Significantly less raw material needed

Why it works

The key lies in the use of a Mesh Track® steel reinforcement layer, as it strengthens the existing pavement structure, allowing for:

• Thinner asphalt layers
• Better load distribution
• Improved crack resistance

In simple terms: You get the strength of a full rebuild without actually doing one.

Beyond carbon: Practical benefits on site

Sustainability is only one part of the story, as Mesh Track® delivers a range of real-world advantages:

• Less material consumption -> lower costs and logistics
• Extended road lifespan -> fewer renovations over time
• Reduced traffic disruption -> faster, less invasive works
• 100% recyclable steel solution
• No microplastic pollution

For contractors and asset owners, that’s a strong combination of performance, efficiency, and sustainability.

Certified and transparent

Adding to it’s credibility Mesh Track® is also verified, making the info we just shared more than just some claims:

• MKI value of Mesh Track® is included in the Dutch National Environmental Database
• Supported by a third-party verified Environmental Product Declaration (EPD)
• Enables transparent lifecycle comparison of materials

This makes it easier to meet sustainability goals and comply with evolving regulations.