What is Recycled Asphalt and What is it Used For?

Recycled Asphalt is a surfacing material reclaimed from existing asphalt surfaces, such as roads or pavements, that have reached the end of their natural life. It is often used for car parks, roads, footpaths and cycleways. When mixed correctly, it can replicate the performance of regular asphalt.

In this guide, we explore what recycled asphalt is used for, its benefits, what it's made from and more.

Recycled asphalt in summary:

What is recycled asphalt?

Recycled asphalt, or “Reclaimed asphalt pavement” (RAP), comes from planings milled off existing surfaces that are at the end of their life. Rather than being sent to landfill where it would contribute negatively to the environment, it is reprocessed into new mixes that can be used for a host of surfacing projects.

The key reason for recycling asphalt is that the bitumen and aggregates that help make asphalt are worth recovering. Both are finite and getting more expensive, so reusing them makes sense both commercially and environmentally.

What is recycled asphalt made from?

Recycled asphalt is made from the milled layers of old roads and pavement surfaces. When a road is resurfaced, the top, worn, layer of asphalt is removed. This produces a granular material known as planings that contain plenty of usable bitumen and aggregates. Rather than waste them, they are used again.

Are asphalt planings and recycled asphalt the same thing?

Sort of. There is often a little confusion. The planings are the material removed directly from the surface. Recycled asphalt is what those planings become once they are screened, graded and blended into a new mix. Think of it like planings are the input, and recycled asphalt is the end product.

How is asphalt recycled?

Asphalt is recycled by milling the old surface, processing the reclaimed material, and blending it into a new mix via a hot or cold method. The process normally takes place at a central plant but can be done on site, depending on the scale of the job. Because asphalt is almost 100% recyclable, the same materials can cycle repeatedly.

The process follows three core steps:

• Milling: A cold milling machine removes the worn surface to produce the asphalt planings.
• Processing: The planings are crushed and screened to remove debris and reach a consistent gradation.
• Blending: The reclaimed material is combined with new aggregate and binder, or graded into a sub-base product.

What’s the difference between hot mix and cold mix recycling?

Hot mix recycling reheats the reclaimed asphalt and incorporates it into a hot paving mixture, most often as a substitute for a share of the new aggregate. It’s the standard route for surface and structural layers on roads and highways.

Cold mix recycling is similar, but avoids the high temperatures; instead, it binds the reclaimed material with a bitumen emulsion or foamed bitumen. Because they use less energy, cold mix and warm mix techniques carry a lower carbon footprint, making them a common feature in modern low-carbon schemes.

Mixing recycled asphalt in-plant or onsite

In-plant recycling of asphalt means the reclaimed material is taken to a central facility where it is processed and blended under controlled conditions before being delivered to the site. Onsite recycling treats the existing surface directly. The surface is milled, mixed with a binder and relaid in one single operation. This reduces transportation costs and keeps materials on site, meaning it can be a far more practical and more cost-effective option. However, the best method always depends on the scope of the project, the condition of the existing surface and the performance expected of it.

What is recycled asphalt used for?

Recycled asphalt is used in a variety of surfacing projects. It can be used for car parks, footpaths, roads and more. It is also used frequently as a sub-base material. Thanks to this versatility, it’s commonly found in most asphalt production by default.

The most common applications for recycled asphalt include:

• Road resurfacing
• Binder and base courses beneath the surface
• Commercial car parks and access roads
• Footpaths and cycleways
• Driveways
• Sub-base and capping layers

Highways and road resurfacing

Recycled asphalt is widely used in road resurfacing across motorways, A-roads, local roads and estate streets. In the UK, the amount of recycled content permitted in the surface layer is governed by National Highways’ Manual of Contract Documents for Highway Works. Contractors and highway authorities can pursue higher percentages through performance testing, and several landmark schemes have proven that high-RAP surfaces stand up well to heavy traffic. Where resurfacing works tie into or alter the adopted public highway, they may fall under a section 278 agreement, which governs how private works interface with public roads.

Binders and base courses

Recycled asphalt can also be found beneath the visible surface. It is well suited to the structural binder and base layers that carry the load. These layers already permit a higher share of recycled content than the surface course, making them a practical, high-volume use for reclaimed material in both new construction and major maintenance work.

Car parks and access roads

For commercial and industrial surfaces, recycled asphalt offers a cost-effective and sustainable option that balances performance against lower material and disposal costs. Car parks, service yards and access roads rarely face the same structural demands as highways, which makes them ideal for higher recycled content.

Footpaths and cycleways

Recycled asphalt provides a smooth, durable finish for footpaths, cycleways and shared-use paths. These lighter-traffic routes suit sustainable, lower-carbon mixes and recycled surfacing supports the wider shift towards greener infrastructure.

Driveways

For homeowners, a recycled asphalt driveway is a low-cost and environmentally friendly alternative to a new tarmac driveway. Compacted asphalt planings form a firm, long-lasting driveway surface, while recycled aggregate is routinely used to build the sub-base beneath a new driveway, patio or path.

Sub-base and capping layers

One of the most common uses for recycled asphalt is as a sub-base. Graded aggregates such as 6F2 and MOT Type 1 create a stable, free-draining foundation that sits beneath roads, driveways and footpaths.

A recycled sub-base is typically cheaper than primary quarried stone and carries a much lower carbon footprint whilst still performing comparably.

What are the benefits of recycled asphalt?

Recycled asphalt has three core benefits: it lowers the environmental impact of surfacing work, reduces project costs and rivals conventional asphalt in performance. Those benefits are among the reasons recycled asphalt has become a default of modern asphalt rather than a distinct alternative.

Environmental benefits

By reusing asphalt, it’s kept out of landfill and cuts demand for newly quarried aggregate and imported bitumen. As reserves deplete, costs continue to rise. It also lowers embodied carbon by reducing extraction, production and transport emissions. Where reclaimed material is reused locally or in place, shorter haulage distances further reduce carbon emissions and reduce disruption on the road network.

Cost benefits

Recycled asphalt reduces raw material costs and cuts the disposal expense of removing old pavement. Because planings are readily available as a by-product of routine road maintenance, they provide a lower cost option than newly sourced aggregates and bitumen. A saving here means budgets can be optimised without the surface being compromised.

Performance and durability

When properly designed and quality-controlled, recycled asphalt is on par with conventional asphalt for strength and durability. It stands up well to heavy traffic, the varied British weather and long-term wear. Trials on heavily trafficked RAP surfaces have proven its durability and have helped enforce a shifting industry perception that recycled content is a reliable option.

Is recycled asphalt as good as new asphalt?

Yes. When designed correctly, and produced under proper quality control, recycled asphalt performs to the same standard as conventional asphalt. The important caveat is that the condition of the recovered bitumen and aggregates matters more as the recycled proportion rises. A higher RAP mix needs more careful mix design, and in some cases, a specialist plant. For structural or heavily loaded surfaces, an experienced surfacing contractor like Tidey & Webb adds real value by matching the mix to the demands of the site.

Speak to the Tidey & Webb team today to discuss your surfacing project and what surfacing option may suit you best. Whether you are resurfacing a car park, laying an access road or enhancing a cycleway, our team can advise on the best recycled asphalt solution for your site.