Repave is a hot in situ recycling process for rejuvenating and resurfacing existing surface courses on carriageways and airfields. It minimises the need to remove existing material to go to landfill.

Our Repave process is the only in situ surface course recycling process that is currently available in the UK. It has been established in the industry for more than 30 years and has become a recognised solution for surface course recycling for carriageways and airfields.

Colas' Repave process is approved under clause 926 of the Specification for Highway Works and can be applied and completed throughout the year. It can also be combined with other surface courses, particular important if clients prefer to reuse the existing material but opt for a different finish.

The operational and sustainable benefits, combined with the cost saving efficiencies have made Colas' Repave process a popular choice against some of the conventional surfacing options. 
Repave has been used on a number of Highways England projects in the past and has been recently used on the motorway network in the UK.

How does it work?

A pavement, although sound, can sometimes show signs of deformation or surface fretting and Repave provides a faster, more cost effective alternative to traditional forms of surfacing. The process allows flexibility of programming as the heat from Repave penetrates deep into the road material allowing work to take place at virtually any time of the year.

The existing road surface is heated to 150°C and is scarified to a depth of 30mm using a two stage scarifier with spring loaded tines to avoid damage to street furniture. Next an oscillating, floating screed reprofiles and corrects levels for the required crown or crossfall.

The process is completed by the immediate application of either a 25mm bituminous wearing course, hot rolled asphalt with 20mm pre-coated chippings, high stone content asphalt or a proprietary thin surfacing, the heat from the Repave machine welds the new materials removing the need for a tack coat.

The process is suitable for any class of road. Material is recycled in situ, cutting lorry movements, considerably reducing the use of new aggregates and minimising waste material and cost.


  • Achieve total resurfacing without the removal of any materials
  • Reduced carbon emissions
  • Reduced energy consumption
  • Avoids waste being sent to landfill
  • Minimised disruption to the local road network
  • Reduced time on site and road space occupation
  • Significantly reduced costs
  • Can be used in low ambient temperatures

Versatile application makes Repave a success

Lwd 1827-37The application and operational benefits of Colas' Repave Process are clearly visible and in recent years it has also been used as a solution for contracts where night works are required. It is ideal for use for projects where short operational windows restrict conventional processes as Repave can produce higher outputs that save both time and cost.

Blackpool International Airport - Runway Resurfacing

Blackpool Airport required a large proportion of the existing surface to be regulated for re-profiling and for a final surface course to be applied. An expensive option would have been to remove the large quantities of material for regulating.

We specified our Repave process which allowed us to then significantly reduce the amount of material to be removed from the site. Completion of the runway works was achieved within 10 days of night work and this was during tight operational windows.

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Isle of Man Airport -Taxiway Refurbishment

Isle of Man Airport had originally budgeted for a three year maintenance programme allowing them to update seven taxiways.

Both our Deep Recycling and Repave processes were specified and zero waste to landfill was achieved along with significant savings in vehicle movements, energy and CO₂ emissions.

Rather than opting for a three year maintenance programme Colas' approach allowed the client to achieve its target of all seven taxiways being refurbished within a programme of four weeks.

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M56 Junction 10

In 2010 Colas' Repave process was used for the first time on a UK motorway. The process was chosen due to its operational benefits Colas Repave Process offers a quick application for large areas and the experienced teams are able to complete night works.

This was an important requirement for Highways England, through completing the operation at night the impact to local network users was significantly reduced.

Since the successful completion of this project Colas' Repave process has been specified and used for a number of motorway resurfacing schemes.

Read Case Study »

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