Quieter Roads, Longer Lifespan: How Concrete Retexturing is Changing Highways

A groundbreaking road resurfacing technique is making waves in the UK, offering a cost-effective and sustainable solution to extend the lifespan of concrete roads while significantly reducing noise pollution. A trial conducted on a 1.5km stretch of the A30 in Cornwall has demonstrated that this advanced concrete retexturing technique can reduce road noise by up to 7dB, benefiting both drivers and nearby communities.

The innovative process, spearheaded by National Highways in collaboration with Tarmac, Wirtgen, and Atmo Technology, involves a single-pass grinding and grooving technique. This method enhances the surface texture and reduces the contact area between vehicle tyres and the road, which helps in absorbing and minimizing noise. Unlike traditional resurfacing techniques that require frequent maintenance, this approach is expected to extend the operational lifespan of the road by up to 15 years, effectively doubling the durability of concrete roads.

Concrete roads, which make up approximately 640km (4%) of the UK’s strategic road network, were primarily constructed in the 1970s and 80s. Until now, resurfacing relied on diamond fine milling, which removes around 3mm of road material and lasts only five years before requiring intervention. The new retexturing technique significantly reduces maintenance cycles, cutting costs and minimizing environmental impact by eliminating the need for frequent roadworks.

One of the key advantages of this method is that it does not damage pavement joints, which reduces future maintenance expenses and ensures long-term structural integrity. The initiative is part of Tarmac’s Next Generation Concrete Solutions (NGCS) portfolio, which aims to enhance the sustainability and efficiency of road infrastructure across the UK.

The Cornwall trial tested five different surface profiles, each featuring unique groove dimensions and patterns, with noise levels assessed using Atmo Technology’s mobile sound monitoring devices. The results were consistently positive, paving the way for wider implementation.

Specialized companies developed a cutting-edge resurfacing machine capable of grinding and grooving in a single pass, improving productivity by 150%. This machine can resurface a width of 1.85m per pass, covering an entire lane in just two passes—making it one of the most efficient resurfacing solutions to date.

As part of its Concrete Roads Programme, National Highways aims to replace all legacy concrete roads while simultaneously finding cost-effective ways to maintain those still in use. The NGCS technique is showing promising results in both noise reduction and improved ride quality, with ongoing trials set to confirm its full potential. If widely adopted, this technique could redefine road engineering, making highways quieter, smoother, and more durable for decades to come.