Pacific Highway Upgrade Project

Plant Mixed Foam Bitumen (PMFB) was produced and stockpiled at a nearby quarry, then hauled to the paving sites. The production target at the plant was to be a consistent 1500 tonnes per day with sufficient road haulage vehicles to ensure continuous operation of the paving operations.



Project Scope

95,000m² of two plant mixed foam bitumen layers totaling 385mm over a sealed SMZ layer.

Project Date

February 2019 - July 2020

Project Aus Pacific Highway 1

Key Challenges

  • Distance from production source to paving train.
  • Minimisation of segregation during the transfer and haulage operations.
  • Ensuring a consistent supply of materials at the paver to minimise stop-start paving.
  • Paving variable widths to achieve joint locations at specified offsets.

Logistics Management

Careful daily planning and management of all aspects of the production supply chain from raw materials selection, production, haulage, placement and compaction ensured a successful delivery outcome. MTBB was conformed in stockpiles at the quarry and were carefully managed to prevent contamination or excess water ingress. Carefully selected haulage vehicles and transfer activities were implemented to minimise segregation of the foamed bitumen materials.

Careful planning and close liaison between Hiway Stabilizers’ logistics management and the client ensured the works were delivered within client specified programme deadlines.  

Robust Long Term Quality & Performance

Provision of sufficient specialised delivery trucks in the fleet ensured consistent production and a continuous paving operation with a high standard of compaction and geometric conformance. This was further enhanced with Hiway Stabilizers’ high end level control system installed on its specialised paver. This delivered significantly better than specified ride count requirements – a factor in pavement longevity.

Sustainable Solution

PMFB uses less bitumen binder than a full depth asphalt whilst delivering similar strength. This helps preserve a valuable finite material and reduces costs.

new south wales
Project Aus Tooloom Road 1

Tooloom Road Rehabilitation Project

The 6m wide existing pavement required a safety upgrade to enable the safe passage of tourism and logging traffic. Tenterfield Shire Council was seeking a best value for money alternative to maximise length of upgrade for the funds available.

Project Details

Project NZ Transmission Gully 1

Transmission Gully

Hiway Stabilizers was engaged by the client to provide a wide range of materials stabilisation and modification across a 27km greenfields four-lane motorway project including four new interchanges and two new link roads.

Project Details

Project NZ Puhoi Warkworth 3

Pūhoi to Warkworth

Pūhoi to Warkworth is the first of two stages for Ara Tūhono, an extension of Auckland’s Northern Motorway on State Highway 1. Hiway Stabilizers are working alongside NX2 to deliver both the stabilised Subgrade and Subgrade Improvement Layer for the 18.5km project.

Project Details