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A road rehabilitation project carried out for the City of Turku demonstrated how substantial savings can be achieved by using the tractor-mounted MeriRoad RC90-221 DTG milling crusher. The area to be repaired was approximately 950 m², with an asphalt thickness of 10–15 centimetres. Reinforced curb stones were removed before milling, but the remaining paving and asphalt could be crushed and re-used directly on-site.

On-site asphalt recycling reduces transport needs and emissions

Traditionally, similar rehabilitation work would be carried out using the mass replacement method: damaged asphalt and structural layers are excavated, transported away by trucks and replaced with new materials brought in from elsewhere. In addition, the removed asphalt must be taken to an asphalt plant for crushing and reuse. This results in high volumes of transport traffic, fuel consumption, and CO₂ emissions.

The MeriRoad recycling method works in the opposite way. The old asphalt is crushed and mixed on-site, forming a uniform and load-bearing base layer beneath the new pavement. Because the material is reused directly, the worksite does not require continuous truck movements—no material needs to be hauled away and no new aggregate has to be delivered. This greatly simplifies logistics and directly reduces the carbon footprint of the rehabilitation work.

The role of the MeriRoad milling crusher in the mixing and recycling process

In this project, the MeriRoad RC90-221 DTG milling crusher processed the asphalt and old structural layers into a reusable form quickly and efficiently. At the same time, the material was mixed into a consistent base, providing a structurally sound foundation without the need to fully replace the existing layers. Once shaping and compaction were completed using the recycled material, the result was a strong, uniform base ready for a new asphalt surface.

An additional advantage of the method is that all stages of the work can be completed with the same machine, reducing the need for multiple pieces of equipment and saving time on-site. The advanced crushing and mixing technology ensures that the asphalt is processed evenly and effectively, maximising the use of existing materials. A particular benefit of the tractor-mounted crusher is its excellent mobility.

Clear savings: 70–75% lower total costs

The recycling and mixing method delivered significant savings. Total project costs were estimated to be 70–75% lower compared to the mass replacement method. The primary reason is that the existing material is reused entirely, eliminating the need for heavy transport operations and extensive excavation work.

This cost-efficiency is also reflected in the project timeline: when unnecessary transport and replacement tasks are removed, the overall duration of the work is markedly shorter.

Emission reductions: 75–80% lower CO₂ emissions

The greatest environmental benefit comes from reduced logistics. When no materials need to be transported away and no new materials are brought in, heavy vehicle fuel consumption drops dramatically compared to traditional methods. Calculations for this project showed that the MeriRoad-based recycling method produced 75–80% lower CO₂ emissions than mass replacement.

The reduced truck traffic also minimised disruption to the surrounding area, making the method especially suitable for urban locations and sites where minimising transport impacts is crucial.

A flexible and easily transportable solution, even for smaller sites

The tractor-mounted MeriRoad milling crusher is well-suited to a wide range of environments and is particularly effective for small and medium-sized projects where moving heavy machinery would be costly or impractical. No low-bed trailer transport is required, as the crusher can be moved from one site to another easily using the tractor’s three-point linkage.

This mobility enhances overall efficiency and further reduces both costs and emissions.