Future-proofing roads: How advanced bitumen and preventive treatments tackle potholes

This surge in potholes is closely linked to a steep decline in proactive surface dressing and routine preventive maintenance over the past decade, leaving many roads increasingly vulnerable to accelerated wear and deterioration. For those in the road industry, embracing advanced bitumen technologies combined with targeted preventive surface treatments offers a cost-effective, durable, and sustainable strategy to extend pavement life, enhance driver safety, and dramatically reduce pothole formation.

Sunk costs

 Data shows that potholes are becoming a more frequent problem. According to the RAC figures pothole-related incidents have increased by 11% over the past year, with more than one in three British drivers reporting experiencing damage. The cost of repairing this network is rising annually with some projections putting it as high as £17 billion but still, many local authorities report no tangible improvements to their networks over the last 12 months.

Between 2022 and 2023, 1.4 million potholes were filled in England and Wales, down from 1.7 million the previous year. In part, this is due to short-term funding allocations that prioritise reactive rather than preventive work. This approach places a growing financial burden not just on road users but on local authority budgets, further stretching the need for smarter, longer-lasting road surface solutions.

 To address this issue, the road industry needs to begin addressing road surface decay at its root, supported by technology that makes lasting repairs more cost-effective.

The role of preventive treatments

A key factor behind the increase in potholes is the sharp decline in surface dressing applications. Surface dressing is a fundamental preventive treatment that extends road life by creating a protective layer against water ingress and wear. Since 2012, surface dressing rates in the UK have dropped by nearly half, and the Department for Transport reports a 30% decrease between 2016 and 2022 for A, B, and C classified roads. Given that surface dressing can add 10-15 years to road lifespans at a cost of just £4-5 per square metre, this decline represents a lost opportunity for efficient asset preservation.

Beyond surface dressing, there is a suite of preventive options that offer effective alternatives to more expensive reconstruction. For example, microsurfacing can be used to add an enhanced repair layer for roads with greater surface distress, improving skid resistance and road texture. Geosynthetic interlayers, meanwhile, play a crucial role in halting reflective cracking within surface structure by dispersing stresses and reinforcing the asphalt overlay. Research indicates that this form of reinforcement not only extends road life but also enables thinner asphalt layers, reducing material usage and carbon emissions. 

These methods form an integral part of a more sustainable road maintenance strategy focused on asset longevity. Industry experts and associations like the Road Surface Treatments Association (RSTA) emphasise that renewed commitment to preventive maintenance is both a financially prudent and safety-critical approach. By investing in surface dressing, microsurfacing, and geosynthetic interlayers early, road authorities can reduce the need for expensive pothole repairs and full-depth reconstructions later. 

Innovations in advanced bitumen technologies 

The materials used in asphalt production lie at the heart of road surface performance and durability. ACI Group offers an extensive range of premium bitumen additives that significantly improve asphalt’s resilience against potholes and weathering. Bitumen emulsifiers such as C320e, EM44, Redicote, and Wetfix enhance binder properties and adhesion for surface dressing and micro asphalt applications. Warm mix asphalt additives like Wetfix BE, LQ1200, AP47, and plant-derived Vialit LT130 enable lower temperature production with energy savings and improved compaction, cutting carbon emissions without compromising strength.

 Natural modifiers including Gilsonite and lignin also can help to enhance asphalt properties. Gilsonite increases asphalt strength, rutting resistance, and weatherproofing capability, helping to seal surfaces against water ingress and slow deterioration. Lignin powder, a bio-based additive, supports binder replacement and warm mix asphalt formulations, aligning with sustainability goals while enhancing road flexibility and durability.

ACI Group: Your partner in future-proofing roads

With decades of experience serving the road industry, ACI Group is uniquely positioned to support contractors and authorities in implementing sustainable, high-performance surface repair solutions. Our comprehensive portfolio includes top-quality additives for asphalt production alongside high-performance pigments and intelligent dosing systems designed in partnership with ASL for precise, efficient handling of liquid additives on site.

By choosing ACI Group products, road projects benefit from enhanced binder performance, superior adhesion, and improved durability. Coupling our advanced bitumen additives with preventive treatments designed to extend asset life ensures roads stay safer, smoother, and more cost-effective over the long term.

To explore how ACI Group’s advanced additives and dosing systems can help your team tackle potholes and extend pavement life, contact us at info@acigroup.biz