Case Study: BORAL – Asphalt at Western Sydney International Airport
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Boral was selected as the supply partner responsible for producing, delivering, and laying the asphalt for the runways, taxiways, and airside roads and pavements at Western Sydney International (Nancy-Bird Walton) Airport (WSI).
Working with the CPB Contractors and ACCIONA Joint Venture, our teams oversaw the surfacing works to ensure this critical infrastructure was completed to a high-quality standard, on time, on budget, and most importantly safely and sustainably. The airport, scheduled to open in 2026, will have the capacity to accommodate up to ten million passengers annually. The airport has been designed harmoniously with the natural environment and First Nations heritage to serve as a shining example of sustainable infrastructure.
As part of Boral Asphalt’s contribution to the build of WSI, the team implemented an Australian first through the extensive use of a biogenic bitumen binder on an airfield. In addition, it is the first use of biogenic binder in asphalt in permanent infrastructure in NSW.
In this Boral-led initiative, the Boral asphalt team (with technology support from PUMA) used CarbonBind bitumen in the asphalt used to construct some of the tug-loop roads around the airfield. These roads are designed to a high standard, similar to the runway, to allow them to withstand the forces associate with aircraft tugs. We placed about 5,370 tonnes.
CarbonBind bitumen uses a plant-based component to replace some of the traditional crude oil-based ingredients. The plant derived feedstock, processed locally into a biogenic bitumen component, is blended with conventional bitumen for use.
For each tonne of CarbonBind bitumen used, it permanently sequesters about 150 kg of carbon by locking it into the asphalt pavement, which in turn, can then be recycled at the end of its working life.
Recycled Asphalt Pavement (RAP) is recycled asphalt and the most reused construction material in the world. Reuse of asphalt can reduce the demand for imported bitumen and replaces new high-quality aggregate raw materials that can then be used for other projects.
Further to this, as part of the overall project. Boral asphalt offset our diesel at the asphalt plant to carbon neutral and trialled a solar hybrid generator to power our site compound.
Outcomes:
Boral used Carbonbind in the 5,370t tonnes of asphalt supplied to construct some of the tug-loop roads around the airfield during the 2024 financial year (June 2023-July 2024).
Within the 5,370 tonnes, approximately 300 tonnes of CarbonBind bitumen was used.
For each tonne of CarbonBind bitumen, about 150kg of carbon is permanently sequested. For the project at WSI, approximately 45,000 kg of carbon has been sequestered as a result of Boral’s use of the CarbonBind bitumen technology in the asphalt supplied to construct the access roads at WSI.
Boral’s use of this technology and its contribution to the overall sustainability of the WSI project has been communicated to CPB Contractors / ACCIONA (CPBACC) Joint Venture, who in turn sought validation via the Australian Flexible Pavement Association, who confirmed Boral’s use of CarbonBind bitumen was:
• The first airport application
• The first permanent infrastructure application in NSW
Our broader work as part of the overall project, to offset our diesel at the asphalt plant to carbon neutral and trial a solar hybrid generator to power our site compound, resulted in a saving of 5.1 million kg of carbon and recognition from our client.
Working with the CPBACC Joint Venture (CPBACCJV), Boral has been progressing plans to have a sign installed at WSI outlining the sustainability aspects and explicitly, the use of the biogenic bitumen, in the construction of the roads.
Separately, Boral has worked collaboratively to gather validation and endorsement documentation about the initiative to support CPBACCJV in its application for innovation certification from the Infrastructure Sustainability Council (ISC). The biogenic bitumen initiative has also been communicated internally to Boral employees via internal communication channels.
It is anticipated this initiative will feature in future WSI Airport sustainability reporting.
Leaving a Legacy:
The Australian public have a more sustainable piece of landmark infrastructure as a result of the use and application of biogenic bitumen in the asphalt supplied to build the WSI access roads.
About 45,000 kg of carbon have been permanently sequestered through Boral’s use of CarbonBind bitumen.
The use of biogenic bitumen has helped WSI contribute to the following United Nations Sustainable Development Goals:
Goal 9: Industry, innovation and infrastructure
Boral’s application of CarbonBind technology promotes how industry can facilitate more sustainable development and infrastructure that supports economic development.
Goal 11: Sustainable cities and communities
Through this initiative, Boral has helped to deliver a solution that provides a more sustainable transport system for the Australian public. It has enhanced sustainable urbanisation and in the application of biogenic bitumen, also delivered against the Goal 11 target of reducing the adverse per capita environmental impact of cities.
Goal 13: Climate action
Boral’s use of CarbonBind contributes towards Goal 13’s aim to adapt to climate change and invest in low-carbon development.
Goal 15: Life on land
The use of biogenic bitumen highlights the importance of sustainable management of forests to support this form of sustainable development, along with the benefits that arise from organic resources.