The carbon case

Per repair: as low as 0.8kg CO₂ vs typically over 3.2kg for traditional methods — 75% less carbon per repair lifespan (East Ireland trial, 2024).

vs hand-lay repairs: 96% carbon reduction (Volker Highways, 2023).

The lifespan multiplier: because spray patches last around 4× longer, fewer interventions are needed over the road’s lifespan — less travel, less material, less equipment, and fewer carbon events in total.

Zero material waste: traditional crews carry more than they use, and unused hot material must be disposed of at day’s end. Roadmaster mixes at the point of delivery; unused material returns to depot for the next day. Zero disposal carbon.

Fuel options

All Roadmaster machines can run on HVO (Hydrotreated Vegetable Oil), a renewable diesel substitute that reduces lifecycle carbon with no engine modification required. Dual-fuel and hydrogen-ready configurations are under development. Roadmaster provides a carbon-calculation matrix to support annual reporting.

Health & safety

No worker stands in live traffic. The operator completes every repair from inside the cab; at no point does a crew member step onto the carriageway. Traditional repair requires 3–5 crew on the live carriageway; two-operator machines put one person on the road surface. The risk differential is significant — and regulation is moving in one direction.

• 66% less manpower exposed to live traffic per repair
• Zero manual lifting at the point of repair
• No exposure to bitumen fumes from standing in the carriageway
• No heavy material handling on site

From a health and safety point of view, they are safer. It’s far safer to have one operator in a truck. That’s a big benefit — and it’s an issue that’s going to get more prominent.

— Pat Fitzgerald, formerly Tipperary County Council

The market right now

With net-zero mandates tightening across the sector, repair method is now a reporting issue as much as an operational one. Each Roadmaster repair also takes under three minutes — versus 20+ minutes for a traditional crew — cutting crew and road-user exposure on every job.