Gernatt Asphalt Products Inc. recently became the first company to deploy a revolutionary low-emission asphalt technology in Western New York, marking a significant milestone for sustainable road construction in the region. This innovative approach, known as Low Emission Asphalt (LEA), represents a major step forward in reducing the environmental footprint of asphalt production without sacrificing performance or cost-effectiveness. For contractors and paving professionals seeking to understand the implications of this technology for their own operations, understanding the fundamentals of asphalt safety and hazard management in hot mix operations provides essential context for evaluating warm mix alternatives like LEA.
Understanding Low Emission Asphalt Technology
Low Emission Asphalt is a warm mix asphalt technology that dramatically reduces the temperature required to produce and place asphalt pavement. Unlike traditional hot mix asphalt (HMA), which is produced at temperatures exceeding 300 degrees Fahrenheit, LEA achieves full coating and workability at significantly lower temperatures through a combination of chemical additives and a specialized sequential mixing process.
The Origins of LEA
LEA technology was originally developed by a French company named LEA-CO and was brought to North America in 2006 through an exclusive agreement with Suit-Kote Corp., a vertically integrated asphalt company headquartered in Cortland, New York. Suit-Kote has been researching, manufacturing, and paving LEA since 2006, successfully completing over 40 projects including work with the New York State Department of Transportation and various county and municipal agencies. This established track record gave Gernatt confidence in adopting the technology for its first LEA project on Allen Road in Erie County.
How the Chemical Additive Works
The catalyst behind the temperature reduction in LEA is a proprietary chemical additive that enhances multiple performance properties simultaneously. The additive functions through three primary mechanisms:
- Increased adhesion between the asphalt binder and aggregate particles, ensuring durable bonding even at reduced temperatures
- Improved coating of aggregate surfaces, allowing complete asphalt coverage at lower production temperatures
- Enhanced workability of the mix, making it easier to place and compact without requiring high heat
These enhancements are achieved through a sequential mixing process that differs from conventional HMA production methods. The chemical additive is introduced at a specific point in the production cycle, ensuring optimal dispersion and activation throughout the mix. Suit-Kote Corp. provided the chemical additive to Gernatt and installed the necessary plant modification equipment to produce the LEA, demonstrating that existing asphalt plants can be retrofitted for this technology with relatively minor modifications.
The Allen Road Project: A Case Study in Green Paving
The inaugural LEA project in Western New York involved resurfacing 4.4 miles of Allen Road in Erie County. Before placing the LEA, the existing asphalt surface underwent cold in-place recycling, further enhancing the environmental credentials of the project. Understanding how asphalt plants and pavement construction equipment function in hot mix production helps contractors appreciate the operational adjustments required when transitioning to warm mix technologies like LEA.
Project Specifications and Equipment
The paving work consisted of two lifts placed over the recycled base:
- A 2.5-inch 19 mm binder course
- A 1.25-inch surface course
- A total of 8,100 tons of binder mix and 3,100 tons of surface mix
- All materials incorporated reclaimed asphalt pavement (RAP) in quantities of up to 13 percent
The asphalt was placed using a Terex 552 paver equipped with a material transfer device, which was rented from Union Concrete and Construction. Compaction was accomplished using standard rolling equipment appropriate for the job specifications. The project proceeded without any production delays, despite being the first LEA production run for Gernatt’s team.
Energy Savings and Production Performance
Bill Schmitz, vice president of sales and quality control for Gernatt, reported that the company burned approximately 25 percent less fuel producing LEA compared to traditional hot mix asphalt. This figure is particularly significant because it was achieved without any optimization of the plant for low-temperature production. Research has shown that even greater energy savings can be realized with small modifications to the plant, suggesting that the 25 percent figure represents a baseline that can be improved upon as producers gain experience with the technology.
Schmitz noted that production capability was not limited in any way during the first LEA production run. The ease of production, combined with the immediate energy savings, made a compelling case for the technology from an operational standpoint alone, before considering the environmental benefits.
Environmental Benefits and Emissions Reduction
The emissions reduction potential of LEA is one of its most compelling features. To quantify these benefits precisely, Suit-Kote contracted O’Brien and Gere, an engineering firm based in Upstate New York, to conduct a comprehensive emissions study comparing plant emissions from LEA production against traditional HMA production. The results were striking across every measured pollutant category. Contractors interested in the broader regulatory landscape should also review the latest EPA guidance on asphalt EPDs and what contractors must know about low embodied carbon materials.
Quantified Emissions Reductions
The study documented the following reductions when comparing LEA to traditional HMA production:
| Pollutant | Reduction |
|---|---|
| Particulate matter (baghouse exhaust) | 51 percent |
| Sulfur dioxide (SO2) | 46 percent |
| Nitrogen oxide (NOx) | 21 percent |
| Carbon monoxide (CO) | 82 percent |
| Other air contaminants (total) | 73 percent |
These reductions are achieved primarily through the lower production temperatures, which require less fossil fuel combustion in the drum dryer and result in fewer combustion byproducts being released into the atmosphere. The data provides concrete evidence that LEA delivers meaningful environmental improvements without requiring expensive add-on emissions control equipment.
The Double-Green Advantage
Professional Engineer Frank C. Gaus, representing the project team, described LEA as a double-green technology because it combines emissions reduction with the use of recycled materials. The incorporation of up to 13 percent RAP in the Allen Road project means the environmental benefits extend beyond production energy savings to include reduced demand for virgin aggregate and binder materials.
- First green benefit: Reduced fuel consumption and lower production emissions
- Second green benefit: Integration of RAP, diverting material from landfills and reducing the environmental impact of mining virgin materials
- Combined impact: A more sustainable paving solution that addresses both production and material sourcing concerns
Additionally, LEA provides improved working conditions at the jobsite by significantly reducing smoke and odor compared to traditional hot mix. This creates a safer and more pleasant environment for paving crews, which can contribute to improved worker satisfaction and productivity over the course of a paving season.
Performance, Cost, and Industry Adoption
One of the most important considerations for any new paving technology is whether it can match or exceed the performance of conventional methods. The track record of LEA to date suggests that it not only performs well but may offer durability advantages over traditional HMA in certain applications. Developing strong relationships with asphalt producers and contractors who embrace innovation is essential, and the principles demonstrated by Gernatt align well with broader strategies for building customer loyalty in asphalt and paving through quality and innovation.
Durability and Aging Resistance
The reduced production temperature associated with LEA provides a significant performance benefit known as reduced aging or stiffening of the mix. When asphalt binder is heated to high temperatures, it undergoes oxidation that makes it stiffer and more brittle over time, accelerating the development of cracking and other pavement distress. By producing the mix at lower temperatures, LEA preserves more of the binder’s original flexibility and ductility, which is likely to yield greater pavement durability and longer service life.
Real-world validation of this benefit comes from the first North American LEA project, which was performed in Cortland, New York, over two years before the Allen Road project. After more than 30,000 heavy truck passes, the Cortland pavement looked almost exactly as it did the day it was placed, demonstrating exceptional resistance to traffic loading and environmental exposure.
Cost Competitiveness
Despite its advanced technology and environmental benefits, LEA does not carry a significant cost premium. Once minor modifications are made to an existing asphalt plant, the cost per ton of LEA is approximately the same as traditional hot mix asphalt. This cost parity is a critical factor for widespread adoption, as it means agencies and contractors can achieve substantial environmental improvements without incurring budget overruns.
The cost analysis breaks down as follows:
- Plant modifications: Minor upfront investment to install the chemical additive system and adjust the production process
- Fuel savings: Immediate reduction of approximately 25 percent in fuel costs during production
- Materials cost: Comparable to traditional HMA, with the potential for RAP incorporation further reducing virgin material expenses
- Long-term value: Improved durability and extended pavement life provide additional lifecycle cost savings
Extended Paving Season
An additional operational advantage of LEA is its ability to be placed in cooler weather conditions compared to traditional HMA. Because the mix is produced and placed at lower temperatures, it retains its workability longer in cool ambient conditions, extending the paving season in northern climates. This can be a significant benefit for contractors operating in regions where the traditional paving window is limited by cold weather.
Industry Recognition
The Allen Road project was such a success that Gernatt received an award from the New York Construction Materials Association. The award citation highlighted that this was Western New York’s first warm mix project, recognizing Gernatt’s leadership in adopting environmentally innovative paving technology. The achievement reflects the collaborative effort between Gernatt Asphalt Products Inc., Suit-Kote Corp., Erie County, and the various contractors and engineering firms that contributed to the project’s success.
The Role of Suit-Kote and McConnaughay Technologies
Suit-Kote Corp., a diverse third-generation, vertically integrated asphalt company headquartered in Cortland, New York, played a central role in bringing LEA to the North American market. Founded in 1921 by Harry Suits, the company has evolved into a corporation that employs nearly 700 people and operates 17 facilities throughout Upstate New York and Northern Pennsylvania. Suit-Kote is widely recognized as an industry leader because of its quality road maintenance products and services. Its wholly owned subsidiary, McConnaughay Technologies, functions as the engineering and research division, driving continued innovation in low-emission paving technology.
The partnership between Gernatt and Suit-Kote on the Allen Road project demonstrates how technology transfer between established industry players can accelerate the adoption of environmentally beneficial paving methods. As more asphalt producers gain experience with LEA and similar warm mix technologies, the barriers to entry continue to decrease, making sustainable paving an increasingly accessible option for contractors and agencies across the country.