Colas Designs High-Performance HiLAB Pavement for Webb Drive, Hamilton
As urban growth and freight volumes increase, road infrastructure must meet today’s challenges: durability, cost-efficiency, and low environmental impact. In the heart of Ruakura SuperHub, New Zealand’s largest multi-purpose industrial development, Colas New Zealand delivered a bold solution: a next-generation pavement for Webb Drive based on HiLAB technology.
This innovative approach drastically reduced asphalt thickness while maintaining top structural performance, all under a design-build contract with a 7-year warranty.
A strategic project facing rising technical and budgetary pressures
Webb Drive serves as a key logistics corridor connecting industrial areas to the inland port.
Initially, the Hamilton City Council required a 200 mm asphalt pavement, following the premature failure of standard designs nearby.
This upgrade increased the projected budget from NZD 1.3 million to NZD 3 million, putting pressure on developers and stakeholders.
HiLAB Solution: A Cost-Saving and Technically Sound Alternative
Colas New Zealand proposed an alternative solution engineered by Dr. Greg Arnold, reducing the asphalt layer to just 60 mm, supported by a HiLAB base - a cement-stabilised, low-fines crushed rock developed locally.
The benefits were clear:
- A NZD 1 million saving compared to traditional pavement;
- A design approved under a 7-year performance warranty;
- A more sustainable and efficient structure suited to heavy traffic.
What is HiLAB? A New Zealand Innovation for Industrial Pavements
HiLAB (High strength Low fines Aggregate Base) is a high-performance road base system designed for heavy-duty use. It combines:
- Large aggregates with minimal cement;
- Reduced shrinkage and deformation;
- High stiffness (~0.1 mm deflection), comparable to concrete;
- A 70% reduction in asphalt use, lowering carbon emissions.
HiLAB offers a future-proofed solution for roadways subjected to high axle loads, while supporting sustainability goals.
Rigorous Quality Control for Full NZTA Compliance
To meet performance and safety standards, the project followed:
- NZTA specifications B10 and M10;
- GPS-controlled graders for precise shaping and leveling;
- Real-time inspection and correction during construction;
- Full compliance across all quality metrics.
The result? A road delivered on time, on budget, and 100% compliant.
A Model for Collaborative, Sustainable Infrastructure
The Webb Drive project, conducted in partnership with Online Civil Works, Chedworth Properties, and Hamilton City Council, showcases:
- Innovative public-private collaboration;
- A bold approach to design risk, rarely accepted in New Zealand;
- A new standard for cost-efficient, high-performance pavement solutions.
Colas Opens the Way for Smarter Roads
With its HiLAB project in Hamilton, Colas has proven that technical innovation, cost control, and environmental performance can go hand-in-hand.
The project stands as a benchmark for modern road design, and a powerful example of how smart engineering leads to sustainable infrastructure.
