Reducing Maintenance on High-Traffic Roadways

Challenge

Infrastructure Under Pressure

Wisła, located in the Silesian Beskids mountain range, relies heavily on tourism, including internationally recognized ski jumping events. This creates an intense and continuous flow of traffic, particularly along Voivodeship Road DW942, one of the town’s main access routes.

For ZDW Katowise, the regional road authority, the challenge extended beyond construction. The focus was clear:

• Keep traffic moving with minimal disruption
• Deliver pavement that withstands heavy, repetitive loads
• Manage cost without sacrificing performance

Conventional asphalt solutions often require intervention in these conditions, creating uncertainty, higher maintenance demands, and increased disruption for both residents and visitors.

Solution

A More Reliable Approach: Designing for Performance

To address these demands, ZDW Katowice adopted a performance-driven approach by selecting Orbiton asphalt with HiMA technology, developed by ORLEN Asfalt, and using Kraton’s HiMA.

HiMA technology enhances resistance to rutting, cracking, and fatigue, helping roads maintain structural integrity even under sustained traffic volumes.

This decision reflects a broader industry shift. Infrastructure leaders are no longer focused only on initial cost. They are prioritizing materials that deliver consistent, predictable performance over time.

Impact

Turning Strategy into Results

The reconstruction of a 3.5 km (2.17 mi) section of DW942 demonstrates how advanced materials can be applied at scale:

• 20 cm (7.87 in) AC 22 base layer using Orbiton 25/55-80
• 8 cm (3.14 in) AC 16 base layer using Orbiton 25/55-80
• 4 cm (1.57) SMA 11 wearing course using Orbiton 45/80-80

This structure approach ensures that each layer contributes to overall durability and load resistance.

The impact extends beyond a single project. Between 2015 and 2016, ZDW Katowice completed 78 km (48.46 mi) of HiMA pavement across 26 sections. This level of implementation signals confidence in repeatable, reliable results.

Measurable Performance with Controlled Costs

The data from ZDW Katowice provides a clear and practical insight:

• Reconstruction cost increased by only 3.5%
• New construction costs increased by just 1%

These modest increases support a significant improvement in pavement durability and reduce the need for frequent repairs.

For decision makers, this reinforces a critical point. Reliable infrastructure is not defined by the lowest initial cost. It is defined by consistent performance, reduced intervention, and greater predictability.

What This Means for Infrastructure Leaders

The Wisła project highlights key considerations for organizations managing high-demand road networks:

• Reliability is essential in high-traffic environments
• Performance-based materials support more predictable outcomes
• Life cycle thinking strengthens both sustainability and cost control

As traffic volumes grow and expectations rise, infrastructure strategies must deliver steady performance while minimizing disruption.