From Roof Shingles to Road Performance: BATT Supports RenuCore’s™ Lab Validation and MnROAD Pilot Pave
Turning waste into a high-value pavement ingredient is no small task — but that’s exactly what CertainTeed has accomplished with the RenuCore™ technology, an asphalt binder-replacement product launched in 2024 and engineered from post-industrial or post-consumer roofing shingles. To support the product’s advancement and demonstrate its performance benefits, CertainTeed called on BATT for laboratory mix evaluation, performance testing, and on-site quality control during a pilot pave at MnROAD, Minnesota’s nationally recognized pavement research facility.
RenuCore acts not only as a performance-enhancing binder alternative, but also as a circular-economy solution with benefits for three major sectors:
Hot mix asphalt producers would gain a consistent, melt-ready source of recycled binder that can help reduce reliance on higher-cost virgin asphalt while supporting strong mix performance.
DOTs and county road agencies gain a practical way to offset virgin binder while improving mix properties.
Construction and Demolition (C&D) recycling operators gain a technology that can convert shingle waste into a manufacturable, revenue-generating product.
RenuCore is now being offered as a technology licensing opportunity for HMA producers and C&D recycling operators who want to turn large volumes of roofing-shingle waste into a new, revenue-generating manufactured product—while giving asphalt producers a high-value recycled binder alternative. RenuCore is a coated pellet product that can be stored long term, making it an easy-to-use solid modifier for hot mix asphalt.
Furthermore, the pellets integrate easily into standard mix-design workflows. As with any recycled or performance-enhancing component, its contribution to fines and binder is simply accounted for in the JMF, much like RAP, RAS, or polymer-modified additives. Its consistent pellet form makes the adjustment predictable and straightforward for producers.
With BATT’s independent testing and field support, RenuCore pellets have demonstrated that they can add desirable performance properties to asphalt mixes, strengthening the business case for HMA producers and DOTs specifiers.
BATT’s Lab Evaluation: Strong Results with Only 3% RenuCore Pellets
BATT incorporated 3% RenuCore pellets into a central-Kentucky mix typically produced with virgin asphalt binder meeting regional specifications. The results were significant: RenuCore pellets enabled a nearly 15% reduction in virgin binder demand — a valuable offset for agencies and contractors seeking cost and material efficiencies—while enabling a near 14.4% improvement in cracking resistance compared to the control mix from IDEAL-CT testing. This indicates that RenuCore pellets may not only replace a portion of binder but also enhance cracking performance.
“Asphalt shingles are engineered to be stiff, so they generally don’t melt well when added directly into asphalt mixes. RenuCore pellets change that. The pelletized format rejuvenates the shingle binder, allowing it to melt and disperse uniformly. This can broaden the temperature-performance range of a mix and contributes to the strong binder characteristics we observed”, said Zack McKay, BATT Laboratory Operations Manager.
To validate RenuCore pellets beyond the lab, BATT supported CertainTeed during a pilot production and paving operation at MnROAD. BATT provided on-site technical expertise throughout plant production—monitoring material behavior, silo discharge, and overall quality control—and observed that the RenuCore pellets flowed smoothly with the RAP at the collar, producing a mix that looked and behaved like standard production.
During paving of two 250-foot test lanes, BATT continued providing guidance and real-time feedback to the CertainTeed and MnROAD teams. The RenuCore pellet-modified mix laid down cleanly, reached target compaction with minimal effort, and showed excellent workability, demonstrating strong compatibility with conventional paving and compaction practices.
“BATT brought exactly what this technology needed: independent technical expertise and respected industry leadership. Their work not only validated how RenuCore performs, but also helped establish confidence among producers and partners who rely on trusted data to adopt new solutions,” said Maure Creager, Circular Economy Manager, CertainTeed.
Conclusion: A Promising Path Forward for RAS Pavements
From laboratory validation to live mix production and field paving, BATT’s work demonstrates that RenuCore pellets can deliver meaningful performance benefits—reducing virgin binder demand, improving cracking resistance, and integrating smoothly into standard plant and paving operations. For C&D landfills, the technology offers a significant advantage: a practical way to transform large volumes of roofing-shingle waste into a pelletized, revenue-generating product. Hot mix asphalt producers gain a consistent, melt-ready source of recycled binder that supports both cost and performance goals.
Importantly, RenuCore pellets also represent progress for construction materials manufacturers committed to circularity. CertainTeed’s investment in developing and licensing this technology reflects a broader dedication to creating responsible, closed-loop pathways for the materials it produces—turning end-of-life shingles into a useful, high-value ingredient for the next generation of asphalt pavements. As agencies and industry partners look for verified solutions that balance performance, sustainability, and resource stewardship, CertainTeed offers a compelling model for what circular innovation can achieve.
