Brand Highway (H004) forms part of a major road network linking Perth with the regional centre of Geraldton and the North-West of Western Australia. The Highway is a strategic restricted access vehicle (RAV), Category 7 freight route, as well as a local access between town sites and rural access areas. Brand Highway has been constructed in various stages from 1962 using a variety of locally-sourced materials such as crushed limestone, laterite and crushed granite in the subbase and basecourse layers. The section that was investigated as part of the initial project is situated between SLK 4 and SLK 50, directly north of the Muchea Road Train Assembly Area. The posted speed of this section of road is 110 km/h and it consisted of a two-lane, two-direction bituminous sealed surface with 3.5 m lane widths. Sealed shoulder widths varied from 0.5 m to 1.5 m. Apart from the geometric improvements required to widen the surface width to include a 1.0 m wide median strip for riding quality and safety reasons, one of the project objectives was to increase pavement life expectancy with a cost-effective rehabilitation design. In situ recycling of 250 mm of the existing basecourse and subbase layers together with 50 mm imported crushed rock to facilitate shape correction and improve drainage, using foamed bitumen and lime proved to be the optimum solution. This paper will give an overview of the pavement rehabilitation design conducted, describe the construction methodology followed and quality control testing conducted on site.