Reclaimed Asphalt p Pavements

By
Sanjay Garg
SE & RO, MORTH, Bengaluru
Sanjay Garg, RO, Blore 1

What is reclaimed asphalt pavement? t?

Reclaimed or recycled asphalt pavement (RAP) consists of milled or excavated asphalt h l pavement which hi h is i crushed h d and d screened into different sizes to meet specified grading requirements. requirements Recycling is a technique to rehabilitate the bituminous pavement.

Sanjay Garg, RO, Blore

Sanjay Garg, RO, Blore

RAP is produced by
Milling the th upper pavement t Full-Depth F ll Depth Remo Removal al of f the th
layers usually with a depth of 50 mm in a single pass. bituminous pavement completely and then, reprocessed.

Sanjay Garg, RO, Blore

When to Recycle?
Excessive pot holes/raveling or non-structural cracks or surface defects surface renewal is no longer effective, and Pavement at end of design life

Sanjay Garg, RO, Blore

Why Recycle?
Use of RAP brings engineering, environmental benefits. economic and

Improve serviceability of aged and deteriorated pavements enhance the service life of pavement. Scarcity of quality aggregates. Increasing cost of the bitumen. Reuses and conserves non-renewable natural resources (aggregate and bitumen) reduced construction cost. Preservation of the existing pavement geometrics/ thickness Level deformations and restore camber.
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Sanjay Garg, RO, Blore

Why Recycle?
Retain overhead clearances.

(continued)

Conservation of energy as well as preservation of the environment. Minimize lane closure time, and user delays. Reduced land filling. Public acceptance of recycling. recycling Recycled pavement can be recycled itself.

Sanjay Garg, RO, Blore

RAP Economics
Binder Replacement Calculation Binder Replacement, % = {(A X B)/C }100

Where: A = RAP percent binder content, B = RAP percent in mixture, and C = Total percent binder content in mixture.

Sanjay Garg, RO, Blore

RAP Economics
content by mix weight Cost per MT, Rs.

Aggregate Bitumen RAP

95 % 5% 10 %

900 40,000 500

BitumencontentinRAP=4.50%
Mix cost with 0 % RAP = 0.9*.95+40*.05+0.7 = 3.555 Mix cost with 10 % RAP = 0.9*.8545+40*.0455+0.1*.5+.7 = 3.3391 (6.10 % less) Mix cost with 20 % RAP = 0.9*0.759+40*.0410+0.2*.5+.7 = 3.1231 3 1231 (12.15 (12 15 % less)
Sanjay Garg, RO, Blore 9

RAP Economics
content by mix weight Aggregate Bitumen 93-96 % 4-7 % Cost proportion 14-16 % 60-70 %

10/20/30/40% mixing of RAP with virgin aggregate and bitumen will result about 6/12/19/26% decrease in the cost of bituminous pavement construction.
Sanjay Garg, RO, Blore 10

RAP Economics

( (continued) )

Sanjay Garg, RO, Blore

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RAP Economics

( (continued) )

Materials savings will depend on... Virgin binder cost Bitumen content of the mix design Aggregate cost RAP cost Bitumen content of the RAP Percentage of RAP

Sanjay Garg, RO, Blore

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Use of RAP will:

Reduces the need to quarry more aggregates. Reduces bitumen demand. R Reduces d energy/costs / to produce, d process and d transport aggregates as well as bituminous mix. Reduces overall production cost of bituminous mix.

Sanjay Garg, RO, Blore

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RAP can be used for

Base and sub-base courses, Fill, Shoulders Shoulders, Street Roads, walkways, footpaths etc. Back into new bituminous mixtures Highest Hi h t and d best b t use of f RAP, RAP Most cost effective and eco-friendly.

Sanjay Garg, RO, Blore

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With bituminous mix, RAP can be b used d

Virtually for any mix, following best practices Base and intermediate layers Potential to use higher amounts Surface layer Tendency to allow lower amounts Friction and cracking are potential concerns Increased resistance to rutting
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RAP Process will be

Recycling Process

In-situ recycling

Central plant recycling

Hot Recycling

Cold Recycling

Hot Recycling

Cold Recycling

Sanjay Garg, RO, Blore

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Hot Central Plant Recycling (HCPR)

Most common method of recycling. It involves combining RAP with new or virgin aggregate new bitumen binder, aggregate, binder and/or recycling agents in a central hot mix plant to produce a recycled mix. mix Batch mix plant or drum mix plant can be used to p od ce the RAP mixed produce mi ed bituminous bit mino s mix. mi

Sanjay Garg, RO, Blore

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Introduction of RAP material in a drum plant

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Schematic Sc e a co of d drum u mixer e with ce center e e entry y

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Mix Designs with RAP

No guidelines for using RAP. New system lots of unknowns. Interim I i guidance id b based d on Marshall M h ll mixes i Up to 15% RAP, no change. 16-25% RAP, increment. drop binder grade one

Over 25% RAP, blending chart needed.

Sanjay Garg, RO, Blore

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Mix Designs with RAP

(contd..)

Determining the material properties of the RAP. Selecting an appropriate blend of RAP and virgin aggregate to meet gradation. d i g an appropriate pp p neat bitumen g grade to Selecting satisfy specified viscosity and penetration requirements. Designing a mix to comply with stability, flow, and air voids requirements, requirements as usual. usual
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Sanjay Garg, RO, Blore

Mix Designs with RAP

(contd..)

The basic properties of the RAP, tested, are: Moisture Content, Aggregate properties like gradation, g y, specific p gravities, g , % fracture angularity, etc., Bitumen Content Bit C t t and d bitumen bit properties ti (specially penetration and viscosity),

Sanjay Garg, RO, Blore

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Hot In In-situ situ Recycling (HIR)

HIR is the on on-site, site, in in-place place rehabilitation method which consists of heating, softening, scarifying, mixing, placing, and compacting the existing pavement. Virgin aggregates, Bitumen binder, recycling agents, and/or new HMA can be added, on an as required basis, to improve the characteristics of the existing pavement

Sanjay Garg, RO, Blore

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HIR Process
Bituminous surface heated Heated pavement scarified or milled to depth Rejuvenating R j i li id added liquid dd d at design d i content Materials Mixed with virgin aggregate/bitumen Recycled mix placed/re-paved by Paver Mat compacted Surface applied

Sanjay Garg, RO, Blore

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HIR Process
Continuous Process with Self-Contained Train

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Use of Polymer in HIR will improves Flexibility & Durability Adhesion Adh i Temperature Susceptibility Strength & Rutting Resistance Cracking Resistance

Sanjay Garg, RO, Blore

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Benefits of HIR
Aged, Distressed Surfaces Replaced with New Surfaces Deformations Leveled Surface Cracking Removed Clearances, Curb Heights Maintained Reuses Existing Materials Can, Itself, be Recycled

Sanjay Garg, RO, Blore

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Benefits of HIR
Minimizes lane closure time.

(continued)

Other lanes remain open during construction. Quick return to traffic. Aged, Oxidized Asphalt Rejuvenates Aged Excellent Aggregate/RAP Coating

Sanjay Garg, RO, Blore

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Cold Central Plant recycling

Stockpiled and kept clean. Crushed RAP to gradation. Mixed with recycling emulsion in central plant. Transported a spo ted to lay ay down do area. a ea Paved as a recycled mix. Compacted to specified density. Readied for surface treatment

RAP

t Pavement to P t
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Cold In In-situ situ Recycling (CIR)

CIR is the on on-site site recycling process to a typical treatment depth of 2 to 5 inches using a train of equipment (tankers, milling machine, crushing and screening units, mixers, a paver, and rollers), an additive or a combination of additives (i.e. asphalt emulsion), generating and reusing 100% RAP (partial depth), with the resulting recycled pavement usually opened to traffic at the end of the work day.

Sanjay Garg, RO, Blore

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Cold in in-place place recycling

Train of equipment Mills old pavement RAP g Crushes RAP to gradation Mixes with recycling emulsion Re-paves recycled mix Compacts - specified density Readies for surface treatment
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CIR Recycling Train

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Cold In In-situ situ Recycling - benefits

Cost Cost-effective effective rehabilitation Low user delays Engineered E i df for reliability li bili Defined sampling protocol Engineered design Performance Performance-related related specifications Early strength and long term durability

Sanjay Garg, RO, Blore

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Full Depth Reclamation (FDR)

FDR is the rehabilitation technique in which the full thickness of the asphalt pavement and a predetermined portion of the underlying materials (base, subbase, and/or subgrade) is uniformly pulverized and blended to provide an upgraded, homogeneous material.

Sanjay Garg, RO, Blore

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 Mechanical stabilization - 1st step in reclamation; also used to describe FDR without addition of binder (Pulverization) Chemical stabilization - FDR with chemical additive (Calcium or Magnesium Chloride, Lime, Fly Ash, Kiln Dust, Portland Cement, etc.) Bituminous stabilization - FDR with asphalt emulsion, emulsified recycling agent, or foamed / expanded asphalt additive. y combination of above. Any
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FDR can be used in

Stretches with high severity distresses Ruts Cracks C k Potholes Base problems Edge failures Stretches to overcome drainage problems.
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Recommended Practices for Use of RAP

Follow best practices for the processing and management of RAP Good material management practices. Sample and test RAP during processing. RAP usage g specifications p RAP mixes should meet same specifications as virgin mixes. Adjust binder grade, if higher RAP is used. Approved mix design including RAP
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RAP Management & Best practices

Monitor & control incoming RAP Stockpile job millings by job and size QC tests on all ll RAP Fractionate RAP (when applicable) Avoid contamination Keep the RAP dry paved paved and sloped area, covered stockpile ( BTUs= $$$) Know Plant limitations (e (e.g. g Batch plant)
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Agency Concerns (Limitations)

Quality Concerns (including friction) Consistency of RAP Ability Abili to M Meet Volumetric V l i Requirements R i Durability of Mixes Stiffness of Binder Use with Polymers

Sanjay Garg, RO, Blore

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CONCLUSIONS
RAP has long history of successful use. Asphalt recycling is sustainable. Asphalt recycling is economical. Asphalt recycling works!

Sanjay Garg, RO, Blore

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References
Kandhal, P. S., and R. B. Mallick, Pavement Recycling Guidelines for State and Local Governments, Report No. FHWA-SA-98-042, National Center for Asphalt Technology, Auburn, AL, 1997. The Asphalt Institute, Institute The The Asphalt Handbook: MS-4 MS 4, 7th Edition, Edition 2007, The Asphalt Institute, Lexington, KY. David E. Newcomb et.al., Designing HMA Mixtures with High RAP Content - A Practical Guide, Quality Improvement Series 124, 2007, National Asphalt Pavement Association, Lanham, MD.

Sanjay Garg, RO, Blore

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Thanks & Questions?

Sanjay Garg, RO, Blore

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