“Sustainable Pavement Development” Utilizing Reclaimed Asphalt Pavement

(RAP)

James W. Emerson, APM

Pavement Recycling Systems, Inc.

California Asphalt Pavement Association

Spring Conference 2013

JOHN F. KENNEDY

“It’s not the wealth of a nation that builds roads,

but the roads that build the wealth of a nation”

Today’s “Tax Payer Friendly” Topics

Asphalt Recycling and Climate Reduction

Engineered Approach, Mix Design

Cold In-place Recycling (CIR)

Cold Central Plant Recycling (CCPR)

Hot In-place Recycling (HIR)

Other Sustainable Solutions With RAP Summery and Questions

Our Nations Roadways

Federal Roadways = 3% State Roadways = 20% Local Roadways = 77%

Two Thirds are Paved (One Third Unpaved)

94% of Paved Roads have an asphalt surface

FHWA Policy Since 2002 Recycled/Reuse materials are viable resources Recycled materials should get first consideration Consider use of recycled materials early in

planning/design process Restricting the use of materials should be

technically based Material should not adversely impact the

environment and should perform as intended

Recycling Asphalt

Asphalt is the # 1 recycled product in the world yet, only three percent of our roads are recycled in-place.

It is proven that in-place recycling can save up to 50% in costs and reduce construction time.

CIR, CCPR and HIR are recognized pavement preservation techniques and are tried and proven.

Nevada Department of Transportation (NDOT) has saved over 600 million utilizing in-place recycling.

In 2013 Green book and Caltrans up the RAP percent for HMA to 20%. In 2014 the percent of RAP will go up to 25%.

SB-375 and AB-32

Requires Green House Reductions back to the levels of 1990 by the year 2020

The Air Resource Board “cap-and-trade” program includes an enforceable emissions cap. The State will distribute allowances, which are tradable permits, equal to the emissions allowed under the cap. Sources under the cap will need to surrender allowances and offsets equal to their emissions at the end of each compliance period.

The use of low green house gas technology can be used to off set their emissions.

Recycling In-Place Saves Material Resources, Money and Energy

Re-using existing asset’s instead of replacing or discarding

Reduces import-export from 83 truckloads

(mill and fill) to two Fewer emissions, less

traffic,small carbon footprint Structural value and long life:

resists reflective and thermal cracking

Recycling is “Green”

Each lane mile of roadway on which CIR is used instead of traditional Hot Mix Asphalt saves approximately 130,704 lbs of Green House Gas emissions, which is equivalent to taking 11 cars off the road for one year.

Asphalt Recycling Such as Cold In-place Recycling for Climate Reductions

When to Utilize Asphalt Recycling

Anywhere mill and fill is considered

Adequate existing pavement thickness

2 to 4 inches in thickness. Thick enough to take to stable base or

leave 1” of existing pavement over native soils.

Will handle all cracking distress provided not sub-grade or base related

Where surface maintenance is no longer effective

Where safety is a concern When life cycle costs dictate When you need to stretch your

budget

Where to Utilize AsphaltRecycling?

City Streets

Airports

Virtually No Traffic Limitations

Highways

Fatigue Cracking

Thermal Cracking

Dry, Raveled

Patched

Poor Rideability

Type’s of Asphalt to Recycle

Engineered Approach, Mix Design

On all Recycling Projects Prior to bidding the project.

Check existing pavement for adequate thickness Check for stable subgrade Check for fabric and pavement type.

Part of the contract is to core pavement to obtain samples for mix design using a systematic engineered system.

Optimizes the percentage and type of engineered recycling agent unless agency specifies asphalt foam. For asphalt foam the optimum percent asphalt is determined in a mix design

Determine the need for, percentage of and type of recycling additive at the mix design.

Mix Design Process

Defined sampling procedure, cores taken from various locations. Core samples sent to independent AASHTO approved lab.

Lab RAP Analysis

Lab Field cores crushed to

specific gradation bands A design made for 2 of the

gradations

Field Field gradation

depends upon multitude of factors: milling, weather, etc.

Gradation compared to lab tested band

Recycling agent percentage based on applicable gradation

-

10

20

30

40

50

60

70

80

90

100

Sieve Sizes

% P

ass

ing

RAP-medium gradation

RAP - fine gradation

1 in.3/8 in.No. 30

RAP - coarse gradation

Field

Density Compaction EffortSuperpave Gyratory Compactor or Marshal Compactor

Lab

Cold In-place Recycling (CIR)

Distressed Pavement = New Pavement Using A Train of Equipment that:

Mills deteriorated pavement Reclaimed asphalt pavement (RAP)

Crushes RAP to gradation Mixes with recycling agent Re-Paves recycled mix Compacts to specified density Readies for surface treatment Small carbon footprint

Blythe Airport

Cold In-place Recycling (CIR)Preservation or Minor Rehabilitation

6” Stable Base

Native Soil

4” Distressed ACRecycled AC

>1”

Recycle AC to:

• Stable Base

•Within 1” of less Supportive Material

Asphalt Recycling Train

Full Lane Mill

Recycling Unit

Recycling Additive

Crushing and Sizing Equipment, 100% Closed Circuit System.

Crushing and sizing equipment capable of reducing RAP to the 100% passing 1-inch sieve prior to mixing and weighing millings with engineered recycling agent.

Pick Up and Installation

Caltrans State Route 33

Recycled Asphalt Surface

Compaction

25 Ton RTR

12-15 ton steel

Testing and Quality Assurance

City of Palm Desert 100% Recycled Asphalt

Quick Opening to Traffic

Rolling is completed Some cure time, fast return to traffic Fog-seal and sand blotter are applied

Before and After Pictures Recent CIR Projects

Ramona Expressway

State Route 36

New Recycled Surface

Los Angeles County Angeles Forest Highway Winner 2012 Road & Bridges Magazine National Award for CIR

City of Beverly Hills

2010 CIR Project of the year Roads & Bridges Magazine

to Pavement

Cold Central Plant Recycling (CCPR)From RAP

Clean Rap = New Pavement: Stockpiled and kept clean Crushed RAP to gradation Mixed with engineered emulsion or

foamed asphalt In a central plant

Transported to lay down area Paved as a recycled mix Compacted to specified density Readied for surface treatment

“Urban Quarries” Recycle Sustainable Assets on Site!

“Urban Quarries” Recycle Asphalt Assets on Site!

Value Engineered

Project Profile; 500,000 Square Feet “Energy and Cost Savings”

8,744 tons of asphalt removed and repaved. 840 fewer trucks used utilizing CIR,

compared to a mill and fill operation. 1,649 fewer barrels of oil used. 79.6% fewer carbon emissions utilizing CIR

compared to mill and fill operation. Cost savings to the City $262,320.00. Cut 30% off the project schedule.

Nevada Department of Transportation (NDOT)

Cold In-place Recycled (CIR) over 1800 miles of roadways.

Most projects are on state highways. Utilized CIR for over 25 years NDOT has re-recycled over 75 miles of

roadways that got over 22 years of performance

CIR is sustainable pavement development

Specified CIR and CCPR Federal Highway Administration Federal Aviation Administration National Park Service Arizona Dept. of Transportation California Dept. of Transportation Nevada Dept. of Transportation County of Contra Costa County of Los Angeles County of Riverside County of San Diego County of San Bernardino County of San Luis Obispo County of Sonoma City of Agoura Hills City of Anaheim City of Atascadero City of Beverly Hills City of California City City of Chino City of Hanford

City of Highland City of Lancaster City of Modesto City of Lemon Grove City of Moreno Valley City of Palm Desert City of Porterville City of Monterey City of Napa City of Rancho Mirage City of Sacramento City of Santa Ana City of San Diego City of San Jacinto City of South San Francisco City of Shafter City of Susanville County of Tulare City of Vernon

Hot In-Place Recycling – Preservationor Minor Rehabilitation

Distressed Pavement = New Pavement Using A Train of Equipment that: Heats RAP and Existing Binder Scarifies and/or Mills deteriorated pavement Adds Aggregate or Virgin Hot Mix AC Mixes with rejuvenating agent Re-Paves recycled mix Compacts to specified density

Not Used Much In CA

Heater

Scarifier

HIR – Surface Recycling 0.5 to 1”

Surface Recycling — Scarifiers

Hot In-place Recycling (Remix Method)1” to 2”

xx

Heaters / Grinders

Picked Up and Paved

 

            Longer Train and Some Environmental Issues

Check with AQMD

Sustainable Solutions With RAP

Process Reclaimed Asphalt Pavement (RAP) RAP Chips for Chip seals, Cape seals RAP Slurry Type II (stays black longer) RAP Micro Surface (fast cure time, night work) Renew Asphalt (Cold Central Plant Recycling) Cold Mix Dust Control Shoulder Backing Base (Caltrans Route 46) Processed in Place, Met Class II Gradation Requirements.

Caltrans District 8 RAP ProductsCaltrans Interstate 10 near Desert Center

RAP Scrub Seals Caltrans

I-10 Freeway Desert Center RAP Cape Seal

RAP Slurry

RAP Slurry Black Aggregate

RAP Slurry compared to Conventional, City of La Mirada, California. Side by Side – One Year later, RAP is still black!

RAP Slurry Conventional Slurry

Summary - Benefits of Recycling and Reclamation

Shorter Construction Periods with Reduction in User Delays

Improved Pavement and Structural Section Properties

Mitigates Reflective Cracking

20 Plus Years Performance Expectations

Cost Savings Over Traditional Rehabilitation Methods

Sustainable Development “.... Development that meets the needs of the present without compromising the ability of future generations to meet their own needs.”

Reduces the consumption of natural resources Reduce energy consumption Reduces truck traffic Reduce greenhouse gas emissions, pollution

Questions?Contact Information:

James W. Emerson, APM

Pavement Recycling Systems Inc.

(951) 232-6881

JEmerson@pavementrecycling.com