advanced technologies to reclaim roadways
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Advanced Technologies to Reclaim roadways
APWA Annual MeetingTampa, FLApril 5th, 2012
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. Contents:.Eurovia Cold recycling technologies;
.Recyflex’s ®, in‐plant processing:
.Formulation specifications
.Production, laying and compaction operations
.Rheological performances
.VLE roadway concept
.Recyvia ®, in‐place (FDR)
.Recyclovia ®, in‐place (CIR)
.Recycled cold treated materials behavior;
.Environmentals analysis;
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. Recyflex’s specifications:.Strengthening base layer: AEC 25, AEC 20
.Composite binder
.Asphalt emulsion
.Cement or lime
.Dense gradation
.Drainage / Frost protection layer: HD 25
.Composite binder
.High air voids produce by special gradation
..Intermediate layer: AEC 12.5
..Composite binder and dense gradation
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Recyflex AECStrengthening course materials
RECYFLEX AEC : Cold‐in‐plant treated recycled materials by using composite binder
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In‐plant cold retreated material Mineral aggregate using 50 to 100% of recycling material (from existing pavement structure) Asphalt emulsion and cement/ lime treatment Highly improve bearing capacity instead of regular granular material Indirect tensile Resilient Modulus at 10°C > 4 000 MPa Density of 2 100 kg/m³ (air voids of 12‐15%)
Recyflex AEC Base Material
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High drainability material Mineral aggregate using 30 to 50% of recycling material (from existing pavement structure) Low density = Air void insulation, 1 800 kg/m³ Porous material = air voids ± 30% Asphalt emulsion and cement/lime treatment Frost penetration reduction
Recyflex HD
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RECYFLEX AEC 0/20 mm
Production by using portable plant
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RECYFLEX AEC 0/20 mm, Thickness application of 100 @ 300 mm
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RECYFLEX AEC 0/20 mm, Grading/ Compaction operations
Final aspect during the cure period
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Recyflex AEC Protection and Paving
Application of tack coat emulsion
Chipping application
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RECYFLEX AEC, A‐20 Mix Rheological performances
Formulation: 40% of Crushed concrete; 40% of Rap 20% of new aggregates screenings Composite binders: Asphalt emulsion + cement
Physical and Rheologicals Characterization of: Voids and densities; Cohesion built‐up behavior; Rutting resistance; Modulus evolution vs curing time; Effects of Freeze and thaw cycles on the mechanical performances; Tensile stress vs low temperture.
Proportions established from the rehabilitation existing roadway (optimization of the recycled
quantities)
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Laboratory samples preparation by Vibrocompression method Piston : axial force
Vibration Molds
Gammadensitometer
Diameter = 16 cm , High = 32 cmVoids average 16.5%
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Visual Voids analysis with ultraviolets
Crushed ConcreteRAP
Air voids
0
10
20
30
40
50
60
70
80
90
100
0.01 0.10 1.00 10.00 100.00Tamis (mm)
% pas
sant
d-
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Physical Characteristics
Rheologicals Characteristics study 2001 French Gyratory compactor
Voids at 10 gyrations = 21.2% 22% Voids at 200 gyrations = 13.0% 15%
Duriez Resistance before immersion = 6.4 Mpa 4Mpa r/R ratio = 0.68 0.55 Duriez voids = 11.7% 13%
Emulsion treated base material (Grave‐Émulsion)
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Rheological Characteristics
Rutting test analysis Rutting
Only 0.7% after100 000 cycles at 60°C, Exceptional performance
Material without ruttingdue to the internalaggregates friction and the presence of hydraulic binder
Rutting test machine
Rutting resistance spec. on HMA < 10% after 30 000 cycles at 60°C
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Cohesion Built‐up behavior
0
100
200
300
400
500
600
0 30 60 90 120 150 180 210 240
Temps de conservation (minutes)
Forc
e (N
)
Recyflex AEC
Emulsion mix
Time, min.
Forc
e, k
N
Workability of ± 3 hours
Time
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Rheologicals behavior study
Stiffness Modulus analysis
Diametral Sinusoïdal Compression ‐DSC Bresilian test :
Rupture limit establishement = 8800 N DSC strenght at 20% of the rupture limit
DSC testing at 1.00 kN 0.75 kN corresponding of maximale compression of 1750 N
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Modulus evolution with CDS
curve at 15°C
900 Mpaor +11,5%
curve at 10°C
4000
5000
6000
7000
8000
9000
0 7 14 21 28 35 42 49 56 63 70 77 84 91
Time from production (days)
Mod
ulus
at 10
Hz
(MPa
)
Effect of the hydraulic binder
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Freeze and thaw cycles effects
Diametral Sinusoïdal Compression –DSC
Two types of simulation Short term freeze‐thaw : 2 cycles of 24 hours produced between the 4th and
52th hours of curing, each cycle corresponding to a: temperature drop of +5°C to ‐10°C in 12 hours temperature gain of ‐10°C to +5°C in 12 hours
Long term freeze‐thaw : 50 freeze‐thaw cycles after optimun cohesion, each cycle corresponding to a:
Temperature drop of +10°C to ‐20°C in less 3 hours
Temperature gain of ‐20°C to +10°C in less 3 hours
Rheologicals behavior study
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Modulus measurements Diametral Sinusoïdal Compression ‐DSC
Freeze‐thaw at beginning Modulus evolution at 10 Hz
4000
5000
6000
7000
8000
9000
0 10 20 30 40 50 60 70 80 90Temps depuis fabrication (jours)
- 9.4%
- 23.5%
4000
5000
6000
7000
8000
9000
0 10 20 30 40 50 60 70 80 90Temps depuis fabrication (jours)
- 11.5%
- 22.8%
Mo
du
lus
at 1
5°c
, MP
a
Mo
du
lus
at 1
0°c
, MP
a
Air curing
Freeze-thaw
Air curing
Freeze-thaw
Time, hours Time, hours
Effect freeze‐thaw cycles, short term
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Modulus measurements
Diametral Sinusoïdal Compression –DSC
Short term freeze‐thaw during beginning of curing Freeze‐thaw between the 4th and 52th hours of curing Slowing down cement hydratation phenomenon at the beginning with small
effect on long term Delayed internal cohesion Modulus loss of about 23% at 10 days Long term modulus loss of about 10% (> 90 days) Validated value after 365days
Effect freeze‐thaw cycles, short term
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Modulus measurements
Diametral Sinusoïdal Compression –DSC
Long term freeze‐thaw cycles Freeze‐thaw (50 cycles) between 24d et 36d Modulus loss of 20% immediatly after the thermal sollicitations Modulus recovery « normal » at long term
Effect freeze‐thaw cycles, long term
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Effect of 50 freeze‐thaw cycles, long term
curve at 15°C without freeze-
thaw
50 freeze-thaw cycles
4000
5000
6000
7000
8000
9000
10 100 1000
Time from production (days)
Mod
ulus
at 10
Hz
(MPa
)
24 days
37days
- 20%
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Thermal stress, Contraints development
HM A with 70 /100 bitumen
RECYFLEX EBC
0.01.02.03.04.05.0
-35 -30 -25 -20 -15 -10 -5 0 5Température (°C)
Con
trai
nte
(M
pa)
df
Rheologicals behavior study
Temperature, °C
Ten
sile
str
ain
, MP
a
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Recyflex AEC Observations
Process for optimun use of recyclable materials; Cold treatment using composite binder Strenghtened materials Low emissions production Accelarated curing time No rutting Avoid maniability over 3 hours
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Behavior between flexible and rigid pavements DSC Modulus
E (15°C,10Hz) = 7600 Mpa Optimum around 30d‐60d Definitive loss of 10% in case of freeze‐thaw in the firsts hours of cure
Temporary loss of 20% after freeze‐thaw if Recyflex AEC have obtained the optimal cure
Low contrains development with thermal reduction
Fatigue analysis to complete
Recyflex AEC Observations
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60 ESG-10 60 ESG-10 25 RUGOVIA TM
70 ESG-14 70 ESG-1460 ESG-14100 HMA Binder
180 HMA-20160 HMA-20
200 RECYFLEX AEC
050
100150
200250300
350400450
500
Chaussée EcorouteRecyflex AEC
Alternative
Flexibles pavement structures comparaison, A20 Highway
80 M esal : 2X 2 lanes (3450 Truks/day/direction/TL over 20 years)
Supposed Recyflex AEC Resilient Modulus = 3 000 MPa
Residual pavement structure Residual pavement structure
Residual pavement structure
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Highway , Alternate pavement design
Hwy 485 Asphalt Pavement Design
Thickness (in.) MaterialAASHTO Structual Coefficient Value Structual total
3 S9.5D 0.44 1.324 I19.0D 0.44 1.76
11.5 B25.0C 0.3 3.450
7Subgrade
Stabilization 0.14 0.987.51
Alternate 1
Total Structual Value
Thickness (in.) MaterialAASHTO Structual Coefficient Value Structual total
3 S9.5D 0.44 1.326 I19.0D 0.44 2.640 B25.0C 0.3 08 Recyflex 0.34 2.72
7Subgrade
Stabilization 0.14 0.987.66
Alternate 4
Total Structual Value
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Highway , Alternate pavement design
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Recyflex AEC,
Main Runway Montreal airport‐ 1998
Arrival from Paris
Arrival from Orlando
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31
Recyflex AEC
Development of a new Roadway pavement structure concept by using recycled materials
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Recyvia, in‐Place (FDR)
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In‐Place full depth reclamation
Cold In place Recycling using composite binder or bitumen emulsion /foamed bitumen
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Example of using composite binder in‐Place
Réalisation du projetRéalisation du projet
stabilisation
Stabilisation 175mm (16/08 au 28/08)±56800m²
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RECYCLOVIA® Field of application
CIR In‐Place Cold recycling 6 à >15 cm.
Granular Base or Treated base
1 à 5 cm.
Granular base
1 à 5 cm.
Granular base
RECYCLOVIA ®
In‐Place treatment : 6 à 15 cm Asphalt Emulsion with Cement
RECYCLOVIA ®
In‐Place treatment :8 à 15 cm Asphalt Emulsion / Foam asphaltwith Cement or hydrated lime
RECYCLOVIA ®
In‐Place treatment: 8 à 15 cm Asphalt Emulsion / Foam asphaltWith cement or hydrated lime
Supply of aggregate forgradation correction
+ HMA / WMA wearing courseMicrosurfacing / Chip seal / Dense Cold mix (low trafic road)
Existing Asphalt pavement
Chip Seal Chip Seal
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Recyclovia, in‐Place (CIR)
Weight empty: 47 t
Power : 800 hp 600 kW
Lenght : 15 m
Paver screed, extendable equiped with tamper bar compactor
Rotor for milling/recycling/mixing, with possible injection of:
‐ Foam asphalt‐ Asphalt emulsion‐Water
Cement spreader unit
Cement bin (4 t)
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Recyclovia
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Recyclovia, in‐Place (CIR)
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‐Recycled cold treated materials behavior
‐Same mix design methodology for In‐plant, FDR and CIR;
‐Mechanical performances, Stability and Modulus;‐Air Voids;‐Retained Stability;
‐Observations behavior:
‐Effect of RAP content
RequirementsMin.
Mix 138% CC16% RAP45% Aggregates
Mix 240% CC40% RAP20% Aggregates
Mix 3100% RAP
% Recovering Asphalt% Added Bitumen
0,63%1,53%
2,10%1,85%
5,38%1,0%
Marchall Stability at 22.2°C (N)
7 000 @ 10 000 26 200 18 583 8 575
Retained Stability (%) 70 84 90 93
% Coating 50 82 88 95
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‐Recycled cold treated materials behavior
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Complete environmental impact analysis
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Janvier 2011 - page 43
Thanks for your attention