Hot In-Plant Recycling

Module 3-9 Objectives
Types of hot central plant recycling

Types of equipment and operational
sequences
Hot Central Plant
Structural layer coefficients
Recycling
Economics
Specifications
Quality control
Introduction Recycling Methods and Equipment
RAP use Construction sequence

• Tens of millions of tons used
• Pavement removal
• Everyday occurrence
• Crushing and stockpiling
• 45 million tons generated / year
• 1/3 of all HMA removed is recycled into HMA • Mixing in central plant
• Severe limitations in some areas • Laydown and compactions
Generating RAP Milled RAP
Little additional processing required
Uniform properties in layer

• Gradation
• Asphalt content
• Asphalt properties
Usually stored in separate stockpile
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Module 3-9
RAP from Full-Depth Removal RAP Sizing
Pavement broken into slabs

Material must be processed
Often stored for later processing
Material from different sources
Blending / crushing mixed RAP can produce
consistent material
Stockpiling Stockpiling RAP
Large, conical stockpiles preferred
RAP does not re-compact
Forms “crust” (200-250 mm) 8-10 inches
Crust sheds water and easily broken
RAP under crust easy to manage
How to Recycle RAP in Plant Facility
Equipment Plant type

• Batch
Methods • Drum
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Module 3-9
Adding RAP into Weigh Bucket Adding RAP at Pugmill
RAP Dryer RAP Feed to Parallel Flow Drum Mixer
RAP Feed to Drum Drier RAP Added to Continuous Mixer
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RAP Feed to Counter Flow Drum Mixer Laydown and Compaction
Design Methods AASHTO Structural Coefficients
AASHTO
Layer Range Average Typical
The Asphalt Institute
National Crushed Stone Association Surface 0.37- 0.59 0.48 0.44
State DOTs Base 0.37- 0.49 0.42 0.35
RAP Performance Quality Control
FHWA survey of 17 states Similar tests as for virgin asphalt cement

RAP mixes comparable to virgin mixes
Additional tests required
• Proper design
• Process control More frequent testing
Louisiana study
Greater variation in test results
• No significant differences in RAP mix
and control
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Quality Control Tests Summary
Composition and properties of RAP Improved processing equipment

enhances use
Tests on RAP / RAM / aggregate stockpiles
Emission considerations addressed
Tests during construction
Processing and handling techniques
• Gradations of aggregate / RAM established
• Extraction / recovery tests on RAP and Use of RAP is cost-effective
recycled mix
• Density of compacted mix Quality control
Recycled Mixture Design Typical Pavement Core
Project considerations
• Uniformity
• Depth of HMA
• Presence of chip seals
• Asphalt content (bleeding)
• Aggregate gradation
• Asphalt properties
• Traffic
• Types of pavement distress
Looking at the Asphalt Films
Air voids
Modifier
Aged AC
Aggregate
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Module 3-9
Air voids Air voids
Completely
rejuvenated
Rejuvenated AC
Extent of modifier
diffusion Aged AC,
Aged AC, no modifier Extent of modifier
no modifier diffusion
Mixture Design Procedure

Mixture Design
3 Determine
4 Determine need for
Obtain Aggregate “New” aggregate &
representative perform tests as
Evaluated salvaged material 1
Properties
required
field samples
• Asphalt properties of mixtures
to be recycled Gradation
• Aggregate properties ASTM Gradation
C - 136 ASTM
Need for additional aggregate C - 136
Selection of recycling agent Extract and
Abrasion 5
ASTM Abrasion
• Type recover the C - 131 ASTM
asphalt &
• Amount 2 aggregate
C - 131
Preparation and testing of mixtures ASTM D2172 Polish value

& D1856 ASTM D3319 Polish value
Select optimum for design ASTM D3319
9 10
6 Obtain example Blend modifier
11
7 of modifier and with recovered
Determine Determine type and perform tasks asphalt and test
Asphalt amount of modifier
Properties assuming 100%
5 recycled aggregate Viscosity, 140 0
Figure G2 & G3 and 275 0 F Viscosity, 140 0 F
Determine Percent asphalt ASTM D2170, 2171 ASTM 2171
asphalt ASTM D2172
demand
for recycled 8 Penetration Penetration, 77 0 F
aggregate & ASTM D6 ASTM D5
“new” aggregate Viscosity 140 F Compare asphalt
ASTM D2172 demand in step 5
and step 6. Select
a suitable modifier Flash point Thin film oven
from tables G1 & ASTM D92 test ASTM D1754
Penetration 77 F G2 or D2872
ASTM D6
Thin film oven
9 test ASTM D1754
or D2872
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12 13
11 Other Tests
Select 3 most
Mix and fabricate promising mixtures Select
3 samples at 5 and perform this optimum
select modifier appropriate portion mixture
contents and test of test program in design
figure G4 Resilient modulus
HVEEM or Marshall Creep (permanent deformation)
stability ASTM Stability test
D1560 and D1559
Indirect tensile strength
Water sensitivity
Air void content
ASTM D2041 Water susceptibility
& D2726 Air void content
Resilient modulus
Summary
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Module 3-9

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Module 3-9 Objectives

Types of hot central plant recycling

Introduction Recycling Methods and Equipment

RAP use Construction sequence

Generating RAP Milled RAP

Little additional processing required

Uniform properties in layer

Usually stored in separate stockpile

Pavement broken into slabs

Stockpiling Stockpiling RAP

Large, conical stockpiles preferred

RAP does not re-compact

Forms “crust” (200-250 mm) 8-10 inches

Crust sheds water and easily broken

RAP under crust easy to manage

How to Recycle RAP in Plant Facility

Equipment Plant type

RAP Dryer RAP Feed to Parallel Flow Drum Mixer

RAP Feed to Drum Drier RAP Added to Continuous Mixer

Design Methods AASHTO Structural Coefficients

National Crushed Stone Association Surface 0.37- 0.59 0.48 0.44

State DOTs Base 0.37- 0.49 0.42 0.35

RAP Performance Quality Control

FHWA survey of 17 states Similar tests as for virgin asphalt cement

Composition and properties of RAP Improved processing equipment

Recycled Mixture Design Typical Pavement Core

Looking at the Asphalt Films

Mixture Design Procedure

Preparation and testing of mixtures ASTM D2172 Polish value

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