In Place Asphalt Recycling

THE TECHNICAL ASSISTANCE OF DINAH EMERY OF SHILOH CANCONSTRUCT LIMITED WITH THIS PRESENTATION IS GRATEFULLY ACKNOWLEDGED

FEBRUARY 2014

PARTNERS IN QUALITY [email protected]

MARTEC HIROTTAWAJEGEL FDRCOLOMBIASEELEY CIRONTARIO

CIR – FDR – HIR

MISSISSAUGA

PRACTICAL EXPERIENCE WITH PARTIAL AND FULL DEPTH IN-PLACE REHABILITATION TECHNIQUES

SCOTT McKAY

JOHN EMERY PRESIDENT AND PRINCIPAL ENGINEER SHILOH CANCONSTRUCT LIMITEDADJUNCT PROFESSOR McMASTER UNIVERSITY

UNIVERSITY OF WATERLOO

ARRA BASIC ASPHALT RECYCLING MANUAL IS A KEY REFERENCE

(COPIES AVAILABLE FROM ONTARIO ARRA COMPANY MEMBERS)

• MILLING• HOT-MIX ASPHALT PLANT RECYCLING• HOT IN-PLACE RECYCLING (HIR)• COLD IN-PLACE RECYCLING (CIR)• COLD PLANT RECYCLING (CCPR)• FULL DEPTH RECLAMATION (FDR)

OVERVIEW OF ASPHALT PAVEMENT RECYCLING

ONTARIO PROVINCIAL STANDARDS FOR CIR – FDR – HIROPSS 330

OPSS 331

OPSS 332

OPSS 333

OPSS 335

OPSS 501

CONSTRUCTION SPECIFICATION FOR IN-PLACE FULL DEPTH RECLAMATION OF BITUMINOUS PAVEMENT AND UNDERLYING GRANULAR (NOV2011) NOTE: LIMIT OF 50% RAP.

CONSTRUCTION SPECIFICATION FOR FULL DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION (NOV2011) NOTES: CORRECT TERM IS FOAMED, AND DOES NOT REFLECT SOME IMPORTANT CURRENT TECHNOLOGY (ASPHALT ACADEMY, WIRTGEN, AND CALTRANS, FOR INSTANCE).

CONSTRUCTION SPECIFICATION FOR HOT IN-PLACE RECYCLING AND HOT IN-PLACE RECYCLING WITH INTEGRAL OVERLAY (APR2004).

CONSTRUCTION SPECIFICATION FOR COLD IN-PLACE RECYCLED MIX (NOV2011) NOTE: SHOULD BE REVIEWED FOR CURRENT TECHNOLOGY (ASPHALT ACADEMY, WIRTGEN, AND McASPHALT, FOR INSTANCE).

CONSTRUCTION SPECIFICATION FOR COLD IN-PLACE RECYCLED EXPANDED ASPHALT MIX (NOV2011) NOTE: CORRECT TERM IS FOAMED AND DOES NOT REFLECT SOME IMPORTANT CURRENT TECHNOLOGY (ASPHALT ACADEMY, WIRTGEN, AND CALTRANS).

CONSTRUCTION SPECIFICATION FOR COMPACTION (NOV2010) NOTE: BASED ON STANDARD PROCTOR WHILE MOST AGENCIES BASED ON MODIFIED PROCTOR (SIGNIFICANTLY HIGHER COMPACTION REQUIRED).

MILLING OF OLD ASPHALT PAVEMENT PRIOR TO OVERLAYTHE RAP IS USED IN RECYCLED HMA (RHM)

MILLING

CITY OF TORONTO ELLESMERE ROAD PRECISION MILLING TO REMOVE RUTTING

PRECISION MILLING

HOT-MIX ASPHALT PLANT RECYCLINGCOMBINED DRUM-BATCH PLANT

HMA PLANT RECYCLING (RHM)

HOT IN-PLACE RECYCLING (HIR)

REMIX (FULL RECYCLING) – HEATING TO A DEPTH OF UP TO 75 mm, HOT MILLING, REJUVENATION/ NEW AGGREGATE/ NEW MIX (OPTIONAL –

DESIGNED), MIXING, REPROFILING/PLACING WITH PAVER, AND COMPACTIONMARTEC AR2000, INTERSTATE 85, NORTH CAROLINA, OFC, 2001

COLD IN-PLACE RECYCLING

CIR (EMULSION)

CIR (FOAMED)WIDE RANGE OF CIR EQUIPMENT

AND PROCESSES AVAILABLE

ROTO-MILL

PAVER LAID CIR WITH FOAMED ASPHALT

Paver Laid Expanded TrainPaver Laid Expanded Train

CCPR (EMULSION OR FOAMED)ALSO HAVE COLD CENTRAL PLANT RECYCLING (CCPR) SEE ARRA MANUAL

CCPR (EMULSION) OF NORTHERN AIRPORT APRON AND RUNWAY, MOOSONEEMSO

FOAMED (EXPANDED) ASPHALT FULL DEPTH RECLAMATION

FDR (FOAMED)

COUNTY OF OXFORD, ONTARIO RUBBLIZATION PROJECTOLD ASPHALT CONCRETE REMOVED PRIOR TO RUBBLIZATION OF CONCRETE BASE

CIR FDRANDRUBBLIZATION/CIR (EMULSION)

MILLER

COUNTY OF OXFORD, ONTARIO RUBBLIZATION PROJECTPLACING COLD ON SITE RECYCLED (EMULSION) RAP BASE COURSE

CIR FDRANDRUBBLIZATION/CIR (EMULSION)

CRUSHING OLD CONCRETE PAVEMENT FOR USE AS GRANULAR MATERIAL

CIR FDRANDRECYCLING OLD CONCRETE

JEGEL

FLEXIBLE PAVEMENT LIFE*INPUT INFORMATION

PERFORMANCE CRITERIAPAVEMENT MODELS

PAVEMENT SERVICEABILITY

PAVEMENT DESIGNNEW, OVERLAY, REHABILITATION

CONSTRUCT PAVEMENTOR

OVERLAY PAVEMENTOR

REHABILITATE PAVEMENT

PAVEMENT MATERIALS

SYSTEMATIC PAVEMENT MAINTENANCE MAINTENANCE MANAGEMENT SYSTEM

PAVEMENT MANAGEMENT SYSTEMPERFORMANCE MONITORING

SAFE, SMOOTH, SURFACESHAPPY CUSTOMERS

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SUPERPAVE PLUS CIR PROJECT, FRONTENAC COUNTY, 1996RECONSTRUCTION OF 19 MILES (30 kms) OF HIGHWAY 2 NEAR KINGSTON, ONTARIO

• CIR REFLECTIVE CRACKING MITIGATION• SUPERPAVE TECHNOLOGY OVERLAY

- THERMAL CRACKING RESISTANCE- RUTTING RESISTANCE- FATIGUE CRACKING RESISTANCE

USE OF CIR IN PAVEMENT REHABILITATION‘SUPERPAVE PLUS’

CIR WITH SUPERPAVE HMA OVERLAY

MITIGATION OF REFLECTIVE CRACKINGCIR PLUS HMA OVERLAY

MILLER1996

FEBRUARY 2014MISSISSAUGA CIR (EMULSION), FDR AND HIR

FEBRUARY 2014MISSISSAUGA

LIME - FOAMED ASPHALT BASE STABILIZATION USE OF FDR IN NEW PAVEMENT CONSTRUCTION

BOGOTÁ TRANSMILENIO LAS AMÉRICAS PROJECT

JEGEL2002

CIR, FDR (FOAMED) AND HIR

FEBRUARY 2014MISSISSAUGAMETAPETROLEUM, COLOMBIA, JANUARY 2010






FCIR, FDR AND HIR

ONTARIO HIGHWAY 401 1999 DEMONSTRATION PROJECT3.5 LANE-MILES (5.6 KM) HIR SECTION AS PART OF FIVE REHABILITATION STRATEGIES

COMPARISONHIR SECTION IS CURRENTLY PERFORMING THE BEST OF THE REHABILITATION STRATEGIES

USE OF HIR IN ASPHALT PAVEMENT MAJOR MAINTENANCE

HIR WORK AT NIGHT COMPLETED HIR SECTION HIR SECTION IN FEBRUARY, 2005 JEGELMARTECMARTEC


FCIR, FDR AND HIR

ONTARIO MUNICIPAL CIR PROJECT, 1991

MILLER

CIR FDRANDCOLD IN-PLACE RECYCLING CIR (EMULSION)

CIR, FDR AND HIR FEBRUARY 2014MISSISSAUGA

• OLD ASPHALT PAVEMENT MILLED AND SIZED– MILLED TO AT LEAST 90 PERCENT OF DEPTH TO ENSURE REFLECTIVE CRACKING MITIGATION– 75 TO 125 mm DEPTH TYPICALLY– MINUS 37 mm TYPICALLY

• ABOUT 1.5 PERCENT EMULSION ADDED• COMPACTION WITH HIGH COMPACTIVE EFFORT ROLLERS• CURING AND TRAFFIC COMPACTION (~ 2 WEEKS)• PLACEMENT OF WEARING SURFACE

CIR PROCESSTYPICAL 1993 ONTARIO HIGHWAY CIR WITH EMULSION PROJECT

SEELEY

PAVEMENT MILLED/SIZED AND ABOUT 1.5 PERCENT HF EMULSION ADDED

PROCESSED RECYCLED MATERIAL PLACED WITH PAVER

COMPACTION COMPLETED WITH LARGE RUBBER TIRED ROLLER


CIR FEATURESWIDE RANGE OF CIR EQUIPMENT AND PROCESSES AVAILABLE

ROTO-MILLMILLER MILLER

1996 CIR WITH EMULSION AND FIRST ONTARIO SUPERPAVE HMA OVERLAY

1999 CIR WITH EMUSION EQUIPMENT CAN ADD CEMENT OR LIME SLURRY

2004 PAVER LAID CIR WITH FOAMED ASPHALT

• PAVEMENT EVALUATION AND STRUCTURAL DESIGN METHODS DEVELOPED• CIR IS A 4 COMPONENT SYSTEM COMPARED TO HMA 3 COMPONENT SYSTEM • COLD MARSHALL MIX DESIGN METHOD USED IN ONTARIO – SGC METHOD

DEVELOPED• USED FOR A WIDE RANGE OF ESALs• MODIFICATIONS FOR IMPROVED ECONOMICS AND/OR SPECIAL CONDITIONS• CONSTRUCTION AND MATERIALS SPECIFICATION DEVELOPED• STRUCTURAL COEFFICIENTS (GBE OR a1) DEVELOPED• LIFE-CYCLE COST EFFECTIVENESS SHOWN• MITIGATION OF REFLECTIVE CRACKING

Paver Laid Expanded TrainPaver Laid Expanded Train


CITY OF TORONTO ROYAL YORK ROAD CIR PROJECT, 1997~20,000 AADT, BUS ROUTE, WIDENING

MSO – NOW SEELEY AND ARNILL

URBAN CIR (EMULSION) USE

DECEMBER 2008PEEL REGION CIR (EMULSION), FDR AND HIR FEBRUARY 2014MISSISSAUGA

APPROPRIATE USE OF CIR REQUIRES AN OVERALL DESIGN PROCEDURE

CIR OVERALL DESIGN PROCEDURE

• EVALUATE PAVEMENT SECTION FOR SUITABILITY• CHECK PAVEMENT STRUCTURAL DESIGN INCORPORATING CIR (NOTE THE IMPORTANCE OF DRAINAGE)• DETERMINE PROPERTIES OF REPRESENTATIVE RECLAIMED ASPHALT PAVEMENT (RAP)• PREPARE BRIQUETTES USING ‘COLD MARSHALL’ METHOD• TEST BRIQUETTES FOR AIR VOIDS, STABILITY AND FLOW• CHECK RETAINED STABILITY IF STRIPPING OF CONCERN• SELECT OPTIMUM EMULSION CONTENT FOR AIR VOIDS, STABILITY AND COATING (APPEARANCE)• COMPLETE QUALITY CONTROL AND QUALITY ASSURANCE (ACCEPTANCE) TESTING DURING CIR PROJECT


IS THIS A SUITABLE SECTION FOR CIR? • DRAINAGE?• STRUCTURAL ADEQUACY?

PAVEMENT EVALUATION

• VISUAL CONDITION SURVEY• CORING/BOREHOLE INVESTIGATION TO DETERMINE THE THICKNESS

OF THE HOT-MIX ASPHALT LAYER(S) AND GRANULAR BASE/SUBBASE AND TO OBTAIN SAMPLES FOR LABORATORY TESTING

• FALLING WEIGHT DEFLECTOMETER (FWD) LOAD/DEFLECTION TESTING TO DETERMINE THE STRUCTURAL CAPACITY OF THE PAVEMENT

• LABORATORY TESTING OF MATERIALS OBTAINED ON SITE• MECHANISTIC-EMPIRICAL PAVEMENT STRUCTURE ANALYSIS

(DESIGN)


FWD

FWD LOADING PLATE, LOAD CELL, AND DEFLECTION SENSORSTHE FWD OPERATION IS FULLY AUTOMATED


CIR RAP PROPERTIES

• OBTAIN REPRESENTATIVE SAMPLE OF EACH SECTION– SMALL MILLING MACHINE OR CORING (CORES PREFERRED)– MUST BE REPRESENTATIVE OF MILLINGS PRODUCED DURING RECYCLING OF SECTION

• DETERMINE– MOISTURE CONTENT– ASPHALT CEMENT CONTENT– GRADATION (FOR EMULSION, USE WASHED GRADATION OF EXTRACTED MATERIAL, AND FOR FOAMED, USE DRY GRADATION OF CRUSHED RAP)

– PENETRATION AND VISCOSITY (ABSON RECOVERY)?- WANT TO STOP USING SOLVENTS- IGNITION OVEN - ASPHALT CEMENT CONTENTS/GRADATION- RESILIENT PROPERTIES


ASPHALT PAVEMENT SAMPLES

ASPHALT PAVEMENT SAMPLES MUST BE REPRESENTATIVE OF THE SECTION


IGNITION OVEN FOR DETERMINING ASPHALT CEMENT CONTENT IGNITION OVEN IS CALIBRATED FOR SPECIFIC HOT-MIX ASPHALT

USE OF IGNITION OVEN IS PREFERRED TO ROTAREX(ROTAREX REQUIRES ‘TRI’ USE – SIGNIFICANT HEALTH AND ENVIRONMENTAL CONCERNS)

IGNITION OVEN RAP ASPHALT CEMENT CONTENT


CIR (EMULSION) MIX FOUR-PHASE SYSTEM

• HOT-MIX ASPHALT IS A THREE-PHASE SYSTEM– SOLID AGGREGATE, LIQUID (INITIALLY)/VISCOPLASTIC

ASPHALT CEMENT, GASEOUS AIR

• CIR (EMULSION) MIX IS A FOUR-PHASE SYSTEM– SOLID AGGREGATE (‘BLACK ROCK’ PLUS ADDED AGGREGATE, IF ANY)– LIQUID (INITIALLY)/VISCOPLASTIC ASPHALT CEMENT (EMULSION RESIDUAL ASPHALT CEMENT PLUS SOME ‘ACTIVATED’ OLD ASPHALT CEMENT)– GASEOUS AIR– LIQUID WATER

DECEMBER 2008PEEL REGION CIR (EMULSION), FDR AND HIR FEBRUARY 2014MISSISSAUGACIR MIX EMULSION ‘BEHAVIOUR’

• EMULSION DURING MIXING LARGELY HAS THE PROPERTIES OF WATER (LIQUID)• HIGH FLOAT EMULSIONS CONTAIN SOME SOLVENT (HFR CONTAINS REJUVENATOR)• BREAKING OF EMULSION (CHEMICAL) RESULTS IN COHESION

– SEPARATION OF ASPHALT CEMENT CONSTITUENT RESULTS IN LARGE INCREASE IN MIX CONSISTENCY

• SETTING OF EMULSION– WATER ‘EXPELLED’ (HEAVY ROLLER COMPACTION AND TRAFFIC DENSIFICATION)– DRYING– ADHESIVE STRENGTH (STIFFNESS) INCREASES WITH TIME

OPTIMIZING CIR EMULSION MIX PROPERTIES

PERCENT WATER MIXING TIMEPERCENT TOTAL FLUIDS

PERCEN

T COMP

ACTION

PERC

ENT CO

ATING

PERCEN

T COAT

ING


CIR PROCESS MODIFICATIONS

• ADDITION OF NEW COARSE AGGREGATE– CLOSER VOIDS AND STABILITY CONTROL

• USE OF DIFFERENT EMULSIONS (HFR FOR INSTANCE)

– MORE OLD ASPHALT CEMENT EFFECTIVE

• PROCESS MODIFICATIONS– ADDITION OF CEMENT OR LIME FOR INSTANCE

FLUSHING AND RUTTING, WATERLOO COUNTY ROAD 1, 1993


ADDITION OF 12 PERCENT COARSE AGGREGATE

ADDITION OF COARSE AGGREGATE IMPROVES GRADATION


CIR WITH 1.1 PERCENT HF 150


WATERLOO COUNTY ROAD 1 CONDITION IN 1997


WATERLOO COUNTY ROAD 1 CONDITION IN JANUARY 2002


CIR (EMULSION) MIX DESIGN

• ESSENTIALLY A COLD (60oC) MARSHALL MIX DESIGN METHOD

• PREPARE BRIQUETTES WITH EMULSION– 0.5, 1.0, 1.5, 2.0, AND 2.5 PERCENT– TOTAL ‘FLUIDS’ (WATER AND EMULSION) CONTENT OF 4.5 PERCENT

• TEST BRIQUETTES– AIR VOIDS, STABILITY AND FLOW

• SELECT OPTIMUM EMULSION CONTENT– AIR VOIDS, STABILITY AND COATING

• CHECK FOR POTENTIAL MOISTURE SUSCEPTIBILITY– TENSILE STRENGTH MOISTURE SUSCEPTIBILITY TESTING IF

NECESSARY

JEGEL NEW LABORATORY


MIX RAP WITH WATER, EMULSION AND ANY CORRECTIVE AGGREGATE AT 60oCMIXED AT TOTAL FLUID CONTENT OF 4.5 PERCENT (FIELD TYPICALLY LESS)

ALLOWED TO CURE FOR ONE HOUR AT 60oC


COMPACT 50 BLOWS PER FACE FOR EACH BRIQUETTE


PERFORM INITIAL CURING OF THE SPECIMENS20± 4 HOURS AT 60oC IN MOLD


FURTHER RECOMPACT SPECIMENS AN ADDITIONAL 25 BLOWS PER FACE


FINAL CURING OF THE SPECIMENS24 HOURS AT 60oC IN MOLD, REMOVE FROM MOLD, AND THEN FURTHER 72 HOURS AT

ROOM TEMPERATURE


• DETERMINE MAXIMUM THEORETICAL DENSITY FOR MIX– BREAK UP ONE BRIQUETTE FOR MIX

• DETERMINE BULK RELATIVE DENSITY– REMAINING FOUR BRIQUETTES

• COMPUTE AIR VOIDS

• DETERMINE MARSHALL STABILITY AND FLOW– TWO BRIQUETTES AT 25oC (~ROOM TEMPERATURE)– TWO BRIQUETTES AT 60oC

TEST BRIQUETTES FOR EACH EMULSION ADDITION LEVEL


DETERMINE THE MAXIMUM THEORETICAL RELATIVE DENSITY OF THE MIX


DETERMINE THE BULK RELATIVE DENSITY OF THE BRIQUETTES


DETERMINE THE MARSHALL STABILITY AT ~25oC, AND THE MARSHALL STABILITY AND FLOW AT 60oC OF THE BRIQUETTES

(CHECK FOR POTENTIAL MOISTURE SUSCEPTIBILITY – TSR – IF NECESSARY)




• PLOT DENSITY, AIR VOIDS AND STABILITY (22oC AND 60oC) AGAINST PERCENT ADDED EMULSION

• OPTIMUM EMULSION CONTENT– MINIMUM STABILITY AT 25oC – 8900 N– MINIMUM STABILITY AT 60oC – 4500 N– AIR VOIDS – 8 TO 12 PERCENT RANGE– ADEQUATE COATING

CIR MIX DESIGNREPORT AND SELECTION OF OPTIMUM EMULSION CONTENT


CIR MIX DESIGN PLOTS

COLD MARSHALL PLOTS SIMILAR TO HMA MARSHALL PLOTS


CIR RECOMMENDED PROPORTIONS

NOTE - THE RECOMMENDED CIR PROPORTIONS ARE SUBJECT TO FIELD ADJUSTMENT(S) BASED ON CONTRACTOR QUALITY CONTROL


SHRP GYRATORY COMPACTOR

SHRP GYRATORY COMPACTOR BASED METHOD HAS BEEN DEVELOPED RMRC RESEARCH ON CIR FOR INSTANCE NDESIGN FOR CIR

JEGEL LABORATORY

CIR, FDR AND HIR


CONSTRUCTION OF COLD IN-PLACE RECYCLED ASPHALT

CIR (EMULSION) PROCESS WITH QCCIR (EMULSION), FDR AND

HIR


SURFACE TREATMENT USED WITH LOW AADT (ESALs)

PLACING SURFACE TREATMENTCIR (EMULSION), FDR AND HIR


HMA OVERLAY THICKNESS BASED ON PAVEMENT STRUCTURE CONSIDERATIONS (SUBGRADE, AND ESALs MAINLY)

PLACING HMA OVERLAYCIR (EMULSION), FDR AND HIR


CIR (EMULSION) STRUCTURAL EQUIVALENCY FACTOR

MTO HIGHWAY 3 CIR COMPLETED IN 19921.4 PERCENT HF 150P, CONDITION IN 1997

CIR (EMULSION), FDR AND HIR


1 2 3 4 5 6

2.2

2.0 1.8 1.6 1.4 1.2 1.0

GRAN

ULAR B

ASE

EQUIVA

LENCY

AGE OF COLD IN-PLACE RECYCLINGGRANULAR BASE EQUIVALENCY (GBE)NATTYPICAL CIR STABILIZED BASE CORES

HMA

QUALITY GRANULAR BASE

• NEW PROJECTS• HOT-MIX ASPHALT INCLUDING HIR 2.0• GRANULAR BASE (CRUSHED, CBR 60) 1.0• GRANULAR SUBBASE (CBR < 60) 0.67• RESURFACING PROJECTS

• OLD HOT-MIX ASPHALT 1.25• OLD GRANULAR BASE 0.75• OLD GRANULAR SUBBASE 0.50• CIR AND FDR 1.80

• RECONSTRUCTION PROJECTS• OLD HOT-MIX ASPHALT 1.0• OLD GRANULAR BASE 0.6• OLD GRANULAR SUBBASE 0.4

GBE BASED ON ONTARIO EXPERIENCE

CIR WITH EMULSION GRANUAR BASE EQUIVALENCY FACTORS (GBE)


CIR (EMULSION) AND SHRP

FRONTENAC COUNTY 1996 SUPERPAVE PLUS - CIR + SHRP



SUPERPAVE PLUS CIR PROJECT, FRONTENAC COUNTY, 1996RECONSTRUCTION OF 30 kms OF HIGHWAY 2 NEAR KINGSTON, ONTARIO

• CIR (EMULSION) REFLECTIVE CRACKING MITIGATION• SUPERPAVE TECHNOLOGY OVERLAY

- THERMAL CRACKING RESISTANCE- RUTTING RESISTANCE- FATIGUE CRACKING RESISTANCE

‘SUPERPAVE PLUS’

MITIGATION OF REFLECTIVE CRACKINGCIR PLUS HMA OVERLAY

MILLER


TEXTURE OF SUPERPAVE SURFACE COURSE (~MODIFIED HL1)

SUPERPAVE SURFACE COURSE HMA



CIR MITIGATION OF REFLECTIVE CRACKINGPERFORMANCE OF 1996 CIR WITH EMULSION AND SUPERPAVE OVERLAY

CONDITION OF SUPERPAVE HMA IN 2004 NO CRACKING

CONDITION OF ADJACENT 1997 MILL/HMA OVERLAYWITHOUT CIR – SIGNIFICANT CRACKING

JEGEL JEGEL


CIR (EMULSION) SPECIFICATIONS• CONTRACTOR RESPONSIBLE FOR MIX DESIGN, CIR PROCESS AND QUALITY CONTROL (QC)• RECOMMEND RECYCLING PROCESS, EMULSION AND MODIFICATION(S) BE SEPARATE PAY ITEMS• ENCOURAGE ALTERNATIVES TO FOSTER INNOVATION• PERFORMANCE REQUIREMENTS• AGENCY QUALITY ASSURANCE (QA) AND ACCEPTANCE

– INCLUDING USE OF CONTRACTOR QC TO REDUCE QA• OPSS 333 CONSTRUCTION SPECIFICATION FOR COLD IN-PLACE

RECYCLING– USE WITH CARE AS MAINLY FOR MTO PROJECTS AND SHOULD BE

REVIEWED FOR CURRENT TECHNODLOGY (ASPHALT ACADEMY, WIRTGEN, AND McASPHALT, FOR INSTANCE)


CIR PERFORMANCE REQUIREMENTS AND ACCEPTANCE

• PERFORMANCE REQUIREMENTS– REFLECTIVE CRACKING MITIGATED– PAVEMENT STRUCTURE STRENGTHENED– PAVEMENT SHAPE IMPROVED (CAN BE WIDENED)

• ACCEPTANCE– TYPICAL CONTRACTOR PRODUCING UNDER TYPICAL CONDITIONS

• PERFORMANCE PARAMETERS (ACCEPTANCE)– STRENGTH– DURABILITY– SMOOTHNESS

CIR, FDR AND HIR


• TEST EMULSION• TAKE DRY CUT SAMPLES (INDICATES ‘ADEQUATE’ STRENGTH)

– INSPECT FOR SURFACE DEFECTS AND SMOOTHNESS• DETERMINE

– THICKNESS AND MOISTURE CONTENT– BULK DENSITY– MARSHALL STABILITY AND RETAINED STABILITY (25ºC)– RECOMPACTED (60ºC) DENSITY OF SAMPLE

• REPORT– EMULSION TEST RESULTS– SITE AND SAMPLE LOCATION– THICKNESS AND MOISTURE CONTENT – BULK AND RECOMPACTED DENSITIES– MARSHALL STABILITY AND RETAINED STABILITY– PERCENT COMPACTION

• TEST SURFACE COURSE MATERIALS

CIR (EMULSION) QUALITY MONITORING


BRUCE COUNTY ROAD 31 CIR PROJECT COMPLETED IN 199115 PERCENT COARSE AGGREGATE, 1.1 PERCENT HF150

CONDITION IN 1997

PERFORMANCE


BRUCE COUNTY ROAD 31CONDITION IN 2002

PERFORMANCE


WATERLOO COUNTY ROAD 1CONDITION IN 2002

PERFORMANCE


CITY OF TORONTO ROYAL YORK ROAD CIR PROJECT COMPLETED IN 1997~ 20,000 AADT, BUS ROUTE, WIDENED

CONDITION IN 1999

PERFORMANCE


COUNTY OF WELLINGTON WR 39 CIR PROJECT COMPLETED IN 1990CONDITION IN JANUARY 2007

PERFORMANCE

MISSISSAUGA CIR, FDR AND HIR FEBRUARY 2014

“WE GO OUT AND BUY PAVEMENTS LIKE WE WOULD ZUCCHINI. ALL WE CARE ABOUT IS PRICE.”

DAMIAN J. KULASH, EXECUTIVE DIRECTOR, STRATEGIC HIGHWAY RESEARCH PROGRAM, 1993

LIFE-CYCLE COST ANALYSIS


LIFE-CYCLE COST ANALYSIS

• ECONOMIC ASSESSMENT OF COMPETING, TECHNICALLY SUITABLE SYSTEMS OVER DESIGN LIFE

• COST COMPONENTSINITIAL COSTS (CAPITAL COSTS)MAINTENANCE COSTSREHABILITATION COSTSRESIDUAL/SALVAGE VALUESUSER COSTS (TRAFFIC DELAY FOR INSTANCE)

• PRESENT WORTH METHODANALYSIS PERIOD (TYPICALLY 30 TO 40 YEARS – AT LEAST ONE

REHABILITATION)DISCOUNT RATE (TYPICALLY ABOUT 4 PERCENT)PRESENT WORTH (REMEMBER RULE OF 72)

• GENERALLY BASED ON PROBABILISTIC PRESENT WORTH METHOD


EXAMPLE OF COLD IN-PLACE ASPHALT RECYCLING LIFE-CYCLE COST ANALYSIS

• INTEREST RATE 8 PERCENT, INFLATION RATE 4 PERCENT- DISCOUNT RATE 3.85 PERCENT

• ALTERNATIVES BASED ON EQUIVALENT GRANULAR BASE EQUIVALENCIES (GBE)

- EXISTING PAVEMENT 4 INCH (100 mm) ASPHALT CONCRETE 6 INCH (150 mm) GRANULAR BASE

GRANULAR SUBBASESUBGRADE

• GBE OF 1.8 USED FOR COLD IN-PLACE RECYCLED MATERIAL

• INITIAL COST OF PAVEMENT STRUCTURE ONLY - AVERAGE MTO 1996 UNIT PRICES - CIR 4 INCH (100 mm) - $ 3.75 PER YD2 (4.50 PER M2) FOR EXAMPLE

• MAINTENANCE AND REHABILITATION SCHEDULE BASED ON JEGEL EXPERIENCE


FLEXIBLE PAVEMENT DESIGNLIFE-CYCLE COST ANALYSIS

EXAMPLEFOAMED ASPHALT OR CIR

PULVERIZE 200 m m40 m m HL 850 m m OF HL 3

CO LD IN-PLACERECYCLE 100 m m50 m m OF HL 3

M ILL 40 m m65 m m OF RECYCLED HL 850 m m OF HL 3

INITIAL CO ST 29,526 31,275 35,700

PRESENTW ORTH O FM AINT. CO STS

12,322 13,715 12,332

PRESENTW ORTH O FREHAB. CO STS

22,478 8,706 22,478

PRESENTW ORTH O FRESIDUALCO STS

(10,178) (2,175) (10,277)

TOTALPRESENTW ORTH O FCO STS

54,158 51,521 60,233

RANK 2 1 3


CIR (EMULSION) FEATURES• CIR AND MODIFIED CIR WELL ESTABLISHED AND PROVEN

REHABILITATION TECHNIQUE• RECOMMEND AGENCY COMPLETE PRELIMINARY PAVEMENT EVALUATION AND SET PERFORMANCE SPECIFICATION• RECOMMEND CONTRACTOR MADE RESPONSIBLE FOR CIR MIX DESIGN, PROCESS AND PERFORMANCE• RECOMMEND RECYCLING PROCESS, EMULSION AND MODIFICATION(S) BE SEPARATE PAY ITEMS• USE FOR HIGH TRAFFIC LEVELS WELL ESTABLISHED• a1 OF ~ 0.30 TO 0.40 FOR AASHTO SN (GBE OF ~ 1.8)

FOR HIGH QUALITY, FULLY CURED, CIR (EMULSION)• MITIGATION OF REFLECTIVE CRACKING• SIGNIFICANT COST SAVINGS• APPLICATION TO AIRPORT ASPHALT PAVEMENTS (CURING TIME LOGISTICS AND STRENGTH REQUIREMENTS)?

CITY OF TORONTO MARTIN GROVE ROAD 1998 CIR PROJECT IN 1999

15,000 AADT, BUS ROUTE

FEBRUARY 2014MISSISSAUGAFULL DEPTH RECLAMATION – FDR

PULVERIZING LIME CEMENT EMULSION FOAMED ASPHALT COMBINATION

CIR, FDR AND HIR


PULVERIZING OLD ASPHALT CONCRETE PAVEMENTFULL DEPTH METHOD WITHOUT STABILIZING ADDITIVE

ONTARIO OPSS 330 MAXIMUM 50% RAP

FULL DEPTH RECLAMATION – FDRPULVERIZING LIME CEMENT EMULSION FOAMED ASPHALT COMBINATION

JEGEL

CIR, FDR AND HIR


LIME STABILIZATION OF OLD ASPHALT PAVEMENT/GRANULAR BASEDOMINICAN REPUBLIC

JEGEL


CIR, FDR AND HIR


CEMENT STABILIZATION OF COLD ASPHALT PAVEMENT/GRANULAR BASENATCHEZ TRACE PARKWAY, MISSISSIPPI


JEGEL

CIR, FDR AND HIR


FDR EMULSION STABILIZATIONSS-1 WITH GRANULAR MATERIAL ADDED

NICARAGUA

JEGEL


CIR, FDR AND HIR


FDR WITH FOAMED ASPHALT ONTARIO


JEGEL

CIR, FDR AND HIR


FDR WITH FOAMED ASPHALT/LIMEGEORGIA


BLOUNT

CIR, FDR AND HIR


Hot asphalt cement

FDR FOAMED ASPHALT BASE STABILIZATION PROCESS

• OLD ASPHALT PAVEMENT PREPULVERIZEDADDITIONAL GRANULAR OR RAP MATERIAL MAY BE ADDED

• TYPICAL STABILIZATION DEPTH OF 125 TO 200 mm• ABOUT 2.0 TO 3.5 PERCENT FOAMED ASPHALT ADDED• SHAPING AND HEAVY COMPACTION • PLACEMENT OF SURFACE TREATMENT OR HMA SURFACE

CIR, FDR AND HIR


CIR AND FDR (FOAMED) FOUR COMPONENT SYSTEM

FOAMED ASPHALT FOR ECONOMICAL ROAD CONSTRUCTION, CSANYI 1962, ASCE

UNIQUE PROPERTIES OF FOAM“Known as the foamed asphalt process, it utilizes the unique properties of foams. When an asphalt cement is foamed, it increases tremendously in volume, its viscosity is materially reduced, and it becomes much softer at lower temperatures. Foaming also introduces energy into the asphalt, thereby modifying its surface tension and making it more sticky. It increases its ability to displace moisture from a surface and to coat a surface with a comparatively thin film. When the foam breaks and the energy is dissipated, the asphalt cement recovers its original properties with no change in its chemical composition. Through modified surface tension, cold, wet aggregates or soils can be used, and wet clayey lumps of soil can be permeated with asphalt. Because of the ability of foamed asphalt to coat mineral particles with thin films, the use of ungraded local aggregates in mixes becomes possible and the production of mastics of mineral dusts and asphalt is also feasible. Thus, through the use of asphalt cements as a foam, materials heretofore considered unsuitable can now be used in the preparation of mixes for stabilized bases and surfacing for low-cost road construction.”

CIR (FOAMED), FDR (FOAMED) AND HIR


CIR EMULSION MIX FOUR COMPONENT SYSTEM• HOT-MIX ASPHALT IS A THREE-COMPONENT SYSTEM

– SOLID AGGREGATE, LIQUID (INITIALLY)/VISCOPLASTIC ASPHALT BINDER, GASEOUS AIR

• CIR MIX IS A FOUR-COMPONENT SYSTEM– SOLID AGGREGATE (‘BLACK ROCK’ PLUS ADDED AGGREGATE, IF ANY)– LIQUID (INITIALLY)/VISCOPLASTIC ASPHALT BINDER (EMULSION RESIDUAL ASPHALT CEMENT PLUS SOME ‘ACTIVATED’ OLD ASPHALT BINDER)– GASEOUS AIR– LIQUID WATER

• RAP AND MOST OF THE ADDED AGGREGATE ARE COATED WITH EMULSION (ASPHALT BINDER) DURING PROCESS MIXING

CIR AND FDR FOAMED ASPHALT MIX FOUR-COMPONENT SYSTEM• COMPONENTS ARE SIMILAR TO A CIR EMULSION MIX• VERY SIGNIFICANT DIFFERENCE IN BINDING AND COATING MECHANISMS • PROCESS INVOLVES PREFERENTIAL COATING OF THE FINE, HIGH

SPECIFIC SURFACE AREA, AGGREGATE PARTICLES WITH THE LOW VISCOSITY FOAM TO FORM A MORTAR (MASTIC) THAT BINDS THE LARGELY UNCOATED COARSE PARTICLES TOGETHER (‘SPOT WELDING’ BINDER)

• FOAMED ASPHALT EXPANSION RATIO AND HALF LIFE VERY IMPORTANT

CIR (EMULSION), CIR (FOAMED), FDR (FOAMED) AND HIR


SURFACETREATMENT

FOAMED (EXPANDEDASPHALT STABILIZEDBASE)

WELLINGTON COUNTY, ONTARIO, ROAD 50, 1997 FDR PROJECT

THE FOAMED ASPHALT EXPANSION RATIO AND HALF-LIFE ARE IMPORTANT STABILIZATION DESIGN AND CONSTRUCTION PARAMETERS. AN EXPANSION RATIO OF GREATER THAN 10 AND HALF-LIFE OF GREATER THAN 10 SECONDS ARE TYPICALLY SPECIFIED (NOTE – DEPENDS ON MATERIAL TEMPERATURE)

FOAMED ASPHALT/COATED FINE AGGREGATE PARTICLES FORM A MORTAR (‘MASTIC’) WHICH BINDS THE COARSE AGGREGATE PARTICLES TOGETHER (“SPOT WELDED”) IN THE STABILIZED BASE. FOAMED ASPHALT HAS AN AFFINITY FOR THE FINE AGGREGATE PARTICLES. THIS IS VERY IMPORTANT TO THE FOAMED ASPHALT STABILIZATION PROCESS.FOAMED ASPHALT IS A FOUR-PHASE SYSTEM COMPARED TO HMA THREE-PHASE SYSTEM – NOTE THE KEY ROLE OF WATER

CIR AND FDR FOAMED ASPHALT KEY FEATURES

Cold W ater

Foam ed Asphalt

Hot Asphalt Cem ent

Foam ing Process



CIR AND FDR FOAMED ASPHALT STABILIZED BASE JEGEL DESIGN AND ESTIMATING GUIDE

• PREFERRED OVERALL GRADATION– MINUS 19 mm 60 - 100%– MINUS 4.75 mm 30 - 60%– MINUS 600 m 15 - 30%– MINUS 75m 7 - 15%

• ESTIMATED FOAMED ASPHALT CONTENT– ‘MOISTURE SUSCEPTIBLE’

• AC% = (%AGG/100 x 4.5) + (%RAP/100 x 1.5)– NOT ‘MOISTURE SUSCEPTIBLE’

• AC% = (%AGG/100 x 4.0) + (%RAP/100 x 1.5)

• GUIDELINES FOR USE OF HYDRATED LIME (SOTER GUIDE)– PLASTICITY INDEX (PI) < 4 NO HYDRATED LIME– PI 4 TO 8 1% HYDRATED LIME– PI > 8 2% HYDRATED LIME

ROTO-MILL


FEBRUARY 2014MISSISSAUGAFOAMED ASPHALT STABILIZATION OVERALL DESIGN PROCEDURE

DEVELOPED FOR FDR - ALSO APPLICABLE FOR CIR (FOAMED)

• EVALUATE PAVEMENT SECTION FOR SUITABILITY (SIMILAR TO CIR (EMULSION))

• DETERMINE PROPERTIES OF RECLAIMED MATERIALS

• COMPLETE MIX DESIGN THE MIX DESIGN METHOD GENERALLY FOLLOWED IS BASED ON THE CURRENT

SOUTH AFRICAN ASPHALT ACADEMY 2009 AND WIRTGEN 2012 PROCEDURES (MANUALS AVAILABLE ON LINE). IT IS RECOMMENDED THAT FOAMED ASPHALT MIX DESIGNS BE COMPLETED BY QUALIFIED ASPHALT TECHNOLOGY LABORATORIES. THE CURRENT OPSS 331 AND OPSS 335 FOR EXPANDED (FOAMED) ASPHALT USE DO NOT INCORPORATE THE FULL NEW AND CRITICAL ASPHALT ACADEMY AND WIRTGEN TECHNOLGY AND MANUALS AND SHOULD ONLY BE USED WITH PROFESSIONAL ADVICE. (THE ASPHALT ACADEMY AND WIRTGEN OVERALL NEW FOAMED ASPHALT TECHNOLOGY IS CURRENTLT UNDER ONTARIO REVIEW.)

• CHECK FOAMED ASPHALT EXPANSION RATIO AND HALF LIFE

• CHECK MOISTURE SUSCEPTIBILITY (TENSILE STRENGTH RATIO)

• SELECT OPTIMUM FOAMED ASPHALT CONTENT FOR TENSILE STRENGTH (MOISTURE SUSCEPTIBILITY), STABILITY, AIR VOIDS AND COATING (APPEARANCE)

HEAVY COMPACTION EQUIPMENT ON FOAMED ASPHALT STABILIZATION PROJECTMILLER

CIR, FDR AND HIR

























JEGEL ASPHALT LABORATORY

• PROCESS RAP SAMPLE(S) AND AGGREGATES• DETERMINE OPTIMUM COMPACTION• CHECK FOAMED ASPHALT EXPANSION RATIO AND HALF LIFE• PREPARE BRIQUETTES

– 2.0%, 2.5%, 3.0%, 3.5%, 4.0% FOAMED ASPHALT (DEPENDING ON RICHNESS, HOT AC + ~ 2% WATER)

– RAP + AGGREGATE + WATER + FA (TOTAL FLUIDS - 8.5%)– 75 BLOWS/FACE AT RESULTING TEMPERATURE (~25°C)– CURE 24 HOURS IN MOLD AT 25°C– REMOVE FROM MOLD– CURE 72 HOURS AT 60°C

• TEST BRIQUETTES AT 25°C (MARSHALL PROPERTIES)• CHECK MOISTURE SUSCEPTABLITY, TSR (SATURATED, SOAKED 4

DAYS AT 25°C)

PTI PUGMILL MIXER

WIRTGEN FOAMER

LOW ESALs FOAMED ASPHALT STABILIZATION MIX DESIGNCIR (FOAMED), FDR (FOAMED) AND HIR


FOAMED ASPHALT STABILIZATIONSPECIFICATION

• CONTRACTOR RESPONSIBLE FOR MIX DESIGN, FOAMED ASPHALT STABILIZATION PROCESS AND QUALITY

• INCORPORATE ALTERNATIVES TO FOSTER INNOVATION

• PERFORMANCE REQUIREMENTS

• AGENCY ACCEPTANCE

• OPSS 331 CONSTRUCTION SPECIFICATION FOR FULL DEPTH RECLAMATION WITH EXPANDED ASPHALT STABILIZATION (November 2011)– USE WITH CARE AS MAINLY FOR MTO PROJECTS AND DOES NOT

REFLECT SOME IMPORTANT CURRENT TECHNOLOGY (ASPHALT ACADEMY AND WIRTGEN)

CIR, FDR AND HIR


• PREPULVERIZED EXISTING PAVEMENT TO A DEPTH OF 100 mm• PLACED ADDITIONAL GRANULAR MATERIAL (GRANULAR A)• 150 mm FOAMED ASPHALT STABILIZATION• DOUBLE SURFACE TREATMENT

• FOAMED ASPHALT MIX DESIGN– FOAMED ASPHALT 3.2 %– TOTAL ASPHALT CEMENT CONTENT 4.98 %– EXISTING ASPHALT CONCRETE (RAP) 64.9 %– GRANULAR MATERIAL ADDED 31.9 %– AIR VOIDS 10.7 %– STABILITY 28130 N– TSR PASS

TYPICAL FOAMED ASPHALT PROJECT WELLINGTON COUNTY, ONTARIO, 1997

CIR, FDR AND HIR


WELLINGTON COUNTY FDR PROJECT PROCESSING STEPS

PLACING ADDITIONAL GRANULAR MATERIAL ON TOP OF PRE-PULVERIZED OLD PAVEMENT

CIR, FDR AND HIR


150 mm OF FOAMED ASPHALT STABILIZATIONASPHALT CEMENT AT ~ 160oC PLUS ~ 2% WATER


CIR, FDR AND HIR


INITIAL COMPACTION WITH HEAVY RUBBER TIRED ROLLER FOLLOWED BY VIBRATORY STEEL ROLLER


CIR, FDR AND HIR


WELLINGTON COUNTY FDR PROJECT PROCESSING STEPSWR 50, APPLICATION OF DOUBLE SURFACE TREATMENT ON TOP OF FDR

CIR, FDR AND HIR


CONDITION SHORTLY AFTER COMPLETION IN 1997

CIR, FDR AND HIR


WR 50 CONDITION IN JANUARY 2007

WR 50 CONDITION IN JANUARY 2007NOTE DISTRESS IN POOR DRAINAGE AREA

CIR, FDR AND HIR


TESTING WELLINGTON COUNTY FOAMED ASPHALT RUTTING RESISTANCE IN THE JEGEL APA

CIR, FDR AND HIR

PERM ANENT DEFO RM ATIO N IN THE ASPHALT PAVEM ENT ANALYZER SAM PLE O F FO AM ED ASPHALT W ITH AND W ITHO UT SURFACE

TREATM ENT

0

2

4

6

8

10

0 1000 2000 3000 4000 5000 6000 7000 8000NUM BER OF STROKES

PERM

ANEN

T DE

FORM

ATION (mm)

Foam ed Asphalt with Surface Treatm ent

Foam ed Asphalt, Cores 3 & 4




FDR FOAMED ASPHALT FEATURES

• FOAMED (EXPANDED) ASPHALT STABILIZATION WELL ESTABLISHED, PROVEN AND COST EFFECTIVE

• REFLECTIVE CRACKING MITIGATION• PROFILE CORRECTION AND SUPER ELEVATION RESTORATION• RECOMMEND AGENCY EVALUATE PAVEMENT/SET PERFORMANCE

SPECIFICATIONS AND ACCEPTANCE (QA)• RECOMMEND CONTRACTOR RESPONSIBLE FOR DESIGN/PROCESS/MATERIALS

PERFORMANCE AND (QC)• RECOMMEND STABILIZATION PROCESS BE SEPARATE PAY ITEM• a1 OF ~ 0.35 TO 0.40 FOR AASHTO SN (GBE OF ~ 1.8) FOR HIGH

QUALITY FDR • OPSS 331 CONSTRUCTION SPECIFICATION FOR FULL DEPTH RECLAMATION

WITH EXPANDED ASPHALT STABILIZATION FOAMED!– USE WITH CARE AS DOES NOT REFLECT CURRENT TECHNOLOGY!

• ADVANTAGES– EASY APPLICATION– FLEXIBLE LAYER WITH GOOD RUTTING AND FATIGUE PROPERTIES– ECONOMIC (LCCA)– RAPID STRENGTH GAIN - ROAD CAN BE OPENED AFTER COMPACTION– REFLECTIVE CRACKING MITIGATION

• DISADVANTAGES– REQUIRES A SUPPLY OF HOT (~160C PLUS) ASPHALT CEMENT– STABILIZED MATERIAL SHOULD HAVE 5 TO 15 PERCENT PASSING 75 µm

CIR, FDR AND HIR


LADIS H. CSANYI, F. ASCEIOWA STATE UNIVERSITYCIVIL ENGINEERING, JUNE 1962

FOAMED ASPHALT TECHNOLOGY REVIEWTHE ORIGINS OF FOAMED ASPHALT

FOAMED ASPHALT TECHNOLOGY REVIEW

FEBRUARY 2014MISSISSAUGA FOAMED ASPHALT TECHNOLOGY REVIEW

FEBRUARY 2014MISSISSAUGAUSE OF FOAMED ASPHALT IN WAMSHELL BITUMEN WAM PROCESS

(LOWER ‘HMA’ TEMPERATURES) WARM ASPHALT MIX

TWO SEPARATE ASPHALT CEMENTSSOFT GRADE AND FOAMED HARD GRADE

FOAMED ASPHALT TECHNOLOGY REVIEW


STEAM ASPHALT PAVEMENT HEATER WORKING AT QUEEN AND DUNCAN STREETS, TORONTO, 1916 (CITY OF TORONTO ARCHIVES)

EVOLUTION OF HIRCIR, FDR AND HIR


RECYCLING AN ASPHALT PAVEMENT WHICH IS ‘BURNED’ IN THE PROCESS OF STREET RESURFACING, 1936 (APWA ARCHIVES)

EVOLUTION OF HIRCIR, FDR AND HIR


REFORM (HEATER – SCARIFICATION) – HEATING TO A DEPTH OF 20 TO 25 mm, REJUVENATION (OPTIONAL), MIXING, LEVELLING,

REPROFILING, AND COMPACTION

EVOLUTION OF HIRFIRST GENERATIONEVOLUTION OF HIRFIRST GENERATION

CIR, FDR AND HIR


REPAVE (PARTIAL RECYCLING) – HEATING TO A DEPTH OF 25 TO 50 mm, HOT MILLING, REJUVENATION (OPTIONAL), MIXING, LEVELLING,

REPROFILING, AND ADDING A NEW THIN OVERLAY OF HOT-MIX ASPHALTBRITISH COLUMBIA HIGHWAY 1, NEAR VANCOUVER 1988

EVOLUTION OF HIRSECOND GENERATION

CIR, FDR AND HIR

FEBRUARY 2014MISSISSAUGAEVOLUTION OF HIRTHIRD GENERATION

REMIX (FULL RECYCLING) – HEATING TO A DEPTH OF UP TO 75 mm, HOT MILLING, REJUVENATION/ NEW AGGREGATE/ NEW MIX (OPTIONAL –

DESIGNED), MIXING, REPROFILING/PLACING WITH PAVER, AND COMPACTIONMARTEC AR2000, INTERSTATE 85, NORTH CAROLINA, OFC, 2001

CIR, FDR AND HIR


GENERAL STEPS IN A HIR PROJECT

BASED ON CANADIAN EXPERIENCE

NOTE: IT IS ASSUMED THAT THE APPROPRIATE SPECIFICATION PREPARATION, TENDERING, AND QUALITY CONTROL HAVE BEEN INCORPORATED IN THE STEPS, AS REQUIRED.

CO M M ENTS

1. PRELIM INARY PAVEM ENT EVALUATIO N M AINLY TO DETERM INE IF THE ASPHALT PAVEM ENT STRUCTURE IS ADEQ UATE (FW D FO R INSTANCE).

2. APPLICABILITY O F HO T IN-PLACE RECYCLING ? Yes No

3. DETAILED ASPHALT PAVEM ENT EVALUATIO N M AINLY Q UALITY AND PRO PERTIES O F THE EXISTING ASPHALT PAVEM ENT SURFACE CO URSE.

4. SELECTIO N O F HO T IN-PLACE RECYCLING O PTIO N HEATER-SCARIFY, REPAVE, OR REM IX.

5.A. REPAVE-SPECIFY NEW HO T-M IX ASPHALT O VERLAY REQ UIREM ENTS

B.

REM IX-SELECT REJUVENATO R (TYPE AND APPLICATIO N RATE), CO RRECTIVE AG G REG ATE (TYPE AND AM O UNT) AND/O R DESIG N CO RRECTIVE NEW HO T-M IX ASPHALT TO BE ADDED (REM IXED) (TYPE, M IX PRO PERTIES AND AM O UNT)

6. CO M PLETIO N O F HO T IN-PLACE RECYCLING O PTIO N

CO NTRACTO R Q UALITY CO NTRO L IM PO RTANT, W ITH AG ENCY O VERVIEW QUALITY ASSURANCE.

IF HO T IN-PLACE RECYCLING IS NO T APPLICABLE, DEVELO P ALTERNATE REHABILITATIO N OR RECO NSTRUCTIO N M ETHO D(S).

STEP

M AJO R ASPHALT TECHNO LO G Y ASPECTS IN CO NJUNCTIO N W ITH STEP 3.

CIR, FDR AND HIR


MARTEC AR2000 SUPER RECYCLER HIR PROCESSTHIRD GENERATION HIR

THIS UNIT ‘GENTLY’ HEATS AND SOFTENS THE DETERIORATED OLD ASPHALT CONCRETE USING A COMBINED HOT-AIR/

LOW-LEVEL RADIANT HEATING SYSTEM

THE PROCESS IS COMPLETED USING CONVENTIONAL COMPACTIONTHIS UNIT (OPTIONAL – USE DEPENDS ON SPECIFIC PROJECT)

CONTINUES TO ‘GENTLY’ HEAT AND SOFTEN THE DETERIORATED OLD ASPHALT CONCRETE

MARTEC AR2000 HIR PROCESS – A TRAVELLING ASPHALT RECYCLING PLANT

PREHEATER PREHEATER (OPTIONAL) PREHEATER/ HOT MILLER ADMIX TRUCK POSTHEATER/DRYER PAVER ROLLERS MIXER

CIR, FDR AND HIR


THE PROCESS IS COMPLETED USING CONVENTIONAL COMPACTION

THE AIR IN THE DIESEL-FUELED COMBUSTION CHAMBER IS HEATED TO UP TO 700ºC AND BLOWN ON THE PAVEMENT THROUGH HOLES IN THE MANIFOLD, WITH THE SPENT

HOT AIR RECUPERATED AND REHEATEDTHE SOFTENED OLD ASPHALT CONCRETE IS NOT DAMAGED (‘BURNED’) AND EMISSION

LEVELS ARE VERY LOW

MARTEC AR2000 HIR PROCESS – A TRAVELLING ASPHALT RECYCLING PLANT

PREHEATER PREHEATER (OPTIONAL) PREHEATER/ HOT MILLER ADMIX TRUCK POSTHEATER/DRYER PAVER ROLLERS MIXER

HEATER TECHNOLOGYCIR, FDR AND HIR


COMPLETED MARTEC AR2000 HIR SECTION IN SEPTEMBER 1999 WITH TYPICAL HIGHWAY 401 TRUCK TRAFFIC ON THIS US-CANADA NAFTA ROUTE

HIR LANES

ONTARIO HIGHWAY 401 DEMONSTRATION PROJECTCIR, FDR AND HIR


CURRENT CONDITION OF THE MARTEC AR2000 HIR SECTION IN FEBRUARY 2005 SHOWING THE EXCELLENT CONDITION OF THE TWO LANES INVOLVED

HIR LANES



MARTEC AR2000 HIR SECTION, 2005 VERY GOOD RIDE QUALITY AND GOOD SURFACE CONDITION.



SECOND GENERATION HIR SECTION, 2005FAIR TO GOOD RIDE QUALITY WITH CONSIDERABLE RAVELLING



MILL AND FILL WITH DFC SECTION, 2005GOOD RIDE QUALITY WITH OCCASIONAL RAVELLING AND POTHOLING



MILL AND FILL WITH RHM SECTION, 2005 VERY GOOD RIDE QUALITY WITH SOME LOW SEVERITY DETERIORATION



MICROSURFACED SECTION, 2005GOOD RIDE QUALITY WITH VERY COARSE AND OPEN TEXTURE



DEMONSTRATION SECTIONIRI RUTTING (MM) FRICTION (ASTM)

THREE YEARS 2002

BEFORE 1999 ONE YEAR 2000

THREE YEARS 2002

SECOND GENERATION HIR 1.29 4.2 41 44

NEW DENSE FRICTION COURSE (DFC) 1.12 2.9 41 44

MARTEC AR2000 HIR 0.98 2.3 41 47

RECYCLED HOT-MIX DFC 0.98 2.6 42 46

MICROSURFACING – 2000 0.90 4.2 49 44

MICROSURFACING - 1999 0.78 4.6 45 41

RUTTING AND FRICTION MONITORING TEST RESULTS HIGHWAY 401 DEMONSTRATION PROJECT

ONTARIO MINISTRY OF TRANSPORTATION 2002 FINDINGS FOR THIS HIGHLY TRAFFICKED ROUTEMARTEC AR2000 HIR SECTION IS IN EXCELLENT CONDITION AND PERFORMING THE BEST OF ALL THE SECTIONS

CONFIRMED BY JEGEL FEBRUARY 2005 INSPECTIONS

CIR, FDR AND HIR


11.0 M

7.30 M

1.85 M

1.85 M

7.30 M

1.85 M

1.85 M

OVERLAY

Existing PavementNew Hot Mix Asphalt Overlay

Base and Subbase

MILL AND FILL

Base and SubbaseExisting Pavement

HIR

Existing PavementBase and Subbase

New Hot Mix Asphalt

HIR Recycled Mix

NOT TO SCALE

NOT TO SCALE

NOT TO SCALE

BASIS FOR NON-RENEWABLE RESOURCES CONSUMPTION COMPARISON TYPICAL PAVEMENT CROSS SECTIONS FOR A STANDARD TWO LANE ROAD

HIR CONTRIBUTION TO SUSTAINABILITYCIR, FDR AND HIR


PROCESSWIDTHmetres

NON-RENEWABLE RESOURCE CONSUMPTION

TRUCKINGROUNDTRIPSAGGREGATES

tonnes

ASPHALTCEMENTtonnes

REJUVENATORlitres

DIESELFUEL litres

ASPHALT OVERLAY 60 mm

11.0

1442 76 – 52,345 252

(89%) (89%) (72%) (89%)

MILL 60 mm/ FILL 60 mm

7.3957 50 – 41,572 251

(83%) (84%) (64%) (89%)

HIR 60 mm 7.3 160 8 2190 14,784 29

NON-RENEWABLE RESOURCES AND TRUCKING ROUND TRIPS REQUIRED PER ONE KILOMETRE OF THE TWO-LANE ROAD

REHABILITATION PROJECT

CIR, FDR AND HIR


TYPICAL TOP-DOWN CRACKING (TDC) IN WHEELPATH, WITH SOME TRANSVERSE THERMAL CRACKING, OF RELATIVELY NEW EXPRESSWAY NEAR HOHHOT, INNER MONGOLIA, CHINA

HIR CAN BE USED FOR SURFACE REHABILITATION OF PAVEMENTS WITH TOP-DOWN CRACKING

CIR, FDR AND HIR


TYPICAL RECOVERED PENETRATION AND KINEMATIC VISCOSITY BLEND CHART FOR A LOW VISCOSITY REJUVENATOR (RECYCLING AGENT) ADDED TO AGED ASPHALT BINDER

OR RECLAIMED ASPHALT PAVEMENT

Recovered Penetration● Added to RAP ♦ Added to Aged Asphalt Cement

Recovered Kinematic Viscosity▲ Added to RAP■ Added to Aged Asphalt Cement

ASPHALT TECHNOLOGY FOR HIRCIR, FDR AND HIR


• TENDENCY TO USE CONVENTIONAL HOT-MIX ASPHALT (HMA) OVERLAY AND MILLING/HMA FILLING (MILL – FILL) RESURFACINGS

• LACK OF APPRECIATION OF THIRD GENERATION HIR TECHNOLOGY AND THE ASPHALT PAVEMENT RENEWAL QUALITY THAT IS BEING ACHIEVED FOCUS

- COST-EFFECTIVE AND TIME-SAVING- ENVIRONMENT-FRIENDLY

- EMISSION CONTROL, TOTAL REUSE OF OLD ASPHALT CONCRETE, AND REDUCED TRUCKING

- WIDE RANGE OF PROJECTS AND ASPHALT SURFACE COURSE TYPES RENEWED- LOCAL ROADS TO EXPRESSWAYS- CONVENTIONAL SUPERPAVE, OPEN FRICTION COURSE, AND POLYMER

MODIFIED HMA- LESS ROAD-USER DISRUPTION- EQUIVALENT (TO BETTER) QUALITY RENEWED ASPHALT SURFACE

COURSES- REDUCED MECHANICAL AND THERMAL SEGREGATION FOR INSTANCE

WHY NOT MORE HOT IN-PLACE ASPHALT RECYCLING (HIR)?

CIR, FDR AND HIR


• NEW PROJECTS• HOT-MIX ASPHALT (INCLUDING RECYCLED AND HIR) 2.0• GRANULAR BASE (CRUSHED, CBR 60) 1.0• GRANULAR SUBBASE (CBR < 60) 0.67• OGDL (NOT RECOMMENDED) 1.0

• RESURFACING PROJECTS• OLD HOT-MIX ASPHALT 1.25• OLD GRANULAR BASE 0.75• OLD GRANULAR SUBBASE 0.50

• RECONSTRUCTION PROJECTS• OLD HOT-MIX ASPHALT 1.0• OLD GRANULAR BASE 0.6• OLD GRANULAR SUBBASE 0.4• PULVERIZED RAP/GRANULAR BLEND 1.00• CIR AND FDR, EMULSION AND FOAMED,HIGH QUALITY 1.80• RUBBLIZED BASE CONCRETE 1.0+

FLEXIBLE PAVEMENT EMPIRICAL DESIGN METHODS~ GRANULAR BASE EQUIVALENCY FACTORS

ONTARIO EXPERIENCE

CIR, FDR AND HIR


• TRAFFIC• SUBGRADE• DRAINAGE CONDITIONS• ENVIRONMENTAL CONDITIONS• PAVEMENT SERVICEABILITY

•MATERIALSGRANULAR SUBBASEGRANULAR BASEASPHALT CONCRETE

GBEAASHTO 93 ai

FLEXIBLE PAVEMENT EMPIRICAL DESIGN METHODS AASHTO 93 IS COMMONLY USED AASHTO ME COMING

SOON

ASPHALT PAVEMENTSSN = a1D1 + a2D2m2 + a3D3m3

CIR, FDR AND HIR


NOTES: 1. ALL RESILIENT MODULUS VALUES WERE OBTAINED BASED ON THE TESTING OF THREE SAMPLES EXCLUDING OUTLIERS. 2. TESTING RESULTS AT 20ºC WERE CONDUCTED USING A DIFFERENT SET OF SAMPLE SPECIMENS FROM THE SAME CORING LOCATION AS THE REST OF THE TESTING SPECIMENS.

SUMMARY OF RESILIENT MODULUS TESTING RESULTSHOT MIX ASPHALT AND FOAMED ASPHALT MIX

HOUZE WAYAVERAG E RESILIENT M O DULUS (M Pa) LAYER

TYPE 10°C 25°C 35°C 20°C

HM A 11809 5236 2115 7957

TO P FO AM ED ASPHALT 6582 4947 3087 5319

LO W ER FO AM ED ASPHALT 5831 4536 2566 4457

BO TTO M FO AM ED ASPHALT 1970 1639 994 2540

CHARACTERIZATION OF HMA AND FDR FOAMED ASPHALT STABILIZED BASE

CIR, FDR AND HIR


LTPP DESIGN SUMMER PAVEMENT TEMPERATURES (OC)98% RELIABILITY

CHARACTERIZATION OF HMA AND FDR FOAMED ASPHALT STABILIZED BASE

CIR, FDR AND HIR

DEPTH (m m )0 50 100 150

ATLANTA, G EO RG IA 60.1 55.2 52.4 50.5DETRO IT, M ICHIG AN 56.4 51.5 48.7 46.8KANSAS CITY, M ISSOURI 60.6 55.7 52.9 50.9TO RO NTO , O NTARIO 54.9 50 47.2 45.2

CITY


RESILIENT M ODULUS VS. TEM PERATURE RELATIONSHIPHOT M IX ASPHALT AND EXPANDED ASPHALT M IX

(HOUZE W AY, CITY O F ROSW ELL, GEO RGIA)

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

0 5 10 15 20 25 30 35 40TEM PERATURE (°C)

RESILIEN

T MOD

ULUS

(MPa

)

HM A

TOP FOAM ED ASPHALT

LOW ER FOAM ED ASPHALT

BOTTOM FOAM ED ASPHALT

HM A AT 20°C

TOP FOAM ED ASPHALT AT 20°C

M IDDLE FOAM ED ASPHALT AT 20°C

LOW ER FOAM ED ASPHALT AT 20°C

TYPICAL RANGE OF RESILIENT M ODULUS FOR DENSE-GRADED ASPHALT M IXTURES

CHARACTERIZATION OF HMA AND FOAMED ASPHALTCIR, FDR AND HIR


LIME - FOAMED ASPHALT BASE STABILIZATION FOR THE TRANSMILENIO LAS AMÉRICAS PROJECT

JEGEL

CIR, FDR AND HIR


Asphalt Voids Stability Flow TSR Stiffness% % N (0.25 m m ) Dry W et (% ) (M Pa)Additive

41465799

4879431034234479

Tensile Strength, KPa

No Additive

4661329230445766

5674452349945389

4812466042174020

14.414.8

15.116.3

15.913.0

13.514.9

184 26.024.0138

54894 17.6 7083.0 57616.44980815.5

1% Portland Cem ent

2% Portland Cem ent

3% Portland Cem ent

3.53.04.03.5

4.03.53.04.0 684 402 58.8

56.3366650

502 73.664.3386

18.1 68260016.4

17.6526415542753612 22.9

20.0

30.554.3300552

54131 18.1 836 255

55891

6057752768

85.354463820.2

1% Hydrated Lim e

48536

4768814.6

2% Hydrated Lim e

3.03.54.03.03.54.03.03.54.0 52987 21.9 642 414

65.464.5

552 36161.751.253.458.621.818785918.5

58014 20.133354018.857056

19.5 769 39433763116.7

53326

312

13.614.214.814.4

5701455742 15.6 532

11.615.5

8078550991 16.9 10.212.31.91261813.0 15.2

FOAMED ASPHALT MIX DESIGN PROPERTIES 50/50 RAP GRANULAR BLEND

FOAMED ASPHALT MIX DESIGN EXAMPLE TRANSMILENIO LAS AMÉRICAS

CIR, FDR AND HIR

FEBRUARY 2014MISSISSAUGALIME - FOAMED ASPHALT BASE STABILIZATION PROCESS

FOR THE TRANSMILENIO LAS AMÉRICAS PROJECT

JEGEL

50/50 RAP GRANULAR BLENDEXPANDED ASPHALT MIX DESIGN PROPORTIONS

MATERIAL MIX

RECYCLED ASPHALT PAVEMENT 50% 47.3%GRANULAR MATERIAL 50% 47.3%

HYDRATED LIME (2%) 1.9%ASPHALT CEMENT (70-90, ECOPETROL)

3.5%

100% 100.0%TOTAL ASPHALT CEMENT CONTENT (RESIDUAL PLUS ADDED) = 4.88% TOTAL MOISTURE CONTENT (IN-SITU PLUS ADDED) = 4.2% OPTIMUM MOISTURE CONTENT = 7.7%

CIR, FDR AND HIR


• DIVIDE THE PAVEMENT INTO SECTIONS WHICH ARE 300 m LONG. THE SECTIONS CAN BE

OF VARIABLE LENGTH PROVIDED THEY ARE HOMOGENEOUS WITH RESPECT TO THE FACTORS WHICH INFLUENCE THE PAVEMENT DESIGN (e.g., SUBGRADE AND TRAFFIC);

• SELECT AT LEAST 10 STRATIFIED TEST POINTS WITHIN EACH SECTION USING A TABLE

OF RANDOM NUMBERS;

• OBTAIN THE DEFLECTION MEASUREMENT AT THE SELECTED TEST POINTS USING THE FALLING WEIGHT DEFLECTOMETER;

• CALCULATE THE AVERAGE DEFLECTION (X) AND THE STANDARD DEVIATION (x).

• CALCULATE THE ESTIMATED MAXIMUM PROBABLE DEFLECTION VALUE.

Dmax = ( X + 2 x)• DESIGN OVERLAY OR REHABILITATION TO REDUCE DEFLECTIONS TO ACCEPTABLE LEVEL FOR SITE AND TRAFFIC CONDITIONS

WATCH FOR OUTLIERS (LOCAL REPAIR), ADJUST FOR SEASON, SPRING ~ 1.5 x FALL, CONVERT TO STATIC (BENKELMAN BEAM EQUIVALENT), BENKELMAN BEAM ~ 1.5 X FWD

IN ADDITION TO THE SEASONAL VARIATIONS, THE DEFLECTION OF A PAVEMENT SECTION MAY VARY ALONG ITS LENGTH. TO REDUCE THE EFFECT OF BOTH VARIABLES, A STATISTICAL PROCESS IS USED WHEN ESTIMATING THE MAXIMUM DEFLECTION.

DEFLECTION TESTING OF PAVEMENT SECTION FOR OVERLAY OR REHABILITATION DESIGN, TYPICALLY FWD

CIR, FDR AND HIR


PREVENTIVEMAINTENANCE TREATMENT

SURFACE WEAR

SEVERITY

ENVIRO CRACKING EXTENT

CRACK SEALING

SURFACE TREATMENT

CRACK SEALING +40 mm OVERLAY

OR HIR

CRACK SEALING

MILL/FILL 40 mm

OR HIR

MILL/FILL 50 mm

OR HIRMILL/FILL 50

mmOR HIR

FATIGUE CRACKING EXTENT

RUTTING SEVERITY

REHABILITATION TREATMENT

MILL/FILL 50 mm

OR HIRMILL/FILL 40

mmOR HIR

MILL/FILL 40 mmOR HIR

MILL/FILL 50 mmOR HIR

MILL/FILL 75 mmOR HIR (?) OR CIR AND

OVERLAY (DESIGN)MILL 50 mm

OVERLAY 75 mm OR HIR (?)

MILL 75 mmOVERLAY 100 mm OR CIR AND OVERLAY (DESIGN)

REMOVE, REPAIR BASE, REPAVE OR FDR AND OVERLAY (DESIGN)

TOTAL RECONSTRUCTION OR FDR AND OVERLAY

(DESIGN)



MODERATE

MODERATE

LOW

LOW

LOW

HIGH

HIGH

HIGH

MODERATE MODERATE

LOW

HIGH MODERATE

MODERATE

LOW

LOW

LOW

HIGH

HIGH

HIGH

MODERATEMODERATE

LOW

HIGH

STRUCTURAL DETERIORATION

STRUCTURE DRAINAGE

DECISION TREE FOR FLEXIBLE PAVEMENT MAINTENANCE AND REHABILITATION INCLUDING HIR, CIR AND FDR

ADAPTED FROM FP2

NO YES

HIR – HOT IN-PLACE ASPHALT RECYCLINGCIR – COLD IN-PLACE ASPHALT RECYCLINGFDR – FULL DEPTH RECLAMATION

CIR, FDR AND HIR


LONG-LIFE FLEXIBLE PAVEMENT DESIGN CONCEPTSCHEMATIC OF A LONG-LIFE FLEXIBLE (ASPHALT) PAVEMENT SHOWING THE

RENEWABLE SMA, OFC, OR SUPERPAVE HMA/RHM SURFACE COURSE

DESIGN OF LONG-LIFE FLEXIBLE PAVEMENTS

LIMIT BENDING TO < 65 µ (MONISMITH, VON QUINTUS, NUNN, THOMPSON)

LIMIT VERTICAL COMPRESSION TO < 200 µ (MONISMITH, NUNN)

RESURFACING CAN BE RHM OR HIR

CAN BE QUALITY CIR OR FDR

REPEATED DEFORMATION CAN LEAD TO RUTTING

REPEATED BENDING CAN LEAD TO FATIGUE

CIR, FDR AND HIR


CANADIAN SHIELD INCO SUDBURY, ONTARIO

‘DIFFICULT’ FDR PROJECT UNDERGROUNDCIR, FDR AND HIR


UNDERGROUND ROAD (RAMP) ~ 1000 m DEEP

‘DIFFICULT’ FDR (EMULSION) PROJECTCIR, FDR AND HIR


KIRUNA ELECTRIC HAUL TRUCK ON RAMPPAYLOAD ~ 50 TONNES, 18 kmh



ORIGINAL SURFACE WAS EMULSION STABILIZED (SS1 1:4 WATER)FDR WITH SC-1P EMULSION WAS USED TO RESTORE PAVEMENT SMOOTHNESS/DURABILITY



QUESTIONS ?

PLEASE CONTACT JOHN EMERY WITH ANY QUESTIONS 905-880-0510 [email protected]

CIR, FDR AND HIR

Documents

In Place Asphalt Recycling