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AEMA-ARRA-ISSA-PPRA Fall Meeting 2015
Recycling, Ayrton Senna Highway Brasil, & USA
2
2012:
The Ayrton Senna Highway in Brazil was rehabilitated under challenging conditions by using the Wirtgen Cold Recycling technology in plant.
Sao Paulo:
a city with more than
20 million citizen.
CCPR (Cold Central Plant Recycling)
3• KMA 220 – Ayrton Senna Highway in Sao Paulo / Brazil
AYRTON SENNA HIGHWAY
CCPR (Cold Central Plant Recycling)
LOCAL BAR
Ayrton Senna Highway / Brazil:8-lane divided facility – Brazil’s most heavily trafficked highway
5
CCPR (Cold Central Plant Recycling)
6
Ayrton Senna Highway / Brazil: Pavementcondition after standard rehabilitation procedure “Mill and Fill”
CCPR (Cold Central Plant Recycling)
ADT > 250,000vpd (15% Trucks)(OUTER RECYCLED LANE > 15,000 trucks / day in each direction)
Milling & Replacing 4 ins HMA lasts < 3 months
Lane closure only between 21:00 – 05:00
Ayrton Senna Highway / Brazil: Traditional Rehabilitation / Traffic Loading
CCPR (Cold Central Plant Recycling)
8• Results of pavement investigations
HMA ± 4 ins
CEMENTED CRUSHED STONE (G2) ± 10 ins
CRUSHED STONE (G2) ± 8 ins
SELECTED COARSE GRAVEL (G6) ± 8 ins
EMBANKMENT (RIVER LEEVEE) (G7) Semi-infinite
CCPR (Cold Central Plant Recycling)
HMA ?13.75 ins
BSM-a 8 ins Nominal
BSM-b HMA2 ins
4 ins
Rehabilitation options
4 ins
Step 1 - mill off asphalt layers
11
Construction sequence
Ayrton Senna Highway / Brazil:Milling of the asphalt layer (4 ins) at night
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Ayrton Senna Highway / Brazil:Crushing screened RAP – 1 ins minus
Construction sequence
13
KMA 220 – Sized RAP loaded to CCPR (Cold Central Plant Recycler) BSM (Bitumen Stabilised Material) Mix Design: 2.5% Foamed Asphalt + 1.5% Cement
Construction sequence
10 ins
Step 2 - mill and remove CTB layer
15
Ayrton Senna Highway / Brazil:Mill & Remove 10 ins CTB layer in one pass
Construction sequence
16
Ayrton Senna Highway / Brazil:Paving of the first BSM layer with a thickness of 8 ins
Construction sequence
17
Ayrton Senna Highway / Brazil: The BSM layeris levelled and pre-compacted with an asphalt paver
Construction sequence
18
Ayrton Senna Highway / Brazil:Full depth (8ins) compaction of the BSM material with apadfoot roller
Construction sequence
19
Ayrton Senna Highway / Brazil:Final compaction with a tandem steel drum roller
Construction sequence
20
Ayrton Senna Highway / Brazil:Paving the second BSM layer 4 ins
Construction sequence
21
Ayrton Senna Highway / Brazil: 4 ins BSM layer after final compaction. Ready for the asphalt overlay.
Construction sequence
2 ins HMA (gap-graded / fine mix)
Finish – Pave – 2 ins HMA
Rockfill where heavingwas detected.
23
Ayrton Senna Highway / Brazil:A tack coat is applied between the BSM and the asphalt layer
Construction sequence
24
Ayrton Senna Highway / Brazil:Pave 2 ins HMA
Construction sequence
25
Ayrton Senna Highway / Brazil:
Construction sequence
26
Monitoring
Ayrton Senna Highway / Brazil:two months under heavy traffic
Average: 0.45 mm 0.34 mm
Before rehab After rehab
• Deflection decrease from average 0.45 mm to 0.34 mm
Monitoring
Monitoring
June 2015 – 30 months after construction
Est traffic > 9.0 million trucks
Decision to Proceed
Confidence in Concept
I-81 Virginia DoT Recycling Alternative
FIRST MULTI RECYCLING/STABILISATION PROCESS IN N.AMERICA
Interstate I-81
30,000 VPD
8,000 trucks
Continual maintenance problem due to poor base materials
10 ins Asphalt layers
Poor Clay Support
Native
Mill & Fill Maintenance, limited successCracks reflecting back after 6 months
ALTERNATE FOAMED ASPHALT STABILISED BASE PROPOSAL
Material StructuralCoefficient
Thickness S.N
SMA 0.44 2 0.88
IM-19.0D 0.44 2 0.88
BM-25.0 0.40 10 4.00
DGAB 21B 0.12 6 0.72
OGB 0.05 12 0.60
Total 32 7.08
Material StructuralCoefficient
Thickness S.N
SMA 0.44 2 0.88
IM-19.0D 0.44 2 0.88
FBSB 0.30 12 3.60
LSSB 0.15 12 1.80
Total 28 7.16
Re-Construction Design Proposed Recycling Alternative
FBSB – Foamed Bitumen Stabilised Base
LSSB – Lime Stabilised Base
I81 Truck Lane
Milling 10ins depth Lime Stabilisation 12ins depth
100% Recycle Millings Pave Recycled Millings as Base
I81 Fast Lane
Phase 2: LH Fast Lane
Cold In Place Recycle
Depth 5”
Width 12’ 6”
2.2% Foamed Bitumen
Pave with attached AB375T screed
Concept Summary
Right Lane Traffic
7.8 million trucks
20.2 million cars
Left Lane Traffic(overtaking lane)
1.6 million trucks
3.8 million cars
August 2015 (4 years)
Economics of Recycling
Questions
Can we recycle and save $
Do we lose performance
YES SAVE $$
NO LOSS OF PERFORMANCEWELL ENGINEERED PRODUCT