Reclaimed Asphalt Pavement (RAP) and Other Recycled Materials Best Practices

Reclaimed Asphalt Pavement (RAP) and Other Recycled Materials Best Practices MICHAEL MACKAY, M. ENG., P.ENG. – PRINCIPAL ENGINEER VP – PAVEMENT TECHN...
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Reclaimed Asphalt Pavement (RAP) and Other Recycled Materials Best Practices

MICHAEL MACKAY, M. ENG., P.ENG. – PRINCIPAL ENGINEER VP – PAVEMENT TECHNOLOGY ALAIN DUCLOS, P.ENG. – PAVEMENT ENGINEER

RAP and Other Recycled Materials – Best Practices

+ What Is RAP and How Is It Generated? + How Can RAP Be Utilized? + Why Recycle Asphalt? + Other Materials That Can Be Recycled In HMA + RAP Recycling Resource Materials + Discussion

RAP and Other Recycled Materials – Best Practices Where Are Excess Materials Generated and Recycled Materials Used in Transportation Infrastructure Projects

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RAP and Other Recycled Materials – Best Practices

+ What Is RAP and How Is It Generated? Reclaimed Asphalt Pavement (RAP) is the term given to removed and/or processed flexible pavement materials which are composed of a mix of asphalt cement and aggregates

RAP and Other Recycled Materials – Best Practices

RAP is generated when asphalt pavements are removed as part of roadway reconstruction and maintenance (during excavations to access buried utilities, for instance) or during flexible pavement reconstruction or resurfacing (milling)

RAP and Other Recycled Materials – Best Practices

RAP and Other Recycled Materials – Best Practices

1916

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1936

RAP and Other Recycled Materials – Best Practices

RAP and Other Recycled Materials – Best Practices

+ How Can RAP Be Utilized? RECYCLING TECHNOLOGY

YEAR IMPLEMENTED

Central Plant Recycling

Late 70’s

Milling, Partial Depth

Early 80’s

Full Depth Reclamation

Mid 80’s

Cold In-Place Recycling

1989

Hot In-Place Recycling

1990

FDR with Expanded Asphalt

2000

CIR with Expanded Asphalt

2003

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RAP and Other Recycled Materials – Best Practices

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RAP and Other Recycled Materials – Best Practices

Hot In-Place Recycling (HIR) – OPSS 332

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Remix – Heating to a depth of up to 75 mm, hot milling, rejuvenation/ new aggregate/ new mix (option integral overlay), mixing, reprofiling/placing with paver and compaction

RAP and Other Recycled Materials – Best Practices Cold In-Place Recycling with Emulsion (CIR) – OPSS 333

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Cold milling, sizing/crushing, mixing with emulsion, reprofiling/placing with paver and compaction

RAP and Other Recycled Materials – Best Practices Cold In-Place Recycling with Expanded Asphalt (CIREAM) OPSS 335

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Cold milling, sizing/crushing, mixing with expanded asphalt, reprofiling/placing with paver and compaction

RAP and Other Recycled Materials – Best Practices Full Depth Reclamation with Expanded Asphalt Stabilization (FDREAS) – OPSS 331

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Pulverization, mixing with expanded asphalt, reprofiling/placing with grader and compaction

RAP and Other Recycled Materials – Best Practices

Full Depth Reclamation – OPSS 330

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Pulverization, no stabilization, reprofiling/placing with grader and compaction

RAP and Other Recycled Materials – Best Practices Cold Central Plant Recycling – OPSS 334

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Milling, processing in central plant, reprofiling/placing with paver and compaction

RAP and Other Recycled Materials – Best Practices Recycled Hot Mix – OPSS 1003/1150/MUNI 1151

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RAP Crushing and classification, addition to new hot-mix production, placement as a typical hot-mix asphalt

RAP and Other Recycled Materials – Best Practices

Quarry Byproducts Reclaimed Asphalt Pavement Reclaimed Concrete Material Roofing Shingle Waste Scrap Tires Silica Fume Steel Slag Waste Glass and Ceramics Wood Waste

Flowable Fill

Nonferrous Slag

Stabilized Base

Coal Fly Ash

Embankment or Fill

Blast Furnace Slag

Granular Base/Subbase

Baghouse Fines

Portland Cement Concrete Pavement

Commonly Recycled Across Canada

Asphalt Concrete Pavement

Recycled or Byproduct Material

Highest Best Use $$$

RAP and Other Recycled Materials – Best Practices

Bound Applications Partially Bound Applications Unbound Applications

RHM, WAM, HIR

FDREAS, CIREAM, CIR, CCPR FDR, Granular Base/Subbase, Shouldering Material

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RAP and Other Recycled Materials – Best Practices

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Why Recycle Asphalt? How can you afford not to? RECYCLED MATERIAL Crushed Concrete as Granular Material

EXAMPLE COST SAVINGS 30 to 50%

Hot In-Place Recycling

40%

RAP in Hot-Mix Asphalt

10% (15% RAP Addition) $2 - $8 per tonne of HMA 15% (30% RAP Addition in Binder Course)

Full Depth Reclamation with Foamed Asphalt

1/3 the Cost of Reconstruction

Shingles in Hot-Mix Asphalt

$4 per tonne of HMA

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RAP and Other Recycled Materials – Best Practices

+ September 2012 Asphalt Cement Price: $733.15/tonne + For a typical HL 3 (15% RAP) mix with 5.0% asphalt cement, 4.3% new asphalt cement is added, with 0.7% contributed by the RAP. At $733.15/tonne, this reflects a net saving in asphalt cement cost of about $12/tonne. This is offset somewhat by the extra RAP handling/processing cost + Current retail price of HL 3: $64/tonne + Current retail price of HL 3 (15% RAP): $59/tonne + For a 10,000 tonne project, a $50,000 saving! 21

RAP and Other Recycled Materials – Best Practices

A Municipal Example (OHMPA) + Typical municipal road rehabilitation project – a 2-lane arterial road one-kilometre long that requires a 40 mm overlay + If the asphalt could not be recycled, at current tipping fees of around $120 per tonne it would cost around $110,000 to send that material to landfill + using RAP as a hot mix raw material ensures the recovery of the asphalt cement (and aggregates), currently costing about $733.15 per tonne and assuming a blend of 20% RAP should reduce costs by about $5,500 per lane kilometre

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RAP and Other Recycled Materials – Best Practices

OPSS 1101 APPENDIX A-1 PGAC GRADE SELECTION FOR ONTARIO PGAC Zones ZONE 1

ZONE 2

ZONE 3

NEW HOT MIX OR UP TO 20% RAP

52 - 34

58 - 34

58 - 28

21 TO 40% RAP

52 - 40

52 - 40

52 - 34

RAP and Other Recycled Materials – Best Practices

• ~90 million tonnes of asphalt pavement is reclaimed each year in the United States and over 95 percent of that total is reused or recycled • ~70 million tonnes are reclaimed and reused as part of the US’s roads, roadbeds, shoulders and embankments • When RAP is reused in a new asphalt mix, the old asphalt cement is rejuvenated so that it becomes an active part of the glue that holds the pavement together, just like the old aggregate becomes part of the aggregate content of the new mix asphaltroads.org

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RAP and Other Recycled Materials – Best Practices

FHWA-SA-95-060 Conclusions “Long-term pavement performance (17 years)… show that recycled HMA that is designed and controlled during production will perform comparably to conventional HMA and can improve material properties of the existing pavement layer. Similar to poor performing conventional HMA, poor recycled HMA performance can be related to poor mix design procedures or use of control and acceptance procedures that do little to ensure the quality of the recycled HMA. Recycled HMA, which is designed and produced in a quality assurance program that verifies mix design assumptions to reasonable limits, can be expected to perform comparably to conventional HMA.”

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RAP and Other Recycled Materials – Best Practices

Warm-Mix Asphalt

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RAP and Other Recycled Materials – Best Practices

WMA and RAP: A Winning Combination • reduced material costs and less fuel usage • enhanced workability of warm-mix can facilitate using increased RAP contents, which translates into even greater cost savings • conserving natural resources and reducing the emission of greenhouse gases, the WMA/RAP combination also scores high in terms of environmental stewardship

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RAP and Other Recycled Materials – Best Practices

+ Other Materials That Can Be Recycled in HMA Recycled or Byproduct Material Blast Furnace Slag Coal Fly Ash Nonferrous Slag Quarry Byproducts Reclaimed Concrete Material Roofing Shingle Waste Scrap Tires Steel Slag Waste Glass and Ceramics

RAP and Other Recycled Materials – Best Practices

+ RAP Recycling Resource Materials

Coming in 2013

RAP and Other Recycled Materials – Best Practices

+ RAP Recycling Resource Materials

RAP and Other Recycled Materials – Best Practices

+ RAP Recycling Resource Materials

RAP and Other Recycled Materials – Best Practices

+ RAP Recycling Resource Materials

RAP and Other Recycled Materials – Best Practices

Thank You Please contact Michael MacKay at LVM with any questions! 416-213-1060

[email protected]

www.lvm.ca

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