Mike Marshall Wirtgen GmbH Cold Recycling / Stabilisation Cold Recycling / Stabilisation Edn: March 2011
Mike Marshall
Wirtgen GmbH
Cold Recycling / StabilisationCold Recycling / Stabilisation
Edn: March 2011
Strong brands, innovative products and applications know-how
Strong companies united under one roof
The Wirtgen groupThe Wirtgen group
Vögele America Inc.Chambersburg, USA
Ciber Ltda. Porto Alegre, Brazil
Company locations in more than 40 countries
SALES AND SERVICE COMPANIES
Largest plant for the series production of cold milling & recycling machines
Wirtgen Headquarters in WindhagenWirtgen Headquarters in Windhagen
Location: between Cologne and Frankfurt
Employees: 1,000
Assembly plant: 17,000 m²
Annual production: 1,400 machines
��Range of Recycling Equipment & World CoverageRange of Recycling Equipment & World Coverage
��Typical uses of Recyclers / StabilisersTypical uses of Recyclers / Stabilisers
��Key features & Spray SystemsKey features & Spray Systems��Key features & Spray SystemsKey features & Spray Systems
��Foamed Bitumen overview as an alternative binderFoamed Bitumen overview as an alternative binder
��Recycling Project ExamplesRecycling Project Examples
Wirtgen EquipmentWirtgen Equipment
Soil Stabilization / Cold Recycling
WS 2200/2500 WR 2000 WR 2400 WR 2500 S
2200 CR WR 4200 WM 1000 KMA 200
>>1400 Recycler/Stabilisers Worldwide
> 780 Wirtgen Foam Recyclers
Foamed Bitumen Foamed Bitumen recyclersrecyclers
Cement Stabilisation WMCement Stabilisation WM
Soil Stabilization
Stabilizing of the Stabilizing of the Subgrade and / or Subgrade and / or SubbaseSubbase
Soil Modification with Binding Agent
Binding Agent
+ =Lime / Cement
Modification and / or Stabilizing of soils
Lime-Spreader SW 10 TA / SW 16 TA
Tank capacity10 / 16,5 m³
Spreading with:2500 mm
Spreading quantity:2 – 50 l / m²
Spreading auger :manual operation
Lime and Cement Spreader SW 16 TC
Tank capacity16,5 m³
Spreading with:2460 / 3 x 820 mm
Spreading quantity:2 – 50 l / m²
3 x Cellular wheel automatic operation
Lime and Cement Spreader SW 16 MC
Tank capacity16,5 m³
Spreading with:2460 / 3 x 820 mm
Spreading quantity:2 – 50 l / m²
3 x Cellular wheel automatic operation
WS 2500WS 2500
Soil Stabilization in Germany
Soil stabilization of a new construction site, Industrial Area
WR 2500WR 2500
Soil Stabilization in Germany
Ground stabilization with Lime to a depth of 50 cm of a new highway exit
WR 2000WR 2000
Soil Stabilization in France
Soil stabilization on a high speed train to a depth of 420 mm
WR 2000WR 2000
Soil Stabilization in France
Homogeneous mixing of the lime with the heavy soil
WR 2000 (2.4 m wide cutter with no cab)WR 2000 (2.4 m wide cutter with no cab)
Soil Stabilization in Texas
Homogeneous mixing of the lime with the heavy soil
Cold Processing in situ
Construction ofConstruction ofBase layersBase layers
Cold Recycling in situ
Binding Agent
+ =emulsion water
foamed bitumen water
cement wateremulsion
watercement foamed bitumen
watercement
Bound granularbase course
Asphalt coursewith Granular base
Milled material
Binding Agent
Cold Processing in situ
Bound granularbase course
+ =Unbound granular material
Cement Water
WR 2400WR 2400WR 2000WR 2000 WR 2500WR 2500
Full Depth RecyclingFull Depth Recycling
Stabilizer / RecyclerStabilizer / Recycler
Working width: 8ft 0ins
Working depth: 0 – 20ins
Engine output: 570 HP
Weight: 56,540 lbs
Working width: 6ft 7ins
Working depth: 0 – 20ins
Engine output: 422 HP
Weight: 49,060 lbs
Working width: 8ft 0ins
Working depth: 0 – 20ins
Engine output: 690 HP
Weight: 63,000 lbs
Full Depth RecyclingFull Depth Recycling
Stabilizer / RecyclerStabilizer / Recycler
WR2000 VariantWR2000 Variant
Working width:Working width: 8ft 0ins8ft 0ins
Working depth:Working depth: 0 0 –– 20 ins20 ins
Engine output:Engine output: 422 HP422 HP
Weight:Weight: 48,690 48,690 lbslbs
WM 1000
Cement slurry mixer
165 kW / 225 PSPower station
2,900 gal
Weighing auger for accurate cement dosage
Schematic of the mobile cement slurry mixer
2,900 galWater tank
25 cu ydCement tank
260 gal/minSlurry mixer
Pumps for cement slurrySlurry to Recycler via a flexible hose
Twin-shaft mixer:200 t / h
KMA 220KMA 220
Mobile Cold Recycling Mixing Plant
Aggregate Hopper:2 x 6 cu yd
Transport weight:30 t
Power Output:131 kW / 178 PS
Transport:44ft x 8ft x 13ft
Cold Recycling in situ
UpperUpperPavement Pavement LayersLayers
Typical Pavement for Cold Recycling
Cold in situ Recycling: The Process
Milling and Pulverising
Binding agent dosage
Animation of the cold recycling process
Binding agent dosage
Mixing
Compaction
Wearing course overlay
Cold Recycling in situ – typically 4” – 6” USA
Binding Agent
+ =emulsion water
foamed bitumen water
cement wateremulsion
watercement foamed bitumen
watercement
Bound granularcourse
Asphalt course
Milled material
Cold Recycler2200 CR
Cold Recycler WR4200Cold Recycler WR4200
Cold In Place RecyclingCold In Place Recycling
2200CR / 3800CR / WR42002200CR / 3800CR / WR4200
Cold Recycler3800CR
Working Width:7ft 2 ½ insRecycling Depth:8 ins
Power Output:671 kW / 900 HP
Operating Weight:49.7 t
Operating Wieght:approx. 75 t
Power Output:2 x (470 kW / 640 HP)
Recycling Depth:8 ins
Working Width:10ft 0ins – 13ft 9ins
Working width12ft 6ins
Recycling Depth6 insPower Output:671kW / 900 HP
Operating Weight:58 t
��Range of Recycling Equipment & World CoverageRange of Recycling Equipment & World Coverage
��Typical uses of Recyclers / StabilisersTypical uses of Recyclers / Stabilisers
��Key features & Spray SystemsKey features & Spray Systems��Key features & Spray SystemsKey features & Spray Systems
��Foamed Bitumen overview as an alternative binderFoamed Bitumen overview as an alternative binder
��Recycling Project ExamplesRecycling Project Examples
The cutter
WR2000 158 teethWR2000 158 teeth
WR2400 178 teethWR2400 178 teeth
WR2500S 224 teethWR2500S 224 teeth
Changeable Toolholders HT 11
Lower part welded onto the drumUpper part exchangeable
Variable volume mixing chamberVariable volume mixing chamber
The rThe recycling ecycling pprocess, uniformrocess, uniformdispersion of binder across full widthdispersion of binder across full width
Double Spray SystemDouble Spray System
��Range of Recycling Equipment & World CoverageRange of Recycling Equipment & World Coverage
��Typical uses of Recyclers Typical uses of Recyclers \\ StabilisersStabilisers
��Key features & Spray SystemsKey features & Spray Systems��Key features & Spray SystemsKey features & Spray Systems
��Foamed Bitumen overview as an alternative binderFoamed Bitumen overview as an alternative binder
��Recycling Project ExamplesRecycling Project Examples
Heated bitumen systemHeated bitumen system
During stops the system is kept at operating temper ature, e.g. waiting for bitumen, cement and water tankers
No cleaning or flushing of the bitumen lines requir ed at the end of the day‘s operation.
Cold in situ recycling Foamed Bitumen
Hot Bitumen
Water Air
The larger surface area allows the mixingof bitumen with cold and damp aggregate
Foamed Bitumen
Consistent Foamed Bitumen Quality
��Range of Recycling Equipment & World CoverageRange of Recycling Equipment & World Coverage
��Typical uses of Recyclers Typical uses of Recyclers \\ StabilisersStabilisers
��Key features & Spray SystemsKey features & Spray Systems��Key features & Spray SystemsKey features & Spray Systems
��Foamed Bitumen overview as an alternative binderFoamed Bitumen overview as an alternative binder
��Recycling Project ExamplesRecycling Project Examples
WR 2500 S
Stabilizer / Recycler
Micro processor controlled pump for addition of water
Cement StabilisationCement Stabilisation
Schematic of the working method
Milling and mixing chamber
Cement pre-spread
Traditional Spreading Method
Inaccurate and difficult to mix
Traditional Spreading MethodInaccurate and difficult to mix
Traditional Spreading MethodInaccurate and difficult to mix
18 % CEMENT
Cement Spreading Alaska, prior to Stabilisation process, inaccurate & wasteful
Cement Spreading Maine, prior to Stabilisation
process, inaccurate & wasteful
Cement Spreading Iowa, prior to Stabilisation
process, inaccurate & wasteful
Cement spreading Edmonton Canada prior to stabilisation, windblown inaccurate, wasteful
Cement spreading Edmonton Canada, windblown cement hazard to traffic
WM 1000
Cement slurry mixer
165 kW / 225 PSPower station
2,900 gal
Weighing auger for accurate cement dosage
Schematic of the mobile cement slurry mixer
2,900 galWater tank
25 cu ydCement tank
260 gal/minSlurry mixer
Pumps for cement slurrySlurry to Recycler via a flexible hose
Injection of cement slurry into stabiliser mixing drum to achieve uniform dispersion in mix, to meet design criteria
Accurate, quality mix with no waste..
On board microprocessors provide total control of moisture content at all times
Speed: 6.2m / min
Water: 5.3%Water: 5.3%
Cement: 5.8%
Depth: 300mm
Width: 2.9m
Density: 1900kgs
Wirtgen WR2500S / WM1000 Slurry MixerCement Stabilisation
Cement stabilisation using latest technology:
- Accurate
- No waste- No waste
- Uniform dispersion
-Safe
-Cost effective
-QUALITY
Wirtgen WR2500S / WM1000 Slurry Mixer
Cement Stabilisation
12ins stabilisation depth with 5.8%
cement slurry
12” stabilisation depth with 5.8% cement slurry
Stabilised layer cut to level after compaction
Cold Processing in situ
Project Examples FDRProject Examples FDR
WR2000 WR2400 WR2500SWR2000 WR2400 WR2500S
Construction ofConstruction ofBase layersBase layers
Working Width:6ft 7ins
WR 2000WR 2000
Stabilizer / Recycler
Working Depth:0 – 20ins
Power Output:422 HP
Operating Weight:ca. 49,060 lbs
WR2000 Recycling Project
Example
Project example
WR2000 Job Application
Up to 5” Asphalt over crushed limestone base
WR2000 Job Application
Recycling depth 6”
2.5% foamed bitumen2.5% foamed bitumen
WR2000 Job Application
Average working speed 35ft/min
WR2000 Job Application
WR2000 Job Application
Traffic Lane Recycling Lane
WR2000 Job Application
Initial CompactionInitial Compaction
HAMM 3412P
WR2000 Job Application
After cutting levels
Final Compaction
HAMM 3412 V/O
WR2000 Job Application
Surface Finish
HAMM GRW15
WR2000 Job Application
Immediately open recycled lane to traffic
WR2000 Job Application
Working Width:8ft 0ins
WR 2400WR 2400
Stabilizer / Recycler
Working Depth:0 – 20ins
Power Output:570 HP
Operating Weight:ca. 55,540 lbs
WR2400 Recycling Project
Example
Project example
WR2400 Job ApplicationWR2400 Job Application
2” to 3” Asphalt2” to 3” Asphalt
Up to 10” binder courseUp to 10” binder course
ClayClay
WR2400 Job ApplicationWR2400 Job Application
Recycling depth: 7”Recycling depth: 7”
2.8% Foamed Bitumen2.8% Foamed Bitumen
2% stone dust2% stone dust
1% cement1% cement
WR2400 Job ApplicationWR2400 Job Application
Initial compaction Hamm 3516 Pad Foot rollerInitial compaction Hamm 3516 Pad Foot roller
WR2400 Job ApplicationWR2400 Job Application
WR2400 Job ApplicationWR2400 Job Application
Hamm 3410Hamm 3410
Steel DrumSteel Drum
Hamm 3516Hamm 3516
Pad FootPad Foot
WR2400 Job ApplicationWR2400 Job Application
WR2400 Job ApplicationWR2400 Job Application
Finished recycled Finished recycled base covered with base covered with fog seal prior to fog seal prior to overlay with 1 ¾” overlay with 1 ¾” asphaltasphaltasphaltasphalt
WR2400 Recycling Project
Example Cement, Lime & Foamed Bitumen
Project Example
Cement, Lime & Foamed Bitumen
Point Lisas Industrial Port ProjectPoint Lisas Industrial Port Project
Identify Areas of extreme base failure
Cement, Lime & Foamed Bitumen Area
Cement & Foamed Cement & Foamed Bitumen Area
Cement, Lime & Foamed Bitumen Area
Pre Milling Operation
Pre mill area to required depth
Retain millings on site for later use
Spread cement at required design rate of 1% by mass
Spread Lime at required design rate of 1% by mass on top of cement
Stabilise to a depth of 10 ins
Full depth compaction using vibratory pad foot rollers
Finish Compact with vibratory steel drum roller
Re – instate millings from stockpile over 10 ins cement & lime stabilised base
Foam Stabilise 7 inswith 2.5% foamed bitumen & 1 % cement
2 ins Asphalt
3 / 4ins Leveliing Course
Finished Pavement Stabilised Section
Foam Stabilised base 7 ins with 2.5% foamed bitumen & 1 % cement
Working Width:8ft 0ins
WR 2500 SWR 2500 S
Stabilizer / Recycler
Working Depth:0 – 20 ins
Power Output:690 HP
Operating Weight:ca. 63,000 lbs
WR2500 Recycling Project
Example
Project example
Highway 20 Colusa California
Typical condition of pavement prior to Foam Recycling
2001 Traffic, > 5000 vpd, 20% Heavy Trucks
Highway 20 Colusa California
Highway 20, State of California
20 lane miles reconstructed & repaved in 20 days
Highway 20 Colusa California
2 x Wirtgen WR2500s working in echelon
Recycling depth 9ins
Highway 20 Colusa California
14% Super Elevation
Highway 20 Colusa California
The Foam Recycled material is compacted with pad foot rollers, shaped with a motor grader and finish compacted with a steel drum
vibratory roller.
Recycling Results
Construction July 2001 April 2004
Estimated Traffic:
Construction 2001 to
Recycling Results
April 2004
4,350,000 vehicles
(20% truck traffic)
Estimated Traffic:
Construction 2001
Recycling Results
Construction 2001
August 2006
6,750,000 vehicles(20% truck traffic)
Estimated Traffic:
Construction 2001
Recycling Results 2008
Construction 2001
July 2008
10,080,000 vehicles(20% truck traffic)
Recycling Results
June 2000 April 2004
Recycling Results
August 2006 – 5 years after construction
Recycling Results 2008
July 2008 – 7 years after construction
Recycling Results
Construction July 2001 April 2004
Recycling Results
August 2006 – 5 years after construction
Recycling Results 2008
July 2008 – 7 years after construction
California Dept Transportation
Highway 20 Report
Conclusions:
�After 5 years the project is performing better than expected
�Other projects that have been constructed utilizing conventional methods typically have remedial work done at the 3 year point.the 3 year point.
�To date no maintenance activities have been performed on the Highway 20 rehabilitated pavement
�Detailed investigations by the Marysville Materials staff in July 2006 showed no signs of thermal cracking, or other distressed areas.
California Dept TransportationHighway 20 Report
“This project should be considered a success for the following reasons”
�It has exceeded its design life and is performing very well
�During the design life, no maintenance activities have been required
�The roadway was rebuilt in place with minimal impacts to traffic
�The roadway was rebuilt in less than one season, conventional methods would have required multiple seasons
�The reclamation process utilizes fewer ingress/egress of construction vehicles, making it safer for works and the public
�100% of existing roadbed material was recycled,
�The project was accomplished for approximately the same cost as a grind and place of 80mm of HMA.
Information supplied California Dept Transportation
Cold Processing in Plant
Project Examples Base Layer ConstructionProject Examples Base Layer Construction
KMA200KMA200
Construction ofConstruction ofBase layersBase layers
emulsion water
Cold mixing plant - KMA 200 Binding agent dosage
=+
watercement
foamed bitumen water
cement wateremulsion
watercement foamed bitumen
=
Bound base layer
+
Starting aggregate- Milled Asphalt- Crushed concrete
Cementitious and/or Bituminous Binders
Twin-shaft mixer:200 t / h
KMA 220KMA 220
Mobile Cold Recycling Mixing Plant
Aggregate Hopper:2 x 6 cu yd
Transport weight:30 t
Power Output:131 kW / 178 PS
Transport:44ft x 8ft x 13ft
Material hoppers
178 HP Motorstation
Cabin in working position
Injection system for water, bitumen emulsion and foamed
bitumenCement auger
Cold mixing plant - KMA 220 Components
Loading belt
Twin shaft pugmill mixer
Transfer conveyor with scale
4500 l Water tank
All components on one low-bed trailer
Mineral aggregate (2 Hoppers)
Cementitious and/or bituminous binding agent
dosage
Loading belt
Aggregate dosage openings
Cold mixing plant - KMA 220 Material- and/or binder dosage
Binding agent dosage depends on belt scale values
Weighing by means of a belt scale
Transfer conveyor
Cold mixed material conveyed onto a stockpile or transferred into tip trucks
Mixing in a twin shaft pugmill
mixer
Cold mixing plant - KMA 220 Aggregate hoppers
Twin hoppers for the possible dosage of two different mineral aggregate sizes
Aggregate feed with a min. 135 kW Payloader
KMA 220KMA 220
Recycling in plant
Cold recycling of milled asphalt with cement and foamed bitumenKMA 200; bitumen tanker; cement silo; payloader; tip trucks
Cement siloCement silo
Cold mixing plant Cold mixing plant KMA 200KMA 200
10 t tip trucks10 t tip trucks
approx. 65 ft
approx. 65 ft
approx. 100 ftapprox. 100 ft
Cold mixing plant Cold mixing plant -- KMA 220 KMA 220 Mixing plant yardMixing plant yard
20 t Bitumen tanker20 t Bitumen tanker 5000 gal 5000 gal Water tankerWater tanker
Front end loaderFront end loader
approx. 65 ft
approx. 65 ft
Example of a mixing plant yard with min. space requirementsExample of a mixing plant yard with min. space requirements
Cold mixing plant Cold mixing plant KMA 200KMA 200
350 kW Payloader350 kW Payloader
ca. 130 ftca. 130 ft
Cold mixing plant Cold mixing plant -- KMA 220 KMA 220 Mixing plant yardMixing plant yard
30 t Bitumen tanker30 t Bitumen tanker
5000 gal5000 galWater tankerWater tanker
20 t 20 t Cement siloCement silo
15 t tip 15 t tip truckstrucks
ca. 130 ft
ca. 130 ft
Example of a mixing plant yard with ideal space requirementsExample of a mixing plant yard with ideal space requirements
Recycling RAP with Foamed Bitumen & Flyash Blend
UK
KMA200 Application UKKMA200 Application UK
++++
Pre Pre –– BlendedBlended
Coarse millings 1” minusCoarse millings 1” minus
+ PFA+ PFA
Fine Millings 0 Fine Millings 0 –– 3/8 ins3/8 ins
KMA200 Application UKKMA200 Application UK
Blended material & Fine Millings Blended material & Fine Millings loaded into KMA200loaded into KMA200
Material foam stabilisedMaterial foam stabilised
3.0% Foamed bitumen3.0% Foamed bitumen
2.0% Cement2.0% Cement
KMA200 Application UKKMA200 Application UK
Foam stabilised material delivered in Foam stabilised material delivered in conventional dump truck to paver.conventional dump truck to paver.
Material to form new base in pre Material to form new base in pre milled lane.milled lane.
Foam stabilised material paved in two Foam stabilised material paved in two 4 ins lifts4 ins lifts
KMA200 Application UKKMA200 Application UK
Foam stabilised base layers Foam stabilised base layers compacted with conventional Asphalt compacted with conventional Asphalt RollerRoller
Compacted foam stabilised base, Compacted foam stabilised base, ready for;ready for;
2 3/8 ins binder course2 3/8 ins binder course
1 ½ ins wearing course1 ½ ins wearing course
Maine DoTMaine DoT
KMA200 ProjectKMA200 Project
100% Recycled RAP100% Recycled RAP
Example Recycled RAP with Foamed BitumenExample Recycled RAP with Foamed Bitumen
KMA200 set up in RAP siteKMA200 set up in RAP site
Existing RAP StockpilesExisting RAP Stockpiles
Existing RAP stockpile in Existing RAP stockpile in reasonable conditions, no reasonable conditions, no excessive “chunks” of asphaltexcessive “chunks” of asphalt
Screened RAPScreened RAPWater tankWater tank
Position KMA200Position KMA200
KMA200KMA200
Insulated asphalt tankerInsulated asphalt tanker
LoaderLoader
RAP ScreeningRAP Screening
RAP from original stockpile RAP loaded into screen hopper oversized ejected to truRAP from original stockpile RAP loaded into screen hopper oversized ejected to truckck
screened RAP stockpile screened RAP loaded into KMA200 hoppers fitted with additional scscreened RAP stockpile screened RAP loaded into KMA200 hoppers fitted with additional screensreens
Process RAP through KMA200Process RAP through KMA200
Production / Stockpiling ExampleProduction / Stockpiling Example
As an example on As an example on this project an this project an average daily average daily production rate of production rate of production rate of production rate of 1475 tons was 1475 tons was achievedachieved
Foamix RAP stockpileFoamix RAP stockpile
Laying foamix RAP ExampleLaying foamix RAP Example
Existing pavementExisting pavement
Foamix RAP overlay, Foamix RAP overlay, paver laidpaver laid
Laying foamix RAP ExampleLaying foamix RAP Example
Compaction equipmentCompaction equipment
1 x Tandem steel drum roller1 x Tandem steel drum roller
1 x Pneumatic tyred roller1 x Pneumatic tyred roller
Laying foamix RAP ExampleLaying foamix RAP Example
Following compaction the Following compaction the foamix RAP can be foamix RAP can be immediately traffickedimmediately trafficked
Foamix RAP overlay should Foamix RAP overlay should be sealed, typically hotmix be sealed, typically hotmix asphalt or chipsealasphalt or chipseal
Foam Stabilised base with 50mm HMA overlay, 1st Winter Jan 2005Foam Stabilised base with 50mm HMA overlay, 1st Winter Jan 2005Temperature at time of Photo Temperature at time of Photo –– Minus 12 deg CMinus 12 deg C
View Route 138 August 2006, after 2 freeze thaw cyclesView Route 138 August 2006, after 2 freeze thaw cyclesNo evidence of any pavement cracking or failureNo evidence of any pavement cracking or failure
Foam Stabilised Base used as base and shoulder backing to support Foam Stabilised Base used as base and shoulder backing to support HMA overlay August 2006HMA overlay August 2006
Recycling RAP with Foamed Recycling RAP with Foamed BitumenBitumen
Louisiana DOTDLouisiana DOTD
Road 190 Road 190 –– Port Allen, LouisianaPort Allen, Louisiana
Existing Pavement, 12” Existing Pavement, 12” –– 14” Asphalt over 8” Concrete14” Asphalt over 8” Concrete
Existing Pavement removed, Asphalt Milled off, Concrete Broken on siteExisting Pavement removed, Asphalt Milled off, Concrete Broken on site
Base stabilised to a depth of 12” with 9% limeBase stabilised to a depth of 12” with 9% lime
RAP Stockpile from existing pavement adjacent to projectRAP Stockpile from existing pavement adjacent to project
RAP to be Recycled with Foam Bitumen and to be used as base materialRAP to be Recycled with Foam Bitumen and to be used as base material
KMA Cold Mix Plant KMA Cold Mix Plant –– Site SetupSite Setup
Site setup to allow easy movement of trucks and loadersSite setup to allow easy movement of trucks and loaders
(Note: Water supplied via underground piping)(Note: Water supplied via underground piping)
KMA Recycling ProcessKMA Recycling Process
3. Cement, 1.5% added via weigh cell3. Cement, 1.5% added via weigh cell
4. RAP with cement added entering pug mill4. RAP with cement added entering pug mill
Recycled RAP delivered to site and loaded into Recycled RAP delivered to site and loaded into conventional paverconventional paver
Paving width 13.5 ft x 4ins liftPaving width 13.5 ft x 4ins lift
40ft wide stabilised base paved with 3 lanes of recycled RAP40ft wide stabilised base paved with 3 lanes of recycled RAP
2 lifts per lane, total thickness of recycled RAP 8”2 lifts per lane, total thickness of recycled RAP 8”
Steel drum vibratory roller used for compactionSteel drum vibratory roller used for compaction
Excellent compaction and surface finish achievedExcellent compaction and surface finish achieved
The recycled RAP surface is lightly wateredThe recycled RAP surface is lightly watered
A tight surface finish is achieved by final rolling of the moist A tight surface finish is achieved by final rolling of the moist RAP with a Pneumatic Tyred rollerRAP with a Pneumatic Tyred roller
A tight surface finish provides a smooth running surface for A tight surface finish provides a smooth running surface for site traffic as well as preventing ravelling of the surface.site traffic as well as preventing ravelling of the surface.
As an alternative to paving the recycled RAP it is possible to As an alternative to paving the recycled RAP it is possible to dump the material and spread to a nominal thickness.dump the material and spread to a nominal thickness.
Recycled RAP spread to nominal thickness with dozer blade, Recycled RAP spread to nominal thickness with dozer blade, prior to compaction.prior to compaction.
A pad foot roller is best suited for initial compaction of the A pad foot roller is best suited for initial compaction of the “dumped” material “dumped” material
Final compaction of the recycled Rap is again achieved with a Final compaction of the recycled Rap is again achieved with a steel drum vibratory rollersteel drum vibratory roller
Finished full width (40’) recycled RAP baseFinished full width (40’) recycled RAP base
The first lane (right) has fully dried back and is being used for site trafficThe first lane (right) has fully dried back and is being used for site traffic
The recycled RAP base was laid an nominal 1” over required thickness.The recycled RAP base was laid an nominal 1” over required thickness.
This allowed for a final trimming operation to establish finish grade.This allowed for a final trimming operation to establish finish grade.
The recycled RAP was “trimmed” before it had completely dried back, The recycled RAP was “trimmed” before it had completely dried back, this allowed for the trimmed material to be loaded into trucks and be this allowed for the trimmed material to be loaded into trucks and be
used as base material further up the job site.used as base material further up the job site.
Recycled RAP base after trimmingRecycled RAP base after trimming
The trimmed surface was brushed clean with a sweeperThe trimmed surface was brushed clean with a sweeper
Recycled RAP base finished to correct thickness and grade.Recycled RAP base finished to correct thickness and grade.
Surface finish of recycled RAP after trimming and sweeping operations.Surface finish of recycled RAP after trimming and sweeping operations.
Recycling RAP with Foamed Recycling RAP with Foamed BitumenBitumen
Texas DOTTexas DOT
KMA plant set up at RAP stockpileKMA plant set up at RAP stockpile
Site setupSite setup
Phase 1. Widen existing road 3ft either side using Phase 1. Widen existing road 3ft either side using recycled RAPrecycled RAP
Phase 1. Road wideningPhase 1. Road widening
Phase 2. Overlay widened Phase 2. Overlay widened roadway with Recycled RAProadway with Recycled RAP
Paver laid recycled RAP overlayPaver laid recycled RAP overlay
View finished widened road View finished widened road with Recycled RAP Overlaywith Recycled RAP Overlay
Recycled RAP surface finishRecycled RAP surface finish
Recycling RAP with Emulsion
On site
California
KMA220KMA220
Emulsion Stabilised RAP Project CaliforniaEmulsion Stabilised RAP Project California
1.1. Mill existing 30 year old Mill existing 30 year old asphalt, 10cms to 12cmsasphalt, 10cms to 12cms
2. Stockpile RAP2. Stockpile RAP
3. Run RAP through crusher with twin 3. Run RAP through crusher with twin deck screen, 25mm minus deck screen, 25mm minus
4. Feed screened RAP directly to KMA220, 4. Feed screened RAP directly to KMA220, add 3.1% emulsion, 5% water, mixing rate add 3.1% emulsion, 5% water, mixing rate 280 t/hr.280 t/hr.
Note: On overcast days add 0.5% cement to accelerate emulsion breakNote: On overcast days add 0.5% cement to accelerate emulsion break
5. Pave back recycled stabilised RAP at 5. Pave back recycled stabilised RAP at depth of 70mmdepth of 70mm
Wirtgen Model KMA220
Roller Compacted Concrete Application Sept 08
Mike Marshall Wirtgen GmbHMike Marshall Wirtgen GmbH
RCC Mix Design
�19mm aggregate 45%
�Sand 55%
�Cement / Slag 9.5 %�Cement / Slag 9.5 %
(Cement / slag pre blended 80%/20%)
�Moisture added 1.5% to 2.1%
Aggregate
Sand
With close proximity of both sand & aggregate a single loader can maintain the KMA220 charge levels
Material Loading
Agg loaded into left hand hopper
Sand loaded into right hand hopper
Aggregate / Sand Blend
Using the proportional opening on the opening on the feed gates at the bottom of the hoppers a blend ratio of 45% agg to 55% sand is achieved
Aggregate / Sand Belt Feed
Agg / Sand Agg / Sand blend carried to pug mill via feed conveyor
Cement Feed
Cement added via feed auger @ 9.5% by @ 9.5% by mass.
Cement / Slag density 1000kgs/cum
Moisture Content
Added moisture content range 1.5% to 2.1% due to variation in in-situ in in-situ moisture of the sand & agg
As can be seen the in-situ moisture varies within the stockpile
RCC Loading
RH truck loaded with 22 tonnes mixed RCC @ rate of 155 rate of 155 tonnes/hr
Switch to LH truck to allow continuous production runs
RCC Loading
Loading switch from RH truck from RH truck to LH truck by means of conveyor swing
Production Rate
For this Mix:
A consistent high quality uniform mix was achieved at 155 t/hr
Maximum was found to be 180 t/hr
Mix19mm Agg 45% / Sand 55% / Cement 9.5%
15cms RCC Lift
15cms RCC lift15cms RCC lift
Vogele
Super 2100 Paver
15cms RCC Lift
Super 2100Super 2100
Paving Speed
2.0 – 2.5 m/min
15cms RCC Lift
Super 2100Super 2100
Paving width
3.8m
Compaction
Compaction:
Ave: 89% Ave: 89% behind screed
After rolling ave 96%
Vogele AB600 2TP2 Screed
Compaction
HAMM HD120VO Compactor
16.5 cms lift
RCC
16.5cms lift x 3.8m wide
Uniformity
Lifts drying back uniformly indicating a indicating a well mixed homogeneous blend of materials
Joints
20cms RCC Lift
20cms RCC Lift
Finished RCC Section
Cold Recycling in situ
Project Examples CIRProject Examples CIR
2200CR 3800CR WR42002200CR 3800CR WR4200
UpperUpperPavement Pavement LayersLayers
Typical Pavement for Cold Recycling
Recycling Concept 2200CR / 3800CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
City Los Angeles 2200CRCity Los Angeles 2200CR
3800CR Cold In Place Recycling
Technical Specification – 3800CR
Cold Recycler 3800CR
Working width 12ft 6ins
Recycling Depth 0 – 6ins
Milling Depth Up cutting 13.75 insMilling Depth Up cutting 13.75 ins
Tool Spacing HT11 5/8 ins
Number of tools 294
Cutting Direction Up cut or down cut
Requires drum to be removed and turned
through 180 deg and fit either upcut or down cut
planetary drives
Technical Specification – 3800CR
Cold Recycler 3800CR
Engine CaterpillarEngine Caterpillar
Type C27 ATAAC
Cooling Water
No Cylinders 12
Output 708kW/950HP/963PS
Engine Speed 2100 rpm
Fuel consumption full load 49 gal/hr
Fuel consumption 2/3 load 32 gal/hr
Cold Recycler 3800 CRDouble pump for Water and Foamed Bitumen or Emulsion
WaterWater
Foam orFoam orFoam orFoam or
EmulsionEmulsion
supply of Watersupply of Water(out of 3800 CR tank)(out of 3800 CR tank)
Bitumen filter
Cold Recycler 3800 CR Foamed Bitumen or Emulsion with Waterinjection system, 2 Spray bars
Bitumen or Emulsion Bitumen pump Flow meter Test nozzle
Cold Recycler 3800 CR Foamed Bitumen or Emulsion with Waterinjection system 2 Spray bars
WaterWater
Flow meterFlow meter
Foamed BitumenFoamed Bitumen--test nozzletest nozzle
Hot Bitumen or EmulsionHot Bitumen or Emulsion
Bitumen filterBitumen filter
Cold Recycler 2200 CR Foamed Bitumen or Emulsion with Waterinjection system 2 Spray bars
Metered injection of foamed bitumen or emulsionand water via the 3800 CR
3800CR3800CR
drum for up / down cutdrum for up / down cut
Down cut mode fit down cut planetaryUp cut mode swing drum through 180 deg and fit up cut planetary
upcut 93 rpmupcut 93 rpmdowncut 104 rpmdowncut 104 rpm
upcut 73 rpmupcut 73 rpmdowncut 82 rpmdowncut 82 rpm
Bearing adaption
3800CR
Project Examples
38000CR CIR Project Example –Mason County Illinois
Project View – 35 year Pavement, 5ins to 6ins Asphalt
38000CR CIR Project Example –Mason County Illinois
Pavement highly oxidized, major cracking with localised cold mix repair areas
38000CR CIR Project Example –Mason County Illinois
Lane 1 pass 3 ½ ins depth, 2.5% Emulsion
38000CR CIR Project Example –Mason County Illinois
Lane 1 View after Recycling CIR
38000CR CIR Project Example –Mason County Illinois
Recycled Material Surface Finish / Mix
38000CR CIR Project Example –Mason County Illinois
Recycled material at Auger before screed, well mixed and well graded material
38000CR CIR Project Example –Mason County Illinois
Emulsion InletEmulsion Inlet
38000CR CIR Project Example –Mason County Illinois
Screed end plate in open position Excess material run out for shoulderbacking
38000CR CIR Project Example –Mason County Illinois
3800CR Compact Design features allow for traffic accommodation, even on narrow lane widths
38000CR CIR Project Example –Mason County Illinois
Recycling width 12ft 6ins, depth 4ins, average speed 28ft/min
38000CR CIR Project Example –Mason County Illinois
Speed 8.5 m/min (28ft/min)
Compaction water 2.6%Compaction water 2.6%
Emulsion content 2.7%
Approx 400 tons / hour
38000CR CIR Project Example –Mason County Illinois
Compaction immediately behind recycler with HAMM Model HD120 Compactor
38000CR CIR Project Example –Mason County Illinois
38000CR CIR Project Example –Mason County Illinois
CIR Project Example –3800CR Urban Recycling, Toronto
Busy 4 lane through way
Kerb & gutter
Manholes & Side drains
Centre traffic islands
Turning lanes
Traffic Accommodation
CIR Project Example –3800CR Urban Recycling, Toronto
Pre-Mill 4ins with Wirtgen Model W2100 Milling Machine
CIR Project Example –3800CR Urban Recycling, Toronto
The CIR Train comprises 2 units, Wirtgen Model 3800CR & Bitumen Tanker
CIR Project Example –3800CR Urban Recycling, Toronto
Recycle flush to Kerb as approaching Side drains
CIR Project Example –3800CR Urban Recycling, Toronto
Recycle flush with drain
CIR Project Example –3800CR Urban Recycling, Toronto
Steer recycler back to flush with kerb
CIR Project Example –3800CR Urban Recycling, Toronto
Screed end plates in closed position
CIR Project Example –3800CR Urban Recycling, Toronto
Hydraulically open screed end plate to allow sufficient recycled materialto flow around drain and fill taper both sides
CIR Project Example –3800CR Urban Recycling, Toronto
Continue recycle pass flush to kerb
CIR Project Example –3800CR Urban Recycling, Toronto
6 ins overlap at longitudinal joint
CIR Project Example –3800CR Urban Recycling, Toronto
CIR Project Example –3800CR Urban Recycling, Toronto
CIR Project Example –3800CR Urban Recycling, Toronto
Traffic Accommodation -During the recycling operation it is possible to keep the traffic flowing, in this case either side of the 3800CR as the centre pass is being made
CIR Project Example –3800CR Urban Recycling, Toronto
Average recycling speed for the project 27.5 ft/min.
This average speed at a depth of 6 ins and a width of 12.5ft equates to an hourly recycling tonnage of 610 tons per hours.
CIR Project Example –3800CR Urban Recycling, Toronto
Finished foamed bitumen recycled material at screed
CIR Project Example –3800CR Urban Recycling, Toronto
Pavement Recycled & Paved back to 2% slope, stabilized with 2.5% foamed bitumen using the 3800CR
3800CR
Project Examples
Municipal Recycling, Rte 9, Ontario
Lane width: 13ft 6ins
Std’ Cutter: 12ft 6ins
Pre-mill Centre with Pre-mill Centre with W50
Windrow millings
Speed: 26ft/min
Depth: 4ins
Foam: 1.5%
Water: 2.4%
Ave: 400 t/hr
Pave width: 13ft 6ins
Compaction:Compaction:
Hamm HD120
Hamm GRW18
Up to12,000 sq/yds to 15,000 sq/yds
Project End Cofax
Project Location
Project Examples CIRProject Examples CIRWR4200WR4200
80.8 kms (48.68 miles) Shoulder Recycling
40.4 kms (24.34 miles) Traffic lane Recycling
Project Start Bell Road
Existing pavement conditions
Typical pavement condition Eastbound Bell Road to Applegate
Existing pavement conditions
Typical pavement condition Westbound Cofax to Applegate
Traffic volumes in the project area range from:100,000 vpd in Auburn (3 lane section)
with 8.5 % trucks
Traffic Volumes
38,500 vpd in Colfax (2 lane section)with 16% trucks
1 truck per 10 seconds in Auburn1 truck per 15 seconds in Colfax
Data supplied by California Dept Transportation
Existing Pavement:150-200 mm HMA200 mm Concrete Treated
Base300 mm Aggregate Sub-base
Existing Pavement
Pavement Distress:• Block Cracking• Wheel Path Dig outs• Alligator Cracking• Potholes• Severe Oxidation• Exceeded Design Life
Why Recycle
• History of success on previous foam full depth reclamation projects (oldest is 5 years).
• Single Pass all in one Recycle Train, from milling to paving
• Trafficking in as little as 4 hours
Primary Reasons for Choosing Foam Recycling:
• Trafficking in as little as 4 hours
• Reduction in construction window traffic congestion.
• Less construction equipment on roadway.
• Fewer truck ingress/egress
• Preservation of natural resources.
• Significant potential cost savings.
–Shoulders: 60 mm recycle with
1.5 % Cement (added as slurry)
2.5% foamed bitumen
–Mainline: 100 mm recycle with
The foamed recycle design called for:
Mix Design Data
–Mainline: 100 mm recycle with
1.5% cement (added as slurry)
2.5% foamed bitumen
-Initial Seal: Application of 0.008 to 0.010
litres/sqm diluted emulsion
Recycling “train”
Recycling “Train” consists
Oil Truck + WM1000 Cement Slurry Mixer + WR4200 Recycler
WR4200 Recycler
WR4200 Recycler
2.80 m (9’ 2”) closed cutting width
WR4200 Recycler
4.2m (13’ 9”) maximum cutting width
Extension cutters
Position for foam barWorking direction
WR4200 Recycler
Centre cutterTwin shaft pug mill
WR4200 Recycler
Centre cutter with adjustable breaker bar
WR4200 Recycler
PugmillFoam recycled material
Recycling operation
Recycling Shoulder
Width, average 3.20m (10ft 6ins) x 70mm (2 ¾ins) Depth
Recycling operation
Recycling operation
Recycling operation
Extension cutters
Left hand extension cutter, cuts overlap into
Direction of work
cutter, cuts overlap into adjacent traffic lane
Extension cutters
Right hand extension cuts
Direction of work
Right hand extension cuts works flush with guard rail
Extension cutters
Recycled pavement with lane overlap and flush cut to guard rail
Extension cutters
Integral AB500TV Paving Screed
WR4200 fitted with integral Vogele
AB500Tamping & Vibrating Paving Screed
Integral AB500TV Paving Screed
Recycled pavement material immediately after paving screed
Integral AB500TV Paving Screed
A high level of compaction is achieved at the paving screed
Compaction
A flush joint between the recycled pavement and the adjacent traffic lane can be consistently achieved
Compaction
A tightly compacted surface finish is achieved using a pneumatic tyred roller
Compaction
Finish compacted recycled pavement
Cofax to Applegate example
Recycling No 1 Lane
Width, average 3.86m (12ft 8ins) x 100mm (4ins) Depth
Width includes 100mm (4ins) overlap into each adjacent lane
Cofax to Applegate example
Recycling train kept to minimum width to accommodate traffic
Finish fog seal
Full lane width fog spray seal
Finish fog seal
No 1 Lane Cofax to Applegate Recycled Pavement
after Fog Seal
Completed example sections
Bell Road Bridge
Recycled Original Recycled Recycled
Shoulder Pavement No 1 & 2 Lanes Shoulder
Fog Seal Only
No2 lane mill & fill No 1 lane recycled Inside shoulder recycled
with fog seal only with fog seal only
Completed example sections
Westbound Cofax to Applegate
October with 40mm overlay
Completed example sections
Westbound Cofax to Applegate
Recycled Recycled Mill Fill RecycledShoulder No 1 Lane No 2 lane Shoulder
Picture taken 4 hours after completion of the Recycled No 1 laneThe traffic is running on the recycled mat with a fog seal, no asphalt overlay
Note: the tracking lines are tyre tracks through the fresh sand seal
October with 40mm overlay
Completed example sections
Eastbound Applegate to Cofax
Recycled Mill & Fill Recycled Recycled
Shoulder No 2 & 3 Lanes No 1 Lane Shoulder
October 2005 with 40mm overlay
June 2007
January 2011
100,000 vpd, 8.5% trucks Caltr ans 2005 Figures
Construction 2005
Traffic Volume since Cold In Place Recycling
Photo January 2011
5.5 Years Traffic (250 days / year) 137,000,000 ve hicles
11,500,000 trucks
No Calls for Maintenance
Why Recycle
It saved:101,909 metric tons
aggregate2,545 metric tons bitumen9,200 truck trips 9,200 truck trips
@ 80 Km round trip
736,000 truck traveled Km204,000 liters of diesel fuel
7200 Kg of NOx emissions
Bitumen @ $600/ton = $ 1.5 million Diesel @ $3/ gallon = $ 161,000.00
Reference Reports
�Project Example Concrete In -Situ Recycling�Project Example Concrete In -Situ Recycling
Cold Recycling in Romania
Cracked concrete pavement with chip seal
Cold Recycling in Romania
Concrete pavement pre-milled with W 2200 to a depth of 10 ins
Cold Recycling in Romania
Granulated concrete is pre-profiled with a dozer
WR 4200 + WM 1000WR 4200 + WM 1000
Cold Recycling in Romania
Recycling of concrete granulate with foamed bitumen and cement slurry
WR 4200WR 4200
Cold Recycling in Romania
Placing the recycled material with Vögele screed AB 500 TV with tampers and vibration
WR 4200WR 4200
Cold Recycling in Romania
Lifting the concrete granulate, mixing and paving a full 12ft 6ins wide traffic lane
Cold Recycling in Romania
Recycling carried out under traffic.After final compaction the traffic is diverted on to the recycled lane.
�Project Example China Expressway�Project Example China Expressway
Cold Recycling Jinghu Expressway, Tianjing China
1.0 Remove 20 cms existing asphalt by milling
22 cm milling of asphalt in the right laneRecycled layers in the left lane open for traffic
Cold Recycling Jinghu Expressway, Tianjing China
Existing asphalt and CTB milled outSubgrade stabilized soil
Cold Recycling Jinghu Expressway, Tianjing China
Cold Recycling Jinghu Expressway, Tianjing China
Milled Asphalt recycled and stabilised with KMA200 Cold Mix Plant,
2.4% foamed bitumen & 1.5% cement
KMA 200: Mixing of milled asphalt with 2,4 % foamed bitumen and 1.5 % cement
Cold Recycling Jinghu Expressway, Tianjing China
Pave back the recycled millings onto the new stabilised base
Paving the recycled asphalt on top of the recycled base
Cold Recycling Jinghu Expressway, Tianjing China
Cold Recycling Jinghu Expressway, Tianjing China
Placing of the cold mixed material by Vögele PaverFinal compaction by Hamm Roller HD 120
Cold Recycling Jinghu Expressway, Tianjing China
Overlay with 4 cms polymer modified asphalt wearing course
Recycled layer open for traffic before overlay with asphalt
II--81 Virginia DoT Recycling Alternative81 Virginia DoT Recycling Alternative
Wirtgen Developed Project Example
ALTERNATE FOAMED BITUMEN ALTERNATE FOAMED BITUMEN STABILISED BASE PROPOSALBASE PROPOSAL
Material StructuralCoefficient
Thickness S.N
SMA 0.44 2 0.88
Material StructuralCoefficient
Thickness S.N
SMA 0.44 2 0.88
Current Design Proposed Recycling AlternativeCurrent Design Proposed Recycling Alternative
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
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
FBSB FBSB –– Foamed Bitumen Stabilised BaseFoamed Bitumen Stabilised Base
LSSB LSSB –– Lime Stabilised BaseLime Stabilised Base
Mill existing asphalt layers (Mill existing asphalt layers (±±12”) of the slow lane and slow shoulder to stockpile.12”) of the slow lane and slow shoulder to stockpile.
Spread 5% lime after millingSpread 5% lime after milling
InIn--situ recycle 12” of exposed existing pavement in the slow lane and slow shoulder, situ recycle 12” of exposed existing pavement in the slow lane and slow shoulder, whilst simultaneously stabilizing with nominal 5% lime. Shape and compact to whilst simultaneously stabilizing with nominal 5% lime. Shape and compact to
minimum 97% of modified AASHTO compaction or refusal densityminimum 97% of modified AASHTO compaction or refusal density
Stabilize the RAP material in Stabilize the RAP material in stockpilestockpile using a static foamed bitumen plant using a static foamed bitumen plant with nominal 2.2% foamed bitumen and 1% cement.with nominal 2.2% foamed bitumen and 1% cement.
KMA 220: Mixing of milled asphalt with 2,2 % foamed bitumen and 1.0 % cementKMA 220: Mixing of milled asphalt with 2,2 % foamed bitumen and 1.0 % cement
Cold Recycling Jinghu Expressway, Tianjing China
Stabilise base with foamed bitumen 3% and cement slurry 2%
-- Place 2” IMPlace 2” IM--19.0D across the full road width.19.0D across the full road width.-- Surface the mainline pavement and inside shoulder with 2” SMASurface the mainline pavement and inside shoulder with 2” SMA--12.5(7012.5(70--22)22)-- Surface the outside shoulder with 2” SMSurface the outside shoulder with 2” SM--12.5A12.5A
Recycled layer open for traffic before overlay with asphaltRecycled layer open for traffic before overlay with asphalt
�Project Example City Puebla Mexico�Project Example City Puebla Mexico
14 Oriente
Application ExampleApplication Example
Road WideningRoad WideningRoad WideningRoad Widening
Fort McMurray, AlbertaFort McMurray, Alberta
Existing (nominal) 24ft pavement to be extended to 44ftExisting (nominal) 24ft pavement to be extended to 44ft
Cut existing shoulder and vergeCut existing shoulder and verge
Compact with pad foot rollerCompact with pad foot roller
Mill existing pavement and CTB base with W2200 windrow material to new widthMill existing pavement and CTB base with W2200 windrow material to new width
Mill asphalt pavement and CTB base to depth of 10”Mill asphalt pavement and CTB base to depth of 10”
Blade windrowed millings level to width, add 6” to 8” crushed base materialBlade windrowed millings level to width, add 6” to 8” crushed base material
Spread cement at rate 1.5% across extended lane widthSpread cement at rate 1.5% across extended lane width
Stabilise extended lane with WR2500S, 2.5% foamed bitumen to depth of 11”Stabilise extended lane with WR2500S, 2.5% foamed bitumen to depth of 11”
Widened pavement out to 44ftWidened pavement out to 44ft
Recycler and Soil Stabilizer
600
800
1000
Num
ber
of
Col
d R
ecyc
ler
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
0
200
400
600
Num
ber
of
Col
d R
ecyc
ler
Year
Increasing market
** total included CIR units & plant mix units** total included CIR units & plant mix units
Gradation
Gradation Specification Requirement
100% passing 37mm
90% passing 25mm
Statistical Analysis of
Sieve size
Field results
Gradation
Analysis of Percent Passing 37mm 25mm 19mm
Mean 100 96 92
Standard deviation 0 1.69 2.68
Highest value 100 99 96
Lowest value 100 91 81
Coefficient of variation 0 1.8 2.9
2.1 Visual Assessment
The section of Avenida 14 Oriente extends from Cadete Vicente Suarez to the Municipal limit. The road starts as single carriageway and changes to dual carriageway towards the Municipal limit. The existing surface is asphalt that is severely cracked
14 Oriente Investigation / Design
existing surface is asphalt that is severely cracked and loss of surfacing is evident in many places. Areas of block cracking indicate a stabilised base layer.
The block cracks in most areas have degenerated into crocodile cracks and pumping of fines from the base is evident.
This is an indication that the base layer in these areas of pumping has reverted to its granular state .
Table 1: Summary of Asphalt Thickness
The thickness of the asphalt ranged from 9cm to 25cm. The 25cm measurement was taken close to the Municipal limit and can be considered an outlier since the
other 5 measurements and the 4 measurements from the test pits range from 9cm to 13.5cm as shown in Table 1 below. The average thickness of the asphalt can be
taken as 10cm.
Existing Asphalt
Table 1: Summary of Asphalt Thickness
Nucleo No
Thickness (cms)
Test Pit No
Thickness (cms)
1 25.0 PCA 1 10.0
2 9.0 PCA 2 10.0
3 10.5 PCA 3 9.5
4 10.0 PCA 4 9.5
5 10.2
6 13.5
Test Pits
2.3 Test PitsFour test pits were excavated during the September 2006 investigation.
The test pits allowed the pavement profile to be identified and samples of the pavement materials were tested in order to classify the pavement materials.
The base layer was found to have an average thickness of 20cm.
The only indication that this material could have been stabilised is the description of sample (muestra) 3 which reads “GRAVA CEMENTADA”. The CBR of this material ranges from 77% to 108% and only 1 sample showed any plasticity with recorded a linear shrinkage of 4.6%.
The other samples showed zero shrinkage.
3.1 Stabilisation DesignSamples of the asphalt were taken at 2 positions along the road to a depth of 10cm as this is the minimum recommended depth for cold recycling.
Foamed bitumen mix designs were undertaken to determine the application rates for foamed bitumen to achieve optimal strengths and to determine the strength characteristics for use in the structural design exercise. Foamed bitumen was added at between 2.0 and 3.0% foamed bitumen by mass of sample. The foamed bitumen stabilised samples were then compacted using “Marshall” effort and placed on an oven at 40 deg C for 3 days to cure.
Stabilisation Design
Table 2: Foamed Bitumen Mix Designs
BlendFoamed Bitumen (%)
Bulk Density
Average ITS dry
Average ITS
soaked
TSR (%)
Sample 1100% RAP
2.0 1854 335 422 > 100
2.5 1872 343 477 > 100
3.0 1865 360 470 > 100
Sample 2100% RAP
2.0 1782 260 138 53
2.5 1793 278 153 55
3.0 1799 257 162 63
The briquettes were then tested for dry and soaked Indirect Tensile Strength (ITS). A summary of the tests can be found in Table 2 below.
Table 5: Traffic calculations Northbound Southbound
Traffic count per carriageway (9 hour count) 7989 7241
Approximate 24 hour count ( 9 hour count x 1.2) 9600 8700
Average daily truck count ( 4% of total traffic) 384 348
Traffic
Average daily truck count ( 4% of total traffic) 384 348
Average daily axle count (1.7 axles per truck) 655 590
Lane distribution ( 0.9 for slow lane) 590 530
Average daily axle count per carriageway 560
Design traffic for 5 years 1.8
Design traffic for 10 years 3.9
Design traffic for 15 years 6.1
Design traffic for 20 years 8.6
Table 4: Structural Numbers with seal surfacing
Material
Structural
Coefficient (per
cm)
Depth of Recycling
10 12 15 17 20
Recycled layer 0.140 10 12 15 17 20
SN with Seal Only
Recycled layer 0.140 10 12 15 17 20
Existing base 0.055 20 18 15 13 10
Existing subbase
0.040 30 30 30 30 30
Required Structural Number
3.34 3.44 3.59 3.68 3.83
Traffic estimate (million axles)(8 ton axle load)
2.8 3.4 4.5 5.3 7.0
Traffic estimate (million axles)(10 ton axle load)
1.2 1.4 1.9 2.2 2.9
Table 3: Structural Numbers with asphalt surfacing
Material
Structural
Coefficient (per cm)
Depth of Recycling
10 12 15 17 20
Asphalt (new) 0.165 4 4 4 4 4
SN with Asphalt Overlay
Recycled layer 0.104 10 12 15 17 20
Existing base 0.055 20 18 15 13 10
Existing subbase
0.040 30 30 30 30 30
Achievable Structural Number
4.00 4.10 4.25 4.34 4.49
Traffic estimate (million axles)(8 ton axle load)
9.4 11.2 14.5 16.8 21.4
Traffic estimate (million axles)(10 ton axle load)
3.9 4.7 6.0 7.0 8.9
Diagonal Boulevard Investigation / Design
2.1 Visual Assessment
The 3.36km section of Diagonal Ave.that is to be rehabilitated is a dual-carriageway facility with three traffic lanes per carriageway. The existing surface is asphalt that is severelycracked in many places . cracked in many places .
Areas of block cracking indicate a stabilised base layer . The block cracks in most areas have degenerated into crocodile cracks and pumping of fines from the base is evident.
This is an indication that the base layer in these areas of pumping has reverted to its granular state. No rutting or deformation due to pavement failure was noted.
Existing Asphalt / Coring
Table 1: Core Thickness
Northbound Southbound
Distance (from 18 de Noviembre
Blvd)
Thickness (cm)
Base Condition
Distance (from 18 de Noviembre
Blvd)
Thickness (cm)
Base Condition
0+300 6.0 Cemented 0+300 7.0Strongly
cemented
0+600 5.5Strongly
cemented0+600 6.5
Strongly cementedcemented cemented
0+900 8.8 Cemented sand 0+900 9.5 Cemented sand
1+200 5.5 Weakly cemented 1+200 7.8 Weakly cemented
1+500 6.0 Weakly cemented 1+500 11.0 Weakly cemented
1+800 8.5 Weakly cemented 1+800 5.5Strongly
cemented
2+100 8.0Strongly
cemented2+100 10.5 Weakly cemented
2+400 10.2 Weakly cemented 2+400 10.7 Weakly cemented
2+700 12.1 Weakly cemented 2+700 10.0 Weakly cemented
3+000 10.0 Weakly cemented 3+000 13.0 Weakly cemented
3+300 10.3Strongly
cemented
Test Pits
2.3 Test Pits
Two 1m x 1m test pits were excavated to a depth of 0.8m.
Representative samples from each different layer encountered were retained for laboratory testing, including bulk samples from the asphalt and base including bulk samples from the asphalt and base layers for foamed bitumen mix designs.
The asphalt found in the test pits was dry and brittle.
The base material comprised a crushed rock in a sandy matrix. This material was previously stabilised but has reverted to its natural granular state.
The thickness of the base was 23 and 27cm.
Underlying the crushed rock material was residual silty to clayey sands.
Stabilisation Design
Table 2: Foamed Bitumen Mix Designs
BlendFoamed Bitumen
(%)
Cement (%)
Average ITS dry
Average ITS
soaked
TSR (%)
100% RAP
2.0 0 604 187 31
2.5 0 595 263 44
3.0 0 561 179 323.0 0 561 179 32
50% RAP : 50% BaseDiagonal
2.5 1 374 272 73
3.0 1 519 365 70
3.5 1 535 408 76
50% RAP : 50% Base5 de Mayo
2.5 1 646 450 70
3.0 1 638 357 56
3.5 1 629 425 68
25% RAP :75% Base
2.5 1 595 306 51
3.0 1 697 263 38
3.5 1 603 298 49
Table 3: Structural Numbers with asphalt surfacing
Material
Structural
Coefficient (per
cm)
Depth of Recycling
10 12 15 17 20
Asphalt (new) 0.165 4 4 4 4 4
SN with Asphalt Overlay
Recycled layer 0.140 10 12 15 17 20
Existing base layer
0.055 25 23 20 18 15
Required Structural Number
3.43 3.61 3.87 4.06 4.29
Traffic estimate (million axles)(8 ton axle load)
5.6 7.9 12.8 17.9 26.4
Traffic estimate (million axles)(10 ton axle load)
2.3 3.3 5.3 7.5 11.0
SN with Seal Only
Table 4: Structural Numbers with seal surfacing
Material
Structural
Coefficient (per
cm)
Depth of Recycling
10 12 15 17 20
Recycled layer 0.140 10 12 15 17 20Recycled layer 0.140 10 12 15 17 20
Existing base layer
0.055 25 23 20 18 15
Required Structural Number
2.77 2.95 3.21 3.40 3.63
Traffic estimate (million axles)(8 ton axle load)
1.4 2.1 3.6 5.3 8.3
Traffic estimate (million axles)(10 ton axle load)
0.6 0.9 1.5 2.2 3.5