1. Advanced Technologies to
Reclaim roadways
APWA Annual Meeting
Tampa, FL
April 5th, 2012

2. . Contents:
.Eurovia Cold recycling technologies;
.Recyflex’s ®, in‐plant processing:
.Formulation specifications
.Production, laying and compaction operations
.Rheological performances
.VLE roadway concept
.Recyvia ®, in‐place (FDR)
.Recyclovia ®, in‐place (CIR)
.Recycled cold treated materials behavior;
.Environmentals analysis;

3. . Recyflex’s specifications:
.Strengthening base layer: AEC 25, AEC 20
.Composite binder
.Asphalt emulsion
.Cement or lime
.Dense gradation
.Drainage / Frost protection layer: HD 25
.Composite binder
.High air voids produce by special gradation
..Intermediate layer: AEC 12.5
..Composite binder and dense gradation

4. Recyflex AEC
Strengthening course materials
RECYFLEX AEC : Cold‐in‐plant treated
recycled materials by using
composite binder

5. Recyflex AEC Base Material
 In‐plant cold retreated material
 Mineral aggregate using 50 to 100% of recycling material (from existing pavement structure)
 Asphalt emulsion and cement/ lime treatment
 Highly improve bearing capacity instead of regular granular material
 Indirect tensile Resilient Modulus at 10°C > 4 000 MPa
 Density of 2 100 kg/m³ (air voids of 12‐15%)

6. Recyflex HD
 High drainability material
 Mineral aggregate using 30 to 50% of recycling material (from existing pavement structure)
 Low density = Air void insulation, 1 800 kg/m³
 Porous material = air voids ± 30%
 Asphalt emulsion and cement/lime treatment
 Frost penetration reduction

7. RECYFLEX AEC 0/20 mm
Production by using
portable plant

8. RECYFLEX AEC 0/20 mm, Thickness application of 100 @ 300 mm

9. RECYFLEX AEC 0/20 mm, Grading/ Compaction operations
Final aspect during the cure period

10. Recyflex AEC Protection and Paving
Application of tack coat emulsion
Chipping application

11. RECYFLEX AEC, A‐20 Mix Rheological performances
 Formulation: Proportions established from the
 40% of Crushed concrete; rehabilitation existing roadway
 40% of Rap (optimization of the recycled
 20% of new aggregates screenings quantities)
 Composite binders: Asphalt emulsion + cement
 Physical and Rheologicals Characterization of:
 Voids and densities;
 Cohesion built‐up behavior;
 Rutting resistance;
 Modulus evolution vs curing time;
 Effects of Freeze and thaw cycles on the mechanical performances;
 Tensile stress vs low temperture.

12. Laboratory samples preparation by Vibrocompression method
Piston : axial force
Vibration Molds
Diameter = 16 cm , High
= 32 cm
Voids average 16.5%
Gammadensitometer

13. 100
Visual Voids analysis 90
80
70
psa t -
with ultraviolets
% a s nd
60
50
40
30
20
10
0
0.01 0.10 1.00 10.00 100.00
Tamis (mm)
Air voids
RAP
Crushed Concrete

14. Physical Characteristics Emulsion treated base
material (Grave‐Émulsion)
 Rheologicals Characteristics study 2001
 French Gyratory compactor
 Voids at 10 gyrations = 21.2%  22%
 Voids at 200 gyrations = 13.0%  15%
 Duriez
 Resistance before immersion = 6.4 Mpa  4Mpa
 r/R ratio = 0.68  0.55
 Duriez voids = 11.7%  13%

15. Rheological Characteristics Rutting resistance spec. on
HMA < 10% after 30 000
 Rutting test analysis cycles at 60°C
 Rutting
 Only 0.7% after100 000 cycles at 60°C, Exceptional performance
Material without rutting
due to the internal
aggregates friction and
the presence of
hydraulic binder
Rutting test machine

16.  Cohesion Built‐up behavior
Time
600
Emulsion mix
500
Force (N)
Force, kN
400
Workability of ± 3 hours
300
200 Recyflex AEC
100
0
0 30 60 90 120 150 180 210 240
Time, min.
Temps de conservation (minutes)

17. Rheologicals behavior study
 Stiffness Modulus analysis
 Diametral Sinusoïdal Compression ‐DSC
 Bresilian test :
 Rupture limit establishement = 8800 N
 DSC strenght at 20% of the rupture limit
 DSC testing at 1.00 kN  0.75 kN corresponding of maximale compression of 1750 N

18. Modulus evolution with CDS
9000
curve at 10°C
900 Mpa
8000 or +11,5%
Modulus at 10 Hz (MPa)
curve at 15°C
7000
6000
Effect of the hydraulic binder
5000
4000
0 7 14 21 28 35 42 49 56 63 70 77 84 91
Time from production (days)

19. Rheologicals behavior study
 Freeze and thaw cycles effects
 Diametral Sinusoïdal Compression –DSC
 Two types of simulation
 Short term freeze‐thaw : 2 cycles of 24 hours produced between the 4th and
52th hours of curing, each cycle corresponding to a:
 temperature drop of +5°C to ‐10°C in 12 hours
 temperature gain of ‐10°C to +5°C in 12 hours
 Long term freeze‐thaw : 50 freeze‐thaw cycles after optimun cohesion, each
cycle corresponding to a:
 Temperature drop of +10°C to ‐20°C in less 3 hours
 Temperature gain of ‐20°C to +10°C in less 3 hours

20. Effect freeze‐thaw cycles, short term
 Modulus measurements
 Diametral Sinusoïdal Compression ‐DSC
 Freeze‐thaw at beginning  Modulus evolution at 10 Hz
9000 9000 Air curing
Modulus at 15°c, MPa
Modulus at 10°c, MPa
8000 Air curing 8000 - 11.5%
- 9.4% 7000
7000
Freeze-thaw
6000 Freeze-thaw 6000
- 22.8%
- 23.5% 5000
5000
4000 4000
0 10 20 30 40 50 60 70 80 90 0 10 20 30 40 50 60 70 80 90
Temps depuis fabrication (jours) Temps depuis fabrication (jours)
Time, hours Time, hours

21. Effect freeze‐thaw cycles, short term
 Modulus measurements
 Diametral Sinusoïdal Compression –DSC
 Short term freeze‐thaw during beginning of curing
 Freeze‐thaw between the 4th and 52th hours of curing
 Slowing down cement hydratation phenomenon at the beginning with small
effect on long term
 Delayed internal cohesion
 Modulus loss of about 23% at 10 days
 Long term modulus loss of about 10% (> 90 days)
 Validated value after 365days

22. Effect freeze‐thaw cycles, long term
 Modulus measurements
 Diametral Sinusoïdal Compression –DSC
 Long term freeze‐thaw cycles
 Freeze‐thaw (50 cycles) between 24d et 36d
 Modulus loss of 20% immediatly after the thermal sollicitations
 Modulus recovery « normal » at long term

23. Effect of 50 freeze‐thaw cycles, long term
9000
curve at 15°C
without freeze-
8000 thaw
Modulus at 10 Hz (MPa)
24 days
7000 - 20%
6000 37days
50 freeze-thaw
5000 cycles
4000
10 100 1000
Time from production (days)

24. Rheologicals behavior study
 Thermal stress, Contraints development
5.0
Tensile strain, MPa
4.0 HM A wit h 70
Contrainte
(Mpa)df
/100 bit umen
3.0
2.0
RECYFLEX
1.0
EBC
0.0
-35 -30 -25 -20 -15 -10 -5 0 5
Température (°C)
Temperature, °C

25. Recyflex AEC Observations
 Process for optimun use of recyclable materials;
 Cold treatment using composite binder
 Strenghtened materials
 Low emissions production
 Accelarated curing time
 No rutting
 Avoid maniability over 3 hours

26. Recyflex AEC Observations
 Behavior between flexible and rigid pavements
 DSC Modulus
 E (15°C,10Hz) = 7600 Mpa
 Optimum around 30d‐60d
 Definitive loss of 10% in case of freeze‐thaw in the firsts hours of
cure
 Temporary loss of 20% after freeze‐thaw if Recyflex AEC have
obtained the optimal cure
 Low contrains development with thermal reduction
 Fatigue analysis to complete

27. Flexibles pavement structures comparaison, A20 Highway
80 M esal : 2X 2 lanes (3450 Truks/day/direction/TL over 20 years)
Supposed Recyflex AEC Resilient Modulus = 3 000 MPa
Recyflex AEC
Chaussée Ecoroute Alternative
0 25 RUGOVIA TM
50 60 ESG-10 60 ESG-10
60 ESG-14
100 70 ESG-14 70 ESG-14 100 HMA
150 Binder
200 160 HMA-20 180 HMA-20
250
200 RECYFLEX AEC
300
350
Residual pavement structure Residual pavement structure
400
450 Residual pavement structure
500

28. Highway , Alternate pavement design
Hwy 485 Asphalt Pavement Design
Alternate 1
AASHTO Structual
Thickness (in.) Material Coefficient Value Structual total
3 S9.5D 0.44 1.32
4 I19.0D 0.44 1.76
11.5 B25.0C 0.3 3.45
0
Subgrade
7 Stabilization 0.14 0.98
Total Structual Value 7.51
Alternate 4
AASHTO Structual
Thickness (in.) Material Coefficient Value Structual total
3 S9.5D 0.44 1.32
6 I19.0D 0.44 2.64
0 B25.0C 0.3 0
8 Recyflex 0.34 2.72
Subgrade
7 Stabilization 0.14 0.98
Total Structual Value 7.66

29. Highway , Alternate pavement design

30. Recyflex AEC,
Arrival from Paris
Main Runway Montreal airport‐ 1998
Arrival from Orlando

31. Development of a new Roadway pavement structure concept by
using recycled materials
Recyflex
AEC
31

32. Recyvia, in‐Place (FDR)

33.  In‐Place full depth reclamation
Cold In place Recycling using composite binder or bitumen
emulsion /foamed bitumen

34. Example of using composite binder in‐Place
Réalisation du projet
 stabilisation
Stabilisation 175mm (16/08 au 28/08)
±56800m²

36. RECYCLOVIA®
Field of application
 CIR In‐Place Cold recycling
Existing Asphalt
6 à >15 cm.
pavement
Chip Seal 1 à 5 cm. Chip Seal 1 à 5 cm.
Granular base
Granular Base or Granular base
Treated base
Supply of aggregate for
gradation correction
RECYCLOVIA ® RECYCLOVIA ® RECYCLOVIA ®
In‐Place treatment : 6 à 15 cm In‐Place treatment :8 à 15 cm In‐Place treatment: 8 à 15 cm
Asphalt Emulsion with Asphalt Emulsion / Foam asphalt Asphalt Emulsion / Foam asphalt
Cement with Cement or hydrated lime With cement or hydrated lime
+ HMA / WMA wearing course
Microsurfacing / Chip seal / Dense Cold mix (low trafic road)

37. Recyclovia, in‐Place (CIR)
Weight empty: 47 t
Power : 800 hp 600 kW
Lenght : 15 m
Cement bin (4 t)
Paver screed, extendable Rotor for milling/recycling/mixing, with Cement spreader unit
equiped with tamper bar possible injection of:
compactor ‐ Foam asphalt
‐ Asphalt emulsion
‐ Water

38. Recyclovia

39. Recyclovia, in‐Place (CIR)

40. ‐Recycled cold treated materials behavior
‐Same mix design methodology for In‐plant, FDR and CIR;
‐Mechanical performances, Stability and Modulus;
‐Air Voids;
‐Retained Stability;
‐Observations behavior:
‐Effect of RAP content
Mix 1 Mix 2 Mix 3
Requirements 38% CC 40% CC 100% RAP
Min. 16% RAP 40% RAP
45% Aggregates 20% Aggregates
% Recovering Asphalt 0,63% 2,10% 5,38%
% Added Bitumen 1,53% 1,85% 1,0%
Marchall Stability at 7 000 @ 10 000 26 200 18 583 8 575
22.2°C (N)
Retained Stability (%) 70 84 90 93
% Coating 50 82 88 95

41. ‐Recycled cold treated materials behavior

42. Complete environmental impact analysis

43. Thanks for your attention
Janvier 2011 - page 43