Presentation on CIR delivered by Jim Emerson of PRS at the California Asphalt Pavement Association Spring Conference April 25, 2013 in Ontario, CA.

1. “Sustainable Pavement Development”
Utilizing Reclaimed Asphalt Pavement
(RAP)
James W. Emerson, APM
Pavement Recycling Systems, Inc.
California Asphalt Pavement Association
Spring Conference 2013

2. JOHN F. KENNEDY
“It’s not the wealth of a nation that builds roads,
but the roads that build the wealth of a nation”

3. Today’s “Tax Payer Friendly” Topics
 Asphalt Recycling and Climate Reduction
 Engineered Approach, Mix Design
 Cold In-place Recycling (CIR)
 Cold Central Plant Recycling (CCPR)
 Hot In-place Recycling (HIR)
 Other Sustainable Solutions With RAP
 Summery and Questions

5. Our Nations Roadways
 Federal Roadways = 3%
 State Roadways = 20%
 Local Roadways = 77%
Two Thirds are Paved (One Third Unpaved)
94% of Paved Roads have an asphalt surface

6. FHWA Policy Since 2002
 Recycled/Reuse materials are viable resources
 Recycled materials should get first consideration
 Consider use of recycled materials early in
planning/design process
 Restricting the use of materials should be
technically based
 Material should not adversely impact the
environment and should perform as intended

7. Recycling Asphalt
 Asphalt is the # 1 recycled product in the world yet,
only three percent of our roads are recycled in-place.
 It is proven that in-place recycling can save up to 50%
in costs and reduce construction time.
 CIR, CCPR and HIR are recognized pavement
preservation techniques and are tried and proven.
 Nevada Department of Transportation (NDOT) has
saved over 600 million utilizing in-place recycling.
 In 2013 Green book and Caltrans up the RAP percent
for HMA to 20%. In 2014 the percent of RAP will go up
to 25%.

8. SB-375 and AB-32
 Requires Green House Reductions back to the
levels of 1990 by the year 2020
 The Air Resource Board “cap-and-trade”
program includes an enforceable emissions cap.
The State will distribute allowances, which are
tradable permits, equal to the emissions allowed
under the cap. Sources under the cap will need
to surrender allowances and offsets equal to
their emissions at the end of each compliance
period.
 The use of low green house gas technology can
be used to off set their emissions.

9. Recycling In-Place Saves Material
Resources, Money and Energy
 Re-using existing asset’s
instead of replacing or
discarding
 Reduces import-export
from 83 truckloads
(mill and fill) to two
 Fewer emissions, less
traffic,small carbon footprint
 Structural value and long
life: resists reflective and
thermal cracking
Recycling is “Green”

10. Each lane mile of roadway on which
CIR is used instead of traditional Hot
Mix Asphalt saves approximately
130,704 lbs of Green House Gas
emissions, which is equivalent to
taking 11 cars off the road for one
year.
Asphalt Recycling Such as Cold In-place
Recycling for Climate Reductions

11. When to Utilize
Asphalt Recycling
 Anywhere mill and fill is
considered
 Adequate existing pavement
thickness
 2 to 4 inches in thickness.
 Thick enough to take to stable base or
leave 1” of existing pavement over native
soils.
 Will handle all cracking distress
provided not sub-grade or base
related
 Where surface maintenance is no
longer effective
 Where safety is a concern
 When life cycle costs dictate
 When you need to stretch your
budget

12. Where to Utilize Asphalt
Recycling?
City Streets
Airports
Virtually No Traffic
Limitations
Highways

13. Fatigue Cracking
Thermal Cracking
Dry, Raveled
Patched
Poor Rideability
Type’s of Asphalt to Recycle

14. Engineered Approach, Mix Design
On all Recycling Projects
 Prior to bidding the project.
 Check existing pavement for adequate thickness
 Check for stable subgrade
 Check for fabric and pavement type.
 Part of the contract is to core pavement to obtain samples for
mix design using a systematic engineered system.
 Optimizes the percentage and type of engineered recycling
agent unless agency specifies asphalt foam. For asphalt foam
the optimum percent asphalt is determined in a mix design
 Determine the need for, percentage of and type of recycling
additive at the mix design.

15. Mix Design Process
 Defined sampling procedure, cores taken
from various locations. Core samples sent
to independent AASHTO approved lab.

16. Lab RAP Analysis
 Lab
 Field cores crushed to
specific gradation bands
 A design made for 2 of the
gradations
 Field
 Field gradation
depends upon
multitude of factors:
milling, weather, etc.
 Gradation compared
to lab tested band
 Recycling agent
percentage based on
applicable gradation
-
10
20
30
40
50
60
70
80
90
100
Sieve Sizes
%Passing
RAP-
medium gradation
RAP- fine gradation
1 in.3/8 in.No. 30
RAP - coarse gradation

17. Field
Density Compaction Effort
Superpave Gyratory Compactor or Marshal
Compactor
Lab

18. Cold In-place Recycling (CIR)
Distressed Pavement = New Pavement Using A
Train of Equipment that:
 Mills deteriorated pavement
 Reclaimed asphalt pavement (RAP)
 Crushes RAP to gradation
 Mixes with recycling agent
 Re-Paves recycled mix
 Compacts to specified density
 Readies for surface treatment
 Small carbon footprint
Blythe Airport

19. Cold In-place Recycling (CIR)
Preservation or Minor Rehabilitation
6” Stable Base
Native Soil
4” Distressed AC
Recycled AC
>1”
Recycle AC to:
• Stable Base
•Within 1” of less
Supportive Material

20. Asphalt Recycling Train
Full Lane Mill
Recycling Unit
Recycling Additive

21. 100% Closed Circuit System.
Crushing and sizing
equipment capable of
reducing RAP to the
100% passing 1-inch
sieve prior to mixing
and weighing millings
with engineered
recycling agent.

22. Pick Up and Installation
Caltrans State Route 33
Recycled Asphalt Surface

23. Compaction
25 Ton RTR
12-15 ton steel

24. Testing and Quality Assurance
City of Palm Desert
100% Recycled Asphalt

25. Quick Opening to Traffic
 Rolling is completed
 Some cure time, fast return to traffic
 Fog-seal and sand blotter are applied

26. Before and After Pictures Recent CIR Projects
Ramona Expressway
State Route 36

27. New Recycled Surface

28. Los Angeles County
Angeles Forest Highway Winner
2012 Road & Bridges Magazine
National Award for CIR

30. City of Beverly Hills
2010 CIR Project of the year
Roads & Bridges
Magazine

31. to Pavement
Cold Central Plant Recycling (CCPR)
From RAP
Clean Rap = New Pavement:
 Stockpiled and kept clean
 Crushed RAP to gradation
 Mixed with engineered emulsion or
foamed asphalt
 In a central plant
 Transported to lay down area
 Paved as a recycled mix
 Compacted to specified density
 Readied for surface treatment

32. “Urban Quarries”
Recycle Sustainable Assets on Site!
“Urban Quarries”
Recycle Asphalt Assets on Site!
Value Engineered

34. Project Profile; 500,000 Square Feet
“Energy and Cost Savings”
 8,744 tons of asphalt removed and repaved.
 840 fewer trucks used utilizing CIR,
compared to a mill and fill operation.
 1,649 fewer barrels of oil used.
 79.6% fewer carbon emissions utilizing CIR
compared to mill and fill operation.
 Cost savings to the City $262,320.00.
 Cut 30% off the project schedule.

35. Nevada Department of
Transportation (NDOT)
 Cold In-place Recycled (CIR) over 1800
miles of roadways.
 Most projects are on state highways.
 Utilized CIR for over 25 years
 NDOT has re-recycled over 75 miles of
roadways that got over 22 years of
performance
 CIR is sustainable pavement development

36. Specified CIR and CCPR Federal Highway Administration
 Federal Aviation Administration
 National Park Service
 Arizona Dept. of Transportation
 California Dept. of Transportation
 Nevada Dept. of Transportation
 County of Contra Costa
 County of Los Angeles
 County of Riverside
 County of San Diego
 County of San Bernardino
 County of San Luis Obispo
 County of Sonoma
 City of Agoura Hills
 City of Anaheim
 City of Atascadero
 City of Beverly Hills
 City of California City
 City of Chino
 City of Hanford
 City of Highland
 City of Lancaster
 City of Modesto
 City of Lemon Grove
 City of Moreno Valley
 City of Palm Desert
 City of Porterville
 City of Monterey
 City of Napa
 City of Rancho Mirage
 City of Sacramento
 City of Santa Ana
 City of San Diego
 City of San Jacinto
 City of South San Francisco
 City of Shafter
 City of Susanville
 County of Tulare
 City of Vernon

37. Hot In-Place Recycling – Preservation
or Minor Rehabilitation
Distressed Pavement = New Pavement
Using A Train of Equipment that:
 Heats RAP and Existing Binder
 Scarifies and/or Mills deteriorated pavement
 Adds Aggregate or Virgin Hot Mix AC
 Mixes with rejuvenating agent
 Re-Paves recycled mix
 Compacts to specified density
Not Used Much In CA

38. Heater
Scarifier
HIR – Surface Recycling 0.5 to 1”

39. Surface Recycling — Scarifiers

40. Hot In-place Recycling (Remix Method)
1” to 2”
xx

41. Heaters / Grinders

42. Picked Up and Paved

43.
Longer Train and Some Environmental Issues

44. Check with AQMD

45. Sustainable Solutions With RAP
 Process Reclaimed Asphalt Pavement (RAP)
 RAP Chips for Chip seals, Cape seals
 RAP Slurry Type II (stays black longer)
 RAP Micro Surface (fast cure time, night work)
 Renew Asphalt (Cold Central Plant Recycling)
 Cold Mix
 Dust Control
 Shoulder Backing
 Base (Caltrans Route 46) Processed in Place,
Met Class II Gradation Requirements.

46. Caltrans District 8 RAP ProductsCaltrans Interstate 10 near Desert Center

47. RAP Scrub Seals Caltrans

48. I-10 Freeway Desert Center RAP Cape Seal

49. RAP Slurry

50. RAP Slurry Black Aggregate

51. RAP Slurry compared to Conventional, City of La Mirada,
California. Side by Side – One Year later, RAP is still black!
RAP Slurry Conventional Slurry

52. Summary - Benefits of Recycling and
Reclamation
 Shorter Construction Periods with Reduction in User Delays
 Improved Pavement and Structural Section Properties
 Mitigates Reflective Cracking
 20 Plus Years Performance Expectations
 Cost Savings Over Traditional Rehabilitation Methods
 Sustainable Development “.... Development that meets the needs of the
present without compromising the ability of future generations to meet their
own needs.”
 Reduces the consumption of natural resources
 Reduce energy consumption
 Reduces truck traffic
 Reduce greenhouse gas emissions, pollution

53. Questions?
Contact Information:
James W. Emerson, APM
Pavement Recycling Systems Inc.
(951) 232-6881
JEmerson@pavementrecycling.com