Recycling of Asphalt Pavements – An Overview

By

Prithvi S. Kandhal
Associate Director
National Center for Asphalt Technology

Paper published in the Technical Journal of the Association of Asphalt Paving Technologists,
Asphalt Paving Technology, Volume 66, 1997

Abstract

This paper gives a brief overview of recycling of asphalt pavements. Five recycling methods: (1) cold planing,
(2) hot recycling, (3) hot in-place recycling, (4) cold in-place recycling, and (5) full depth reclamation, have been
presented. Strategies for selecting an appropriate recycling method have been discussed. The performance of
different recycling processes based on the review of literature has been presented: Economics,
legislation/specification limits, and structural design associated with recycling of asphalt pavements have also been
presented.

Key Words: recycling, asphalt pavements, hot recycling, cold recycling, hot in-place recycling, full depth
reclamation, economics, performance, specifications, structural design

Introduction

Use of recycled asphalt pavements has increased significantly since its inception in 1915 and revival in the mid-
1970s when Arab oil embargo caused inflation of construction costs.
Recycling of existing asphalt pavement materials to produce new pavement materials results in considerable
savings of material, money, and energy. The specific benefits of recycling can be summarized as follows:
• When properly used, recycling can result in substantial savings over the use of new materials. Also, the cost of
haulage can be avoided if recycling is performed in-place. The need for economic consideration is felt now
more than ever, because of tightening budgets and ever increasing cost of materials.
• Recycling can help in conservation of natural resources by reducing the need for new materials. This translates
to substantial savings in aggregate resources and demand for asphalt binder, especially during supply
interruptions. Even though there may be an abundant supply of aggregates, the distribution of these sources
does not always coincide with the location of need.
• Recycled materials have proven to be equal or even better than new materials in quality. An HMA overlay on
recycled base is expected to perform better than an HMA overlay on the existing surface, even though they
have the same thickness, because the former can substantially reduce the potential of reflective cracking
through the surface course.
• Recycling can maintain pavement geometrics as well as pavement thickness. The existing pavement structure
can be strengthened by recycling without adding substantial overlays. In some cases, the traffic disruption is
lesser than that for other rehabilitation techniques.
• Recycling can save a considerable amount of energy compared to conventional construction techniques. This
factor is of significant importance during an energy crisis like the one experienced during the 1972 Arab oil
embargo.

Over the years, recycling has become one of the most attractive pavement rehabilitation alternatives. With the
continuous accumulation of performance data, field and laboratory evaluations of recycled mixes, and with the

1
simultaneous development of realistic performance-oriented guidelines it is expected that recycling will continue to be
the most attractive rehabilitation technique.
Different recycling methods are now available to address specific pavement distress and structural needs.
These recycling methods will now be described briefly.

Recycling Methods and Strategies

The Asphalt Recycling and Reclaiming Association (1) defines five different types of recycling methods: (1)
Cold Planing; (2) Hot Recycling; (3) Hot In-Place Recycling; (4) Cold In-Place Recycling; and (5) Full Depth
Reclamation.

Cold planing is described as an automatic method of removing asphalt pavement to a desired depth and
restoration of the surface to a desired grade and slope and free of humps, ruts and other distresses. This method
can be used for the roughening or texturing of a pavement to improve frictional resistance. Cold planing is
performed with a self-propelled rotary drum cold planing machine with the reclaimed asphalt pavement (RAP)
transferred to trucks for removal from the job site. The resulting pavement can be used immediately by regular
traffic and overlaid at some future time or left as a textured surface. Hot recycling or hot mix recycling is the
process in which reclaimed asphalt pavement (RAP) material is combined with new materials, sometimes along
with a recycling agent, to produce hot mix asphalt (HMA) mixtures. Both batch and drum type hot mix plants are
used to produce recycled mix. The RAP material can be obtained by milling or ripping and crushing operation.
The mix placement and compaction equipment and procedures are the same as for regular HMA. Typical RAP to
new aggregate ratio varies between 10:90 and 30:70 with a maximum of 50:50 (drum plant). The advantages of
hot mix recycling include significant structural improvement, equal or better performance compared to conventional
HMA, and capability to correct most surface defects, deformation, and cracking.
Hot in-place recycling (HIPR) consists of a method in which the existing pavement is heated and softened, and
then scarified or hot rotary mixed to a specified depth. New HMA or recycling agent may be added to the RAP
material during the recycling process. HIPR can be performed either as a single pass or a multiple pass operation.
In single pass operation, the restored RAP material is combined with new material. In multiple pass operation, the
restored RAP material is recompacted first, and a new wearing surface is applied later. The depth of treatment
varies between 19 to 38 mm (¾ in. to 1½ in.). The advantages of hot in-place recycling are that surface cracks can
be eliminated, ruts and shoves and bumps can be corrected, aged asphalt is rejuvenated, aggregate gradation and
asphalt content can be modified, traffic interruption is minimal, and hauling costs are minimized.
For cold in-place recycling, the existing pavement material is reused without the application of heat. Except for
any recycling agent, no transportation of materials is usually required, and, therefore, haulage cost is very low.
Normally, an asphalt emulsion is added as a recycling agent. The process includes pulverizing the existing
pavement, sizing of the RAP, application of recycling agent, placement, and compaction. The use of a recycling
train, which consists of pulverizing, screening, crushing, and mixing units, is quite common. The processed
material is deposited in a windrow from the mixing device, where it is picked up, placed, and compacted with
conventional hot mix asphalt laydown and rolling equipment. The depth of treatment is typically from 75 to 100
mm (3 to 4 in.). The advantages of cold in-place recycling include significant structural improvement, treatment of
most pavement distress, improvement of ride quality, minimum hauling and air quality problems, and capability of
pavement widening.
Full depth reclamation has been defined as a recycling method where all of the asphalt pavement section and a
predetermined amount of underlying material is treated to produce a stabilized base course. It is basically a cold
mix recycling process in which different types of additives such as asphalt emulsions and chemical agents such as
chloride, Portland cement, fly ash, and lime, are added to obtain an improved base. The five main steps in this
process are pulverization, introduction of additive, compaction, and application of a surface or a wearing course. If
the in-place material is not sufficient to provide the desired depth of the treated base, new materials may be
imported and included in the processing. This method of recycling is normally performed to a depth of 100 to 305
mm (4 to 12 in.). The advantages of full depth reclamation are that most pavement distresses are treated, hauling
costs are minimized, significant structural improvements can be made (especially in base), material disposal
problems are eliminated, and ride quality is improved.

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 All of the different recycling techniques offer some advantages over conventional rehabilitation techniques.
However, the choice of a particular recycling method should be primarily on the basis of the type of distress shown
in the existing pavement. This is because all of the recycling methods are not equally suited for treating different
types of distress, and here the choice must be made for the particular method which is capable of rectifying the
existing distress conditions. The applicability of a particular recycling technique not only depends on the pavement
defect, but also on the extent and severity of the distress. For this reason, a comprehensive evaluation of the
existing pavement is necessary before attempting any recycling process. Once the type, extent and diversity of
distresses have been identified, candidate recycling procedures should be evaluated on the basis of their
effectiveness and cost. The following primary types of distresses have been recognized by the Asphalt Recycling
and Reclaiming Association (ARRA): (1) surface defects, (2) deformation, (3) cracking, (4) maintenance patching,
(5) base/subgrade problems, and (6) poor ride/roughness (1).

Based on these distresses, the ARRA recommends Table 1 as a guideline for selecting a recycling alternative.
This table shows that hot mix recycling (hot recycling) can be used to treat all types of distresses except problem
base or subgrade. Hot in-place recycling can be used for all but reflection cracks, maintenance patching, and
problem base or subgrade. Cold in-place recycling and full depth reclamation are capable of treating rutting,
cracks, and maintenance patches. Only full depth reclamation can be used for rectifying problem base and/or
subgrade. The use of cold in-place recycling and full depth reclamation are not shown for treating surface defects.
However, for these two methods, as well as for multiple pass method of hot in-place recycling, a new surfacing is
generally required. The type of surfacing depends on the amount and type of traffic. An asphalt surface treatment
such as a chip seal, slurry seal or cape seal may be adequate for light traffic, but a HMA overlay should be used for
heavier traffic.

Performance of Recycled Pavements

Experience gained over the years by highway agencies has shown that asphalt pavement recycling is a
technically viable rehabilitation technique. Properly designed recycled asphalt pavements have performed similar to
and in many cases better than the conventional overlays. The performance of different recycling methods is
discussed briefly here.

Performance of Hot Mix Asphalt Recycling

Hot mix asphalt recycling has been used extensively and routinely in the U.S. during the last several years. It is
no longer considered an experimental operation because recycled HMA pavements have generally performed equal
to or better than conventional HMA pavements. Therefore, very few experimental projects which have evaluated
the relative performance of recycled and conventional HMA pavements, have been reported in the literature.
Florida has been using recycled HMA since 1978. Pavements constructed by milling and replacement by
recycled HMA are reported to be performing better than pavements constructed of conventional overlay and
leveling courses. Reflective cracks have been removed successfully by full-depth milling of cracked layers.
Laboratory and in-place evaluation of recycled HMA has indicated similar or better performance compared to
conventional HMA (2).

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4
Table 1. Guide for Selection of Recycling Method. Full Depth1 or Aggregate Base Asphalt Pavements
(Continued)
1
A pavement in which asphalt mixtures are used for all courses above the subgrade or an improved subgrade having Portland cement,
lime, lime-fly ash, fly ash or calcium chloride modification.
2
Applicable if the surface course thickness does not exceed 1 ½"
3
Rutting is limited to the upper portion of the pavement structure (top 1 ½ - 2 inches).
4
Rutting originating from the lower portion of the pavement (below surface course and includes base and subgrade).
5
May be a temporary correction if entire layer affected not removed or treated by the addition of special asphalt mixtures. 6The
addition of new aggregate may be required for unstable mixes.
7
The chemical stabilization of the subgrade may be required if the soil is soft, wet.
8
Applicable if the cracking is limited to the surface course of the pavement.
9
Applicable if treatment is to a depth below the layer where the slippage is occurring.
10
Applicable if the cracking is limited to the surface course of the pavement.
11
In some instances, spray and skin patches may be removed by cold planing prior to these treatments (considered if very asphalt rich,
bleeding).
12
May be only a temporary correction if the distress related to the subgrade problem. 13Used
if depressions due to a soft, wet subgrade condition.
14
Used if the high spots caused by frost heave or swelling of an expansive subgrade soil.

An evaluation study in Georgia consisted of performance evaluation of recycled and conventional HMA surface
courses in five projects. The RAP content in these mixes ranged from 10 to 40 percent (3). Both virgin and the
recycled sections were reported to be performing satisfactorily with no significant rutting, raveling and weathering,
and fatigue cracking. The recycled sections had an average rut depth of 2 mm (0.08 in.), with no raveling or
alligator cracking, and very few transverse and longitudinal cracks. A statistical analysis revealed no significant
difference in the properties of in-service HMA mix and recovered asphalt cement, and performance of recycled and
conventional HMA test sections in these five projects (3).
A project was undertaken in Kansas to evaluate performance of hot recycled mix (4). A 30-mm (1.2-in.) HMA
conventional surface course was constructed over a 130-mm (5-in.) recycled HMA binder course, after cold milling 90
mm (3.5 in.) of the existing pavement. A control section of 100-mm (4-in.) conventional HMA overlay was also
constructed. The Kansas DOT performed crack surveys each spring and fall after construction. Both with respect
to transverse cracks and total cracks, the recycled HMA section had much better performance than the control
section.
A study (5) carried out in Louisiana to evaluate ten recycled pavements (about six to nine years old)
constructed in the late seventies reported that both recycled binder and wearing courses performed similar to
conventional pavements. The pavements, containing 20 to 50 percent RAP material, were compared to
conventional HMA pavements in terms of pavement condition, serviceability, structural analysis, and mixture and
binder properties.
The first recycled HMA project in Minnesota was constructed in 1976 on a 4-lane urban highway, in which the
original pavement was recycled and replaced with a 175-mm (6.9-in.) recycled HMA base, a 40-mm (1.6-in.)
recycled HMA binder and a 19-mm (¾-in.) surface wearing course. The recycled HMA contained 50 percent RAP
material. A control section of full-depth conventional HMA section was also placed (6). Benkelman beam
deflections taken after one year of service showed similar measurements in the test sections with recycled and
conventional HMA (7). This indicates that the structural strengths of recycled and conventional HMA are
comparable. The pavement with recycled HMA base placed in one lift had a higher average deflection than the
pavement with the recycled HMA base placed in three lifts. Visual examination and testing of cores taken in 1991
showed that the recycled mix had a service life comparable to the life of conventional HMA (7).

Performance of Hot In-place Recycling (HIPR)

Performance of HIPR pavements is generally satisfactory based on the reports by most of the states where it
has been used. It should be noted, however, that the HIPR technology and associated equipment have significantly
improved during the last several years resulting in further improvement in pavement performance. Both good and
poor performing pavements have been constructed in some states. The projects rated poor in performance have
generally been considered as bad candidates for HIPR. The performance of some HIPR pavements in Canada and

5
in New York is discussed below followed by the general performance based on a nationwide survey.
A recent reference (8) described the results of a study carried out in 1996 to evaluate the performance of ten
HIPR test sections constructed in Alberta, Canada since 1990. All of these sections were constructed using the two
stage hot in-place recycling (HIPR) processes in which the top 50 mm (2 in.) was removed by heating and milling in
two stages - the top 25 mm (1 in.) in the first step and the bottom 25 mm (1 in.) in the next step. The recycled mix
was laid down as a single course with one pass of a recycling train. The field work for performance evaluation
consisted of obtaining randomly located pavement cores and visual condition survey. The material properties
determined in the laboratory included density, asphalt content, gradation of aggregate, penetration and absolute
viscosity of recovered asphalt cement, binder film thickness, and asphalt absorption. No significant in-place aging
of the binder was observed for the test sections in the six-year performance period. In most of the cases, the
recovered binder penetration values were found to have remained unchanged (or increased) over the six-year
performance period. The performance of all projects was determined to be satisfactory.
Eight hot in-place recycled projects were completed in New York from 1987 to 1992. All of these projects
were reported to be performing satisfactorily in 1992 (9). Of the eight projects, six were on Interstates with
average daily traffic volumes of 9,000 to 62,000 vehicles.
A nationwide survey (10) has indicated excellent to good performance of hot in-place re-cycled pavements in 22
states. Most states which reported fair to poor performance could identify an assignable cause.

Performance of Cold Mix Asphalt Recycling

The general performance data reported by states that have constructed a number of projects indicate that
performance has been mostly good or very good, particularly with respect to cracking (11).
Thirteen cold recycled asphalt pavements were constructed between 1979 and 1983 in California (12). About
seventy percent of the projects had good performance. The poor performance of the rest of the projects was
attributed to incomplete mix design and nonuniform distribution of the binder.
Roughness, deflection, and visual evaluation made after one year of construction (1986) indicated better
performance for a cold in-place recycled mix section compared to a conventional resurfaced pavement in Indiana
(13). Transverse reflection cracks and longitudinal cracks were found in the conventional HMA pavement but not in
the cold recycled mix section.
A three-year performance evaluation in Maine (14) indicated that reflective cracking and frost problems had
been solved by the use of cold in-place recycled mix. A total of 120 cold in-place asphalt recycling projects have
been constructed in New Mexico since 1984. Although some specific deficiencies have been identified, pavement
condition surveys have indicated that these pavements will far exceed their assumed service life (15).
Results from evaluation of 52 cold in-place recycled pavements in Oregon indicated that 47 of the projects had
good or very good performance, and only five had poor performance (16). By 1990, more than 450 miles of
recycled mix had been placed in Oregon (11).
Details of construction and performance data for eight cold in-place recycled pavements in Pennsylvania
constructed in the eighties have been presented in References 17 & 18. These pavements have performed
reasonably well.

Economics of Recycling

Although started as a method of reusing waste materials, recycling of asphalt pavement has proved to be a cost
effective method of pavement rehabilitation. When properly selected, all the different types of recycling methods
are usually cheaper than the conventional rehabilitation methods, even though the relative savings will depend on the
kind of recycling technique used. The primary saving in hot and cold mix recycling comes from savings in the cost
of virgin asphalt cement, whereas the savings in hot in-place recycling comes by elimination of transportation
cost and use of very little amount of virgin material. The major savings in the case of cold-in-place recycling comes
by eliminating the need for fuel or emission control system, since the process is done at ambient temperature,
elimination of transportation costs, and the addition of only a small percentage of virgin asphalt binder.

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Hot Mix Asphalt Recycling
The cost associated with recycling can be presented on a material cost as well as construction cost basis.
Although construction cost may be a more valid approach, an example of material cost comparison is presented
here. This excellent example from Reference 19 shows the amount of savings that can be realized by using recycled
asphalt pavement (RAP) instead of using 100 percent virgin material. Considering $ 5 per ton and $ 120 per ton as
average costs of aggregate and liquid asphalt, respectively, the cost of a 100 percent virgin mix with 6 percent
asphalt comes out to be $ 11.90 (see Table 2). If the contractor uses a half- lane milling machine and hauls the
RAP back to the HMA plant, his/her total cost for RAP is $3.70 per ton, considering $1.70 per ton for machine and
labor for milling, and $2.00 per ton for trucking cost. Hence the savings, compared to using 100 percent virgin
material, is $8.20 per ton, as shown in Table 2. Table 3 shows the savings in using different percentages of RAP.
Reference 2 contains a survey of savings realized by hot recycling in all regions of the U. S.

Hot in-place Surface Recycling

A significant amount of cost data for hot in-place recycling is available in References 10, 20, 22, 23, 24, and
25. The estimated savings over conventional construction methods range from 17 to 50 percent according to
Reference 10.

Cold in-place Recycling

References 11, 21, 26 and 27 contain a significant amount of cost data for cold-in-place recycling. The
reported relative savings of using cold in-place recycling in lieu of conventional construction methods range from 6 to
67 percent according to Reference 11.

Legislation/Specification Limits

In the past few decades, a growing sense of environmental consciousness has resulted in a number of
legislations encouraging the recycling and reuse of waste materials. Since recycling of aggregate and asphalt can
save money and energy as well as natural resources, these legislations have stimulated research, performance
evaluations, and adoption of recycling of asphalt pavements. Experience gained by the different states over the
years indicates that to achieve good performance with recycled asphalt pavements, the recycled mixes should be
designed, produced, and constructed properly, according to agencies' specification guidelines. Hence, based on their
experiences, different states have adopted design and construction specifications related to various aspects of
asphalt pavement recycling. These

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 Table 2. Comparison of Cost for Virgin and RAP Mix (19)

Item Cost per ton ($) Percent used Total Cost ($) per ton
(%)

Aggregate 5.00 94 4.70

Asphalt 120.00 6 7.20

Virgin Mix 11.90

RAP

Trucking 2.00 2.00

Milling 1.70 1.70

RAP Mix 3.70

Savings per ton of RAP 8.20

Table 3. Savings by Using RAP (Based on 19)

Percent of RAP Cost/Ton Savings, $/ton Savings, %

0% 11.90

20% 10.26 1.64 14

30% 9.44 2.46 21

40% 8.62 3.28 28

50% 7.80 4.10 34

specifications are being continuously modified as more and more performance data become available.

Legislations
Under section 6002 of The Resource Conservation and Recovery Act (RCRA) of 1976, procuring agencies of
the federal government and certain other agencies which receive funds from the federal government are required to
purchase material with highest practical percentage of recovered or recycled material (28). This must be done by
maintaining a satisfactory level of product quality, technical performance, and price competition. The procuring
agencies are also required to review and revise the existing specifications so as to facilitate the use of recovered
material to the maximum practical extent (28).
The Intermodal Surface Transportation Efficiency Act (ISTEA) of 1991 authorized the Secretary of
Transportation and the Administrator of the EPA to conduct a joint study with state agencies to determine, among
other things, the economic savings, technical performance qualities, threats to human health and environment, and
environmental benefits of using asphalt containing more than 80 percent reclaimed asphalt (28).
A 1994 questionnaire survey (28) of 45 states indicated that 26 states (57.8 percent) have legislation requiring
DOT or other state agencies to investigate waste material use, at least 27 states (60.0 percent) have beneficial reuse
provision in state law or waste regulation, and 17 states (37.8 percent) have mandatory recycling laws.

Specifications
The important requirements generally specified for hot mix recycling include: (a) maximum percentage of
RAP, (b) maximum (top) size of RAP material, and (c) type of recycling agent. The October 1995 edition of
Roads & Bridges (29) shows the summary of survey on state specifications for hot mix asphalt recycling. The
maximum percentage of RAP allowed for batch plant mix in base and binder courses range from 15 to 100, with a
large number of states (about 26 percent) allowing 50 percent. A substantial number of states (about 20 percent)
8
have no limit on the amount of RAP that can be used. Specification limits on percentage of RAP for batch plant in
surface mixes range from none to 100. A significant percent of states (23 percent) do not allow any RAP, whereas
about 17 percent states allow unlimited RAP. Some states have special provisions for allowing RAP in the surface
mixes.
The most common maximum allowable percentage of RAP for drum-mix plant mix in base course and binder
course is 50, allowed by 30 percent of the states, whereas 20 percent of the states have no limit on the amount of
RAP that can be used. The maximum allowable percentage of RAP for drum-mix plant mix in a surface course
varies from 0 to 100 percent. About 18 percent of the states do not allow any RAP in the surface mix, and about 16
percent have no limit on the amount of RAP.
Specifications for hot in-place recycling (HIPR) must clearly describe the desired finished product (10).
Although in some cases it may be necessary to describe the type of equipment, this can limit the number of potential
contractors. It is recommended that the application rate of the mix should be specified in relation to the forward
movement of the equipment to minimize variation during speed changes and stoppages. Guideline specifications
from the Asphalt Recycling and Reclaiming Association (ARRA) and examples of HIPR state specifications from
California, Idaho, Iowa, Ohio, Texas and Arkansas are presented in Reference 10. The ARRA specifications
mention that surface courses containing unusually large aggregate, i.e., 25 mm (1 in.), may not be suitable for hot
in-place recycling. Guidelines are also presented for selecting different types of equipment and methods. These
include equipment for scarifying, recycling agent application, and compaction. Physical and chemical guidelines on
emulsions are also indicated.
The specification limits on cold recycling are mostly focussed on properties of RAP and recycled mix, rather
than on exact methods of construction (11). The depth, maximum particle size, and gradation of the RAP material
seem to be the controlling factor in most specification limits. The important factors observed in specification limits of
cold-recycling are: (a) maximum (top) size of RAP, (b) RAP aggregate gradation, (c) density of recycled mix,
(d) maximum compacted thickness so that curing is not a problem, and (e) curing of the recycled mix before
placing the overlay. Most specifications limit the top size of the RAP produced by the pulverization equipment.
Some public agencies require 100 percent passing the 25-mm (1-in.) sieve. This type of limit is viewed as overly
restrictive, the preferred alternative is to allow some oversize material to be present in the recycled mix by
specifying a minimum percentage for the nominal maximum size instead of placing restriction on top size
(11).
Some agencies recommend the use of theoretical density instead of lab density to control field density of recycled
mixes, whereas some states like Nevada and Pennsylvania control the density of recycled mixes by constructing
control strips. Typical specifications require air void content of 12 to 15 percent.
A nationwide survey of cold in-place recycling was conducted in the early 1987 for ARRA (30). It was found
that twenty percent of the reporting agencies restrict cold in-place recycling to rural areas, and an additional 20
percent limit its use to traffic with low traffic volumes. About 95 percent of the agencies were reported to limit the
use of cold in-place recycling to base courses only. Pennsylvania DOT has guidelines for use of cold recycling
according to traffic volumes (11).

Structural Design of Recycled Pavements

The method of structural design, which determines the required strength for a pavement structure, has evolved
from an empirical to a semi-mechanistic procedure. Since hot recycled asphalt material can provide similar or even
superior performance compared to conventional hot mix asphalt, the AASHTO design guide (31) indicates that
there is essentially no difference between the recycled and virgin materials, and recommends the structural
rehabilitation analysis method for conventional mix for design of recycled pavements as well.
The AASHTO method for design of hot-mix recycled asphalt is based on the derivation of the structural
number required for the pavement with the help of design traffic, reliability level of prediction of traffic and
performance, performance period, and the pavement condition rating. The structural number can be expressed as
the sum of the product of the depth, layer coefficient, and drainage coefficient of each of the layers. The structural
number for the recycled layer, which can be treated as an overlay, can be calculated as the difference between the
structural number required by the finished pavement and the structural number of the existing pavement. Values of

9
layer coefficients are also presented in the AASHTO design guide. The Asphalt Institute method (32) uses the
traffic level, the subgrade resilient modulus, and the type of surface and base to calculate the design thickness. In this
method also, the hot recycled material can be considered to be similar in performance to conventional hot mix. In
another Asphalt Institute procedure (33), the recycled layer can be considered as an overlay and its thickness can be
calculated as the difference between the total thickness required by the pavement and the thickness of the existing
pavement. The total thickness required can be determined on the basis of condition rating of the pavement and a
method of converting and expressing each type of material or pavement layer as equivalent thickness of asphalt
concrete layer. Other methods include design procedures based on load-deformation response calculation by
computer methods with the help of loading and material properties of the pavement layers. In such methods, the
pavement is assumed to behave as an elastic or viscoelastic layer on an elastic or viscoelastic layer.
The AASHTO design method for cold recycled mixes is similar to the design method for the hot-mix asphalt.
However, layer coefficients for cold-recycled mixes are dependent on construction methods, and should be
determined on the basis of engineering judgement. The Asphalt Institute method (34) assumes the pavement as a
multilayered elastic structure, and determines the required thickness on the basis of design traffic and subgrade
strength. The combined thickness of cold-recycled base and surface course is obtained from charts. The thickness
of cold-recycled bases can be obtained by taking into consideration the recommended thickness of hot mix asphalt
overlay on the cold-recycled base.
Since asphalt surface recycling does not normally improve the structural capacity of an existing pavement,
there is no method for thickness design of surface recycling. However, the thickness of any overlay should be based
on a conventional overlay design method. If the overlay is meant to improve the ride qualities only, then the
minimum thickness should be based on the maximum aggregate size used in the mix.

Summary

Recycling is a viable and cost effective alternative for asphalt pavement rehabilitation. Significant
technological developments in terms of recycling equipment (especially the milling equipment) and recycling
processes have taken place during the last three decades. Performance of recycled pavements has generally been
satisfactory. Substantial cost savings are realized in many recycling processes. Various federal and state
legislations have been enacted to promote pavement recycling. Many highway agencies have developed
specification for pavement recycling. Guidelines are also available for structural design of recycled pavements.

References

1. An Overview of Recycling and Reclamation Methods for Asphalt Pavement Rehabilitation. Asphalt Recycling and Reclaiming
Association, Annapolis, Maryland 1992.
2. Pavement Recycling Executive Summary and Report. Report FHWA-SA-95-060, FHWA, U. S. Department of Transportation, 1995.
3. P.S. Kandhal, Sridhar S. Rao and Brad Young. Performance of Recycled Mixtures in State of Georgia. Report FHWA-GA-
94-9209, FHWA, U. S. Department of Transportation, 1994.
4. Rodney G. Maag, and Glenn A Fager. Hot and Cold Recycling of K-96 Scott County, Kansas. Report FHWA-KS-90/1,
FHWA, U. S. Department of Transportation, 1990.
5. Harold R. Paul, Evaluation of Recycled Projects for Performance. Preprint Prepared for Presentation at the 1996 Annual
Meeting of the Association of Asphalt Paving Technologists.

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6. Richard C. Ingberg, Specifications Related to Project Selection. Proceedings of the National Seminar on Asphalt Pavement
Recycling. In Transportation Research Record 780, TRB, National Research Council, Washington, D. C., 1980.
7. R.C. Ingberg, R. M. Morchinek, and R. H. Carsellius. Minnesota Heat-Transfer Method of Recycling Bituminous Pavement. In
Transportation Research Record 695, TRB, National Research Council, Washington, D. C., 1978.
8. AGRA Earth & Environmental Limited. Development of Guidelines for the Design of Hot-In-Place Recycled Asphalt
Concrete Mixtures. EA-13746, Edmonton, Alberta, 1996.
9. Thomas E. Wohlscheid, In-Place Pavement Recycling in New York State, Paper Prepared for the 19th Annual Meeting of the
Asphalt Emulsion Manufacturers Association and the 16th Annual Meeting of the Asphalt Recycling & Reclaiming Association,
1992.
10. Joseph W. Button, Dallas N. Little, and Cindy K. Estakhri. Hot In-Place Recycling of Asphalt Concrete. In Synthesis of
Highway Practice 193, TRB, National Research Council, Washington, D. C., 1994.
11. Jon A. Epps, Cold-Recycled Bituminous Concrete Using Bituminous Materials, NCHRP Synthesis of Highway Practice 160, TRB
1990.
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