PRESENTATION

Department of Civil Engineering

INDIAN INSTITUTE OF TECHNOLOGY

CHENNAI
ON
HOT-IN-PLACE RECYCLING
JULY 2008
About TERPL

Telcon Eco
Road Resurfaces
Pvt. Ltd.
CONTENTS

•Purpose of Recycling
•Types of Recycling
•Definition of Hot-in-Pl
•Evolution of HIR and
•Delivery of HIR
•HIR Economics
 Traffic Capacity, Vehicle Speed, Pavement
Serviceability
Traffic Capacity
♪ ♪
= f (vehicle speed, number of lanes)

Vehicle Speed
= f (vehicle speed, number of lanes)

Pavement Serviceability
= f (damages pot-hole, cracking, rutting, unevenness)
 Rehabilitation Methods

1. Resurfacing

2. Reconstruction
 Selection of rehabilitation methodology

Through evaluation of pavement structure strength

Non destructive deflection test

•FWD (Falling Weight Deflectometer) test •Benkelman beam test

falling
deflection d3 d2 d1
 Rehabilitation Method Choices
If OK,
Mere Overlay (Conventional)

Resurfacing
Off-site: Plant Recycling

Recycling CIR (Cold In-place Recycling)

On-site
HIR (Hot In-place Recycling)
7
 Why Recycle ?
• 100% Utilization of In-Place materials

• Hence uses lesser energy per square meter

• Superior durability over life cycle

• Cost reduction in rehabilitation 30 to 70%

• Recycled road can be recycled several times

3 E Focus

– Durability
 Types of Recycling

• There are 2 types of recycling

– Cold Recycling
– Hot Recycling
• This discussion is related to Hot Recycling
• There are 2 types of Hot Recycling
– Hot-in-Place or In-situ Recycling ( HIR)
– In-Plant Recycling
• Our discussion is on Hot-in-Place Recycling
 In Plant Recycling
• The process of In-Plant Recycling is to
mill or scarify the surface layer of
bituminous mix, transport it to the Hot
Mix Plant, build a stockpile of recovered
bituminous pavement, screen the
stockpile, then blend it in the Hot Mix
Plant and transport the now Recycled
Mix from Hot Mix Plant to Work site.
– Not more than 50% of existing bituminous
mix can be re-used
– To & Fro transportation adds to cost
A Typical RAP Screening Plant
 What is Hot-in-Place Recycling
• Definition of HIR
Hot-In-Place Recycling is defined as a
process of correcting asphalt pavement
surface distress by softening the
existing surface with heat, mechanically
milling or scarifying the pavement
surface, mixing with recycling agent
and/or possibly adding virgin bituminous
mix and replace it on the pavement
without removing the recycled material
from the original pavement site.
 Reference Projects
96 Bolonga, Italy Highway, Italy No. 1 11,000
'97 Cumberland, Ontario Trim Road, Ottawa No.2 37,960
'97 Ottawa-Carlton, Ontario Robertson Road No.2 43,864
'98 Ottawa-Carlton,Ontario Highway 16 No.1 97,435
'98 Kamloops, Canada Highway 1 &5, B.C. No.1 50,799
'98 Mississippi, USA Highway I-55 No.2 1,31,820
'98 Indiana, USA Highway I-70 No.2 66,132
'98 South Italy Route A14, Bari No.3 45,000
'99 Kamloops, Canada Highway 1&5, B.C. No.1 1,20,081
'99 Cranbrook 99 Highway 95A, B.C. No.1 1,89,000
'99 Campbell River,V-Island Highway 19, B.C. No.1 2,77,000
'99 Kamloops, Canada Highway 1&5, B.C. No.1 78,000
'99 Indiana, USA Washington St.Indiana No.2 47,000
'99 Bologna, Italy Route A16 No.3 15,000
'00 Canada BC various No.1 12,00,000
'00 Ontario,Canada Ottawa No.2 80,000
'00 North Carolina, USA Highway No.2 35,000
'00 Mexico Juarres City No.3 1,00,000
'01 Canada BC various No.1 5,00,000
'01 North Carolina, USA Highway I-85 No.2 1,59,000
'01 Tores City Texas, USA City Road No.3 80,000
'01 Kawasaki, Japan Private Road No.3 8,902
'01 Ube, Japan Private Road No.3 12,160
'01 Canada BC International Highway No.2 4,50,000
'01 Costa Rica International Highway No.2 14,80,000
04 India, Jamshedpur City Road 80,000
06 India, Vadodara Vadodara- Halol Road 4,70,000
07 India, New Delhi Mehrauli Badarpur Road 1,63,000
1 Km = 3500 m2
Evolution –1916
Evolution - 1936
Evolution – 1988
Evolution - 2001
AR 2000 SUPER RECYCLER – HIR RECYCLING TRAIN
AR 2000 – GROUND LEVEL TECHNOLOGY TRANSFER

HEATING TO SOFTEN

HEATING TO SOFTEN

HOT ASPHALT REMOVAL (MILLING)

i) ADD FRESH
MATERIAL
ii) LAYDOWN

COMPACTION
 Schematic Representation
Hot –in-Place Recycling

Rejuvenator Compaction
Admix

Milling
Heating

Mixing Spreading
 Step # 1
Heating to Soften ( Preheaters 1 & 2)

Deteriorated road at start of the job

Gentle heating and softening

the deteriorated asphalt with its
circulating hot air blow
 Step # 2
Hot Asphalt Removal ( Preheater Miller)

Milling heads loosen and remove

the softened pavement

Windrowing the reclaimed asphalt to

the center and adding a softening
agent (rejuvenator oil)
Step # 3 – New Material Addition

Step # 4 – Additive Mixing

Fresh asphalt added to the reclaimed asphalt

in appropriate quantities

Laying down the new mix of the reclaimed

asphalt with softening agent and added
asphalt,
and post-heating to remove moisture
Step # 3 – New Material Addition
Step # 4 – Additive Mixing

Stirring devices under heating tubes allow for

(I) Removal of moisture
(II) Thorough mixture of added material
with reclaimed asphalt.

Transferring the mixture to an

onboard twin-shaft pug mill for
thorough and final mixing
Step # 5 Lay down & Compaction

Laying down the resulting mix, whose

temperature stabilized as programmed,
with a conventional paver

Compacted for finishing the re-pavement

by conventional rollers
 Benefits
Environment Friendly

Preheater bottom directs Hot Air on the road

surface

Hot air system softens asphalt for

milling is also recycled – fumes released
from heating process are returned via the
vacuum to system and reburnt
 Environment
Pollutant comparison

Pollutant Comparison
A Typiclal
Advanced Infra-Red
Pollutant AR2000 Recycler Asphalt Plant
(HIR) (HIR) Stack Emissions
(g/ton) (g/ton) (g/ton)
CO 8.5 290 290
NOx 1.4 15 15
SOx 1.7 ― ―
Particulates 0.9 2 2
Total Hydrocarbons 0.7 13 13
U.S.EPA Report
 HIR Advantages
• Engineering – Gradation, Geometry,
Durability, Roughness Index, Quality

• Environment – Conservation of Aggregates

& Bitumen by re-use

• Economics – 30- 70% superior over life

cycle
 HIR Engineering
• Gradation – proportional blend
• Geometry- profile correction in built
• Durability – hot to hot bonding ;
temperature control
• Quality control – spec centricity
• Ride quality IR Index
 HIR Advantages

Aggregate Grading remains unaltered Pre & Post Milling

100
Before Milling
90
After Milling
80 Grading Limit
70
% of passing (%)

60

50

40

30

20

10

0
0.01 0.1 1 10 100
seive (mm)
 Benefits – Technology
Road Geometry & Materials

• Cross-section
Profile Correction
• Improved drainage
• Providing a smooth
surface for Paving
resulting in superior
riding quality
• No damage to
existing Aggregate
• Can recycle Polymer
Modified Bitumen
 Accruing Benefits - Heights

• Bridge overhead clearances are

maintained
• Heights of central median / separator do
not have to be increased
• Gutters and Manholes do not have to be
replaced / heights altered
• Flooding in monsoon is avoided
 Benefits - Technology
Durability & Longevity

Adhesion between Hot in-place

the repaired layer maintenance enables
and the layer below complete adhesion
is imperfect due to between the repaired
insufficient heating. layer and the layer
Cracks in the lower below it. This
layer may reduces recurrence
eventually lead to of cracks in the
cracking of the repaired layer.
repaired layer.
 Benefits – Technology
Durability & Longevity

In Degrees Celsius

Existing
Heated Road Heated Road New Recycled First
Road Milling
Measurement Surface Surface Admix Materials Compacting
Surface
Point

Work
At 40 110 137 140 148 125 120
Vadodara

Above Above
Desired Above10 Not below 70
150 110

9
 Effect of Recycling on Surface Ride Quality

Pre-Recycling Badarput to Mehrauli Mehrauli to Badarpur

RI Test
Direction Type of UIV (mm Quality as per Type of UIV (mm Quality as per
Road per Km) IRC:SP16 Road per Km) IRC:SP16
Lane1 BC 3328 Average BC 3289 Average
Lane2 BC 4091 Poor BC 3843 Poor
Lane3 BC 3813 Poor BC 3902 Poor

Post - Recycling RI Test Badarput to Mehrauli Mehrauli to Badarpur

Direction Type of UIV (mm Quality as Type of UIV (mm Quality as
Road per Km) per Road per Km) per
IRC:SP16 IRC:SP16
Lane1 BC 1830 Good BC 1784 Good
Lane2 BC 1929 Good BC 1726 Good
Lane3 BC 1995 Good BC 1876 Good
 HIR Economics
• Basic comparison

• Average Rates

• Delhi PWD Tendered Cost Estimates

 Basis of Comparison
Reuse of Existing Asphalt in various Methods of Resurfacing

Overlay – 0% Reused – No recycling

Mill & Fill or In-Plant Recycling – up to 50% Reused

Hot-in- Place Recycling– 100% Reused

 Basic differences
• In Overlay, since height is increased, it
becomes necessary to increase height
of shoulders too to allow for even road
height for safe vehicular movement

• In Mill & Fill or HIR , its is not necessary

to pave the shoulder for only the main
carriageway is milled, consequent layer
of BC levels the road with shoulder for
even surface for safe vehicular
movement
 Comparison Result Summary

Non-renewable resources required per 1 km of a

standard 2-lane road rehabilitation using the
Overlay, Mill & Fill and HIR Processes

Depth Width Non-renewable Resources Consumption

Process Hot Mix Diesel

Milling Paving Milling Paving Aggregate Bitumen Rejuvenator
(milimeters) (milimeters) (meters) (meters) Asphalt (tonnes) (tonnes) (liters) Fuel
(tonnes) (liters)

Overlay (60mm) - 60 - 11 1,518 1,442 76 - 52,345

Mill & Fill (60mm) 60 60 7.3 7.3 1,007 957 50 - 41,572

HIR (60mm,iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
iiiiiiiiiiiiiiincluding 20% corrective 50 60 7.3 7.3 168 160 8 2,190 14,784
iiiiiiiiiiiiiihot mix asphalt)
Average Rates of Bituminous Works
• Pan India the rate of bituminous works for a
Bituminous Concrete Wearing Course of are:
– Rs 330 per Sq.M of 40 mm BC wearing course
– Rs 80 per Sq.M of milling of a 40 mm BC layer

• In a Mill & Fill scenario, the cost of BC layer

will be Rs 410 to each Sq.M

• This will be the nearest to actual Recycling

 DELHI – PWD TENDERED
PRICING
• FOR 50 mm depth of recycling, with
80/100 grade bitumen @ 7.5% use cost
put to tender is Rs 380/ Sq.M
+
Cost of additional mix over 20% that may
be needed for correcting profile per
lane.
Environmental Effects
 Impact of Energy Conservation

Reduced 30% of Total CO2

Fuel CO2equivalent Fuel CO2equivalent
HITONE Quantity Unit Mileage ofmachine Type consumption Ordinary Quantity Unit Mileage ofmachine Type consumption
L)
i kg j
i i
L) kg j
i
1 2
1 Pre-Heater ¦
3 number 0.34 L/m diesel 1790.1 4,725.9 1 Cold Cutting 1 number 0.058 L/m2 diesel 101.8 268.7
1
¦ 2 Transportation of
2 Heater Miller 1 number 0.21 L/m diesel 368.6 973.0 2 26 number 37.5 L/‘ ä diesel 975.0 2,574.0
cutting waste
1 Cleaning ofroad
L/m2 L/m2
¦
3 Mixer Paver 1 number 0.08 diesel 140.4 370.7 3 1 number 0.053 diesel 93.0 245.6
surface
Manufacture of Low
4
New materials
70.2 t 9 L/t sulfuroil 631.8 1,750.1 4 Spraying emulsion 1 number 0.004 L/m2 diesel 7.0 18.5
Transportation of Manufacture of Low
5 7 number 37.5 L/‘ ä diesel 262.5 693.0 5 210.6 ‚” 9 L/t sulfuroil 1,895.4 5,250.3
New materials New materials
Transportation of
6 Compaction 1.0 lot 0.17 L/m2 diesel 298.4 787.6 6
New materials
21 number 37.5 L/‘ ä diesel 787.5 2,079.0
Quarry New 2
7 66.7 ‚” 1.41 L/t diesel 94.0 248.2 7 Pavement 1 lot 0.02 L/m diesel 35.1 92.7
aggregate
Transportation of
8
New aggregate
8 number 75 L/‘ ä diesel 600.0 1,584.0 8 Compaction 1 lot 0.17 L/m2 diesel 298.4 787.6
Recycling of
9 9
asphaltwaste
1 lot 0.61 L/m2 diesel 53.5 141.3
Quarry New
10 10 200.1 ‚” 1.41 L/t diesel 282.1 744.7
aggregate
Transportation of
11 11 23 number 75 L/‘ ä diesel 1,725.0 4,554.0
New aggregate
12 12

TOTAL i
‚Pj 4,185.7 11,132.5 TOTAL i
‚Qj 6,253.8 16,756.4

i -i
‚Pj Reduce Value
‚Qj@ 5,624.0
 Jamshedpur Story
Job Site Recycled
Job Date
Area
TATA M otors
Decem ber,2004
Jam shedpur Private Road
India « 70,000‡ u
Jharkhand Province Jusco April,2005
Private Road
Material Average Maximum Depth Width
Speed Speed
mm M
M / min M / Min
Dense
Graded 2.93 5.54 30 3.5
 Vadodara – Halol Highway
Gujarat Government – IL&FS JV

128 Single Lane Km of a 31.8Km 4 Lane Road

4,70,000 Sq.Mt.
 Delhi Story – currently work is on…..

Before After

Recycling work awarded 13 March 2007 – this is a picture

of the initial trials – Evaluation of Admix pre-monsoon
Going Forward is HIR Compelling enough?

• Conservation of Aggregate & Binder

• Preservation of environment
• Conservation of energy
• Preservation of existing pavement
geometry
• Better durability
• Reduced cost of construction
• Less user delay
Discussions
Thank You