WIBTGEN

1.6 RehabilitationOptions

Thereare usuallymany options availablefor the rehabilitation of a distressedroad and sometimesit is

difficulttodeterminewhichis the best.However, the answertotwo importantquestlonsthat mustbe asked
at the outsetwillassistin selectingthe "right"one,the one that is most cost-effectiveovertheservicelife
of the road.

Thetwo imoortantouestionsare:
- what is actuallywrong with the existingpavement?A cursorysurveyconsistingof a visualinspection
coupledwith a few basictests (e.9. deflectionmeasorements) will normallybe sufficientto be able to
understandthe distressmechanism.Of importanceis to determinewhetherthedistressis conJinedto
the surlacing(upperpavementlayerq or whetherthereis a structuralproblem;andsecondly
- whatdoesthe roadauthorityreallywant?ls a 1s-yeardesignlifeexpected,or is a smallercapitaloutlay
envisagedthat willarrestthe currentrateof deteriorationand holdthe pavementtogetherfora further
fiveyears?

The answersto thesetwo questionswill narrowdown the rehabilitation optionsto onlythosethat will be
cost-effective the natureofthe problemand the timeframe.By separating
withinthe contextoJ,essentially,
the natureot lhe probleminto two categories(surfaceand structure)irom the time frame(shod-termor
long-term),selectingthe best option is simplified.

Oneotherimportant pointthataffectsthe decisionis the practicality

of variousrehabilitation
methods.Traffic
accommodation, weatherconditionsand availabilityof resourcescan all havea significantinfluenceon
how a projectis executedand may precludecertainoptions.

Thiswholeexercisehasonesolepurpose:determining
the mostcost-effective
solutionto the actualproblem
withinthe contextof the oroiectenvironment.

1.6.1 Surfacerehabilitation

Surfacerehabilitationmeasuresaddressproblemsthat are confinedto the asphaltand seal surfacing,usually

withinthe top 50 mm to 100 mm of the pavement.Theseproblemsarenormallyrelatedto agingof bitumen
and crackingthat initiatesat the surfacedue to thermalforces.

The most commonlyusedmethodsfor dealingwith this type of probleminclude:

Asphaltoverlay.Pavinga thin (40- 50 mm)hol-mixasphaltoverlayon the existingsurface.This is the

simplestsolutionto a surfaceproblemsjncethe time requiredto completethe work is shortand there
is minimalimpacton the roaduser.Modifiedbindersareoftenusedin theasphalttoimprovepedormance,
therebyextendingthe lifeofthe overlay.Repeatedoverlays,however,increaseroadsurfaceelevations
that can causedrainageand accessproblems.
l\,4ill
and replace.This methodremovesthe otfendingcrackedlayerof asphaltand replacesit with fresh
hot-mixasphalt,often with a modifiedbinder The processis relativelyfast due to the highproduction
of modernmillingmachines.Theproblemis removedwith the layerofasphaltand pavement
capabilities
levelsare maintained.
thin layerot asphaltmaterialfromthe existingpavement(providedthereis sufficient
Becyclinga relatively
thicknessofasphalt).Such recyclingis donein-placeasa hot process(remixing). In addition,the prop-
ertiesofthe asphaltthatis recycledmaybe modifiedby the additionof newmaterialand/ornewbinders.

Chapter 1 25
,,^\
WIRTGEN

\/

1.6.2 Structural rehabilitation

to addressproblems
Rehabilitation withinthestructureof a pavement is normally treatedas a long-term
solution.Whenaddressing structuralproblems,it shouldbe remembered that it is the structureof the
pavement thatis distressed,
seldomthe materials withinthe structure.
In addition,upgrading anexisting
pavement the structure(e.9.upgrading
by strengthening an existinggravelroadto blacktopstandards)
maybe regarded asa formof rehabiljtation.
Densification(orconsolidation)
of granular
materialis,inJact,a formof improvementsincethehigherthe
densityof a naturalmaterial,
the betterthe strengthcharacteristics.
However,theconsequences ot den-
causeproblems
sification for the overlying
layers,especially
layersconstructed fromboundmaterial.
As a rule,structuralrehabilitation
shouldaimto derivemaximumbenefitfromthe satvage valueof the
existingpavement. Thisimpliesthat material
thathasdensified shouldnot be disturbed.
Thecontinuous
kneading actionoi traffictook manyyearsto achievethisstateandthe benefitsthatsuchhiqhdensities
offershouldbe utilisedwherepossible.
optionsthatarepopularJor
Various structural
rehabilitation
include:

- Totalreconstruction. Thisis oftenthepreferred optionwhenrehabilitationis combined withanupgrading

exercisethat demands changestothealignment
significani oftheroad.Essentially, reconstruction im-
pliesthrow-away-and-start-again. Wheretrafficvolumesarehigh,it is oftenpreferable to constructa
newfacilityon a separate alignment, therebyavoidingtrafficaccommodation probtems.
- Construction of additionallayers(eitherlrom granularmaterialand/orasphalt)on top of the existing
surface.Thickasphaltoverlaysareoftenlhe easiestsolutionto a structuralproblemwherethetraffic
volumesarehigh. However, asdescribed above,anincrease insurfaceelevations oftencreates separate
drainage andaccessproblems.
- Deeprecycljng to thedepthinthepavement at whichtheproblemoccurs,therebycreating a newthick
homogeneous layerthatcanbestrengthened bytheaddition ofstabilisingagents.Additional layersmay
be addedon top of the recycledlayerwherethe pavement is to be significantly
upgraded. Stabilising
agentsareusually addedto therecycledmaterial, especially
wherethematerial intheexistingpavement
is marginaland requires strengthening. Recyclingaimsfor maximum recovery fromtheexisting pavement.
Inadditionto salvaging thematerial intheupperlayersof theexistingpavement, the pavement structure
belowtheleveloJrecycling remainsundisturbed.
- Combining two recycling methods,in-placewithin-plant. ThisoptionallowsJoran increased depthof
existingpavement to be treatedandrequires thata portionofthe upperpavement be initially
removed
to temporary stockpile. Theunderlying materialis
thenrecycled /stabilisedin-place.Thematerial placed
in temporary stockpileis thentreatedin-plantandthe productpavedon top of the in-placerecycled
layer,therebyachievingadditionatstructuralcapacitywithoutsignificantly changingfjnalsurface
elevations.Alternatively, the materialin temporary stockpilecan be spreadas a layeron top of the
in-placerecycled layerandtreatedin-place.
Thepurpose severalpavement
of considering rehabilftation
optionsis to determinethemostcost-effective
Thismanualis aimedat providing
solution. sufficient
information
togetherwith a designapproach
thatwill
allowrecycling
io be includedas oneof theoptions.

26 Chapter 1
 WIRTGEN
\r#

Chapter 2: Cold Recycling

2.1 General

Thischapterdescribesvarioustypesof cold recyclingprocessesand introducesthe equipmentrequired

to cary out the work,specificallytherangeof Widgenmachines.Alsocoveredarethe benefitsthat accrue
fromusingthis processandthe majorfactorsaffectingthe suitabilityofcold recyclingon anyspecificproject.
2.2 The Cold Recycling Process
Cold recycllngcan be achievedeither"in-plant"by haulingmaterialrecoveredfrom an existingroadto a
centraldepotwhereit is fed througha processingunit (suchas a pugmilFtypemixer),or ,'in-place"using
a recyclingmachine.,n-plantprocessingis generallythe moreexpensiveoptionin termsof cost per cubic
metreof materialprocessed,primarilydueto haulagecoststhat are absentfrom in-placerecycling.How-
ever,both recyclingmethodshavetheir placein the constructionindustryand the decisionas to which
shouldbe appliedis dictatedby:
- Typeoi construction.ln-plantprocessingis normallyconsideredwhererecycledmaterialis usedin the
construction ofa new pavementlayer,suchas strengthening an existingpavement.
- The in-placematerial(alsoreferredto as "in-situmaterial"in this manual)in an existingpavementthat
is to be recycled.Wherematerialfrom the upperlayersol an existingpavementis to be recycled,the
variabilityand/or condition oJ the recycledmaterialsometimeswanants a processof selectionor
pre-treatment (e.9.crushingand sizingofthick in-situasphalt.)
In-placetreatmentis popularduelo the adventof largepowerfulreoyclingmachinesthat can rehabilitate
pavementsat a fractionof the cost oJ conventionalreconstructionmethods.And, in light of pavement
deterioratjon worldwide,rehabilitationofexistingpavementsJar exceedsthe demandfor newroads.As a
result,in-placerecyclinghas beenadoptedin manycountriesas the prefenedmethodfor addressingthe
enormousbacklogin pavementrehabilitation and thereforejustifiesthe focus ofthis manual.
2.2.1 In-plantrecycling
In-planttreatmentalways remainsan option that should be consideredwhen recyclingis applicable,
particularlythosethat
requireablendof recycledandvirginmaterials
to betreated,andespecially
whentreatjng
with foamedbitumenand stockpilingfor lateruse.

The mainbenefitsthat accruefrom in-plantmixingcomparedto in-placemixinginclude:

- Controlof inputmaterials.Whereasin-placerecyclingallowslittlecontrolon the materialrecoveredfom
an existingpavement,a requiredend-productcan be obtainedby blendingdifferentaggregates usingin-
plantmixing.Inputmaterialscan be stockpiledandtestedprlorto mixingand inputproportionschanged
as requtreo.
- QualityoJmixing.Vdriouschangescan be madeto the mixingoperationof the pugmi to varythe time
the materialis retainedwithinthe mixingchamber,therebychangingthe qualityofthe mix.
- Stockpilingcapabilities.Particularlywith foamedbitumentreatedmateriat,the mixed productcan be
placedin stockpileandusedwhenrequired, therebyremoving
the inter-dependencyof themixingand plac-
ing processes.

Chapter2 27
2.2.2 ln-placerecycling
Becyclingmachines haveevolvedovertheyearsfrommodifiedmillingmachines andsoilstabilisers
to the
specialised
recyclersoJtoday.As theyarespecifically designed to havethe capability
of recycling
thick
pavefient-layeE
in a singlepass,modernrecyclers tendto be largepowerfulmachine!whichmay-either
DerracKmounted,,or mounted.on highflotationpneumatic tyres.Thefullrangeof widgenmachines and
Inerrvanousrecyctingapptications
is describedin Section2.4below_
Theheartofarecycring machine
isthemilingandmixingrotorequipped witha rargenumberof speciarcutting
tools.The drumnormallyrotatesupwards,pulverising the rirai6riat
in ttre eiistingroadpavement,ai
illustrated
in Fioure2.'1.

Fig2,1 The recycling prccess

Injectionof water and/or ftuid
stabilisingagents
Deep
recycled rayer

II
t Millingdrum

Distressedasphalt

Granularmaterial

As the machinemovesforwardwiththe drumrotating,waterfrom a tankercoupredto the recycrer is

deliveredthroughaflexiblehoseandis sprayedintotherecycler's mixingchamber. Therateor aerluery
ii
meteredaccurately througia micro-processor pumpingsystemandthe rolatingdrummiies
controlled
tne waterthoroughtywiththe recycledmaterialto achievethe moisturecontentnecessaryhrachieving
highlevelsof compaction. Fluidstabilising agents,likecemenvwater slunyor bitumenemulsion,eithei
individually
or incombination,
canalsobe introduced direcdyintothe mixingchamberina similarmanner.
In addition,foamedbitumenmay be injectedinto the mlxing a separatespeciafly
designed spraybar.Powdered stabirising .chamber'through
agents,suchashydrated rime.arenormaiiyspreadonthesurfaci>
ortheexistingroadaheadofthe recycter. Therecycler passesoverthepowder.miiingit togetherwiththe
recovered materialandjnjectedwater,all in a singleoperation.

28 Chapter2