METHODOLOGY FOR

ASPHALT COLD – MIX RECYCLING

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 Methodology For Asphalt Cold-Mix Recycling.

1.1 General
1.1.1 Purpose / aim of the Method Statement submission:

Laying of Asphalt Cold-Mix recycling over remaining portion of old granular base as
shown in working drawings.

1.1.2 Scope of the Method of Statement:

Construction of Asphalt Cold-mix recycling thickness varies depends on design

recommendation / as per Tech. Specifications and contract drawings.

1.1.3 Reference to other controlling documents where appropriate:

As per Tech. Specifications A – 6, MOST Cl. 519, BOQ item No. 4.06 and as per working
drawings.

1.2 Temporary Works

Temporary diversion will be constructed for vehicular traffic in a manner creating least
interference to the flow of traffic.

1.3 Surveys
Asphalt cold recycling mix will be laid after completion of necessary survey checks on
remaining portion of old granular base surface by supervision staff.

1.4 Utilities

All identified utilities will be relocated before starting of the Asphalt cold recycling mix
processing.

1.5 Traffic arrangements and Control

Traffic will be diverted on another carriageway by providing traffic signals and safety
measures. More over necessary extra man power and display boards will be placed to
regulate the flow of traffic without causing any congestion or stagnation.

1.6 Access

Land access will be provided with the temporary diversion where necessary.

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1.7 Work Sequence Program

a) Prepare the sketch showing the overall layout of the length and width of road
intended for recycling during the day, broken into the number of parallel cuts
required to achieve the stated width, and the over lap dimensions at each joint
between cuts.

b) The sequence and length of each cut to be recycled before starting on the
adjacent or following cut.

c) Estimate the time required for milling, mixing and compacting each cut.

d) The location where samples were taken for determing in-situ moisture contents
and the results of the tests.

e) Proposed water addition for each cut, and the location at which any change is to
be made with in that sequence.

f) The locations and quantity of material to be imported.

g) Proposed control testing program.

1.8 Work Methodology

a) Field Samples: The locations for sampling should be selected by random
sampling techniques. A minimum of 5 samples per kilometer should be taken for
laboratory analysis.

b) Reclaimed Asphalt pavement & Aggregate materials: The aggregate and

Asphalt contained in reclaimed Asphalt pavement must be evaluated
independently.

(i) Aggregate materials: The gradation of the aggregate separate from the
Asphalt and found by sieve analysis by ASTM C 136 and found the all physical
analysis like shape, AIV, stripping and water absorption.

(ii) Asphalt Content: The Asphalt is extracted and found the existing asphalt
content in the pavement by ASTM D 2172.

c) New Aggregate: If new aggregate is needed to correct the gradation of the

reclaimed aggregate material or to increase the thickness of the recycled
pavement and satisfy the requirements as specified in MOST – Table 500-3 and
Table 500-4 (Gr.I).

d) Asphalt Stabilizing Agent: Asphalt stabilizing agent shall be Medium Setting

(MS) Bitumen Emulsion.

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e) Mix Design:

(i) Gradation of Recycled Mixture: Fix the gradation as per MOST – Table
– 500.4 (Gr.I) with combination of the reclaimed aggregates and new
aggregates (if any).

(ii) Select the Grade of New Asphalt: A grade of Asphalt is selected as

specified in Tech. Specifications A – 6.2.3 (i.e. Medium Setting (MS)
Bitumen Emulsion).

(iii) Percent Asphalt demand of the combined Aggregate: Asphalt

demand of the combined aggregate may be calculated by the following
empirical formula.

Pc = (0.035 a + 0.045 b + K c + F) / R

Where,

Pc = Percent of Asphalt by weight of total mix.

K = Constant – 0.18 for 6 – 10% passing 75 mic. Sieve.

- 0.20 for < 5% passing 75 mic. Sieve.

a = Percent of aggregate retained on 2.36 mm sieve.

b = Percent of aggregate passing on 2.36 mm & retained on

75 mic. Sieve.

c = Percent of aggregate passing 75 mic. Sieve.

F = Percent of water absorption ( 0 – 2%).

R = Constant – 0.60 to 0.65 for Bitumen Emulsion.

(iv) Percent of New Bitumen in Mix: The quantity of new asphalt to be

added to the recycled mixtures equals the calculated asphalt demand
minus the percentage of asphalt in the reclaimed asphalt pavement.

Formula is Pr = Pc – (Pa X Pp) / R

Where,

Pr = Percent of new asphalt in the recycled mix.

Pc = Percent of asphalt by weight of total mix.

Pp = Decimal percent reclaimed asphalt pavement in the

recycled mix.

R = Constant – 0.60 to 0.65 for Bitumen Emulsion.

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f) Construction operations:

(i) Weather and seasonal limitations: Construction with cold mix must not
be under taken when temperature below 100C, during rain, in standing
water or generally when poor weather is predicted.

(ii) Preparation of Base: The base on which cold mix is to be laid shall be
prepared, shaped and leveled to the required profile as mentioned in Sl.
No. 1.7, and a prime coat, where specified shall be applied in accordance
with clause 502. A tack coat in accordance with clause 503 shall be
applied over the base on which the cold mix is to be laid, where specified
in the contract.

(iii) Preparation of the Mixture: Constructing recycled pavements using

both in-place and central plant production methods.

In-place recycling: The first step in In-place recycling is to break up the

road surface up to the depth indicated by the structural design (i.e..160
mm). Using pull type rippers in a single pass.

Mixing the Bitumen Emulsion uniformly with the sized asphalt pavement,
old granular base and new aggregate if used. When new aggregate is
added to In-place materials, a spreader box or windrow size should be
used to ensure the required quantity is evenly placed.

Cold mix prepare with proper proportioning of the asphalt and uniformly
by using blade mixing / rotary mixing / travel plant mixing. The entire
operation will be in a single pass.

The Milling and Recycling machine shall have the following

features.

Capacity of milling to depths up to 300 mm in a single pass and fitted

with an automatic sensor system to accurately maintain the depth of
cutting.

Milling drum which rotates up wards into the direction of advance and
achieves at least 2.0 m of cut width in a single pass.

Mix the milled material with stabilizing agent, the recycling machine
shall have the following features.

A microprocessor controlled system to regulate the application of

stabilizing agent in relation to travel speed and mass of material being
recycled.

The pumping system for stabilizing agents shall be calibrated to deliver

with a tolerance of + / - 3% of volume.

A system of self cleaning nozzles that promotes an uniform application of

stabilizing agent across the full width of treatment.

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(iv) Spreading: Mixtures that have been windrowed by a travel plant or by
blade mixing are spread and shaped to the desired cross section by
successive passes with a motor grader.

Mixtures that do not required aeration may be spread to the required

thickness immediately after mixing.

The thickness of layer should not exceed 150 mm, when multiple lifts are
required, curing time must be allowed between 2 to 5 days under good
curing conditions.

Note: Emulsified asphalt mixes gain stability as the fluids (mainly water)
evaporate. It is important not to retard this process. Therefore, lift
thickness must be limited by the rate at which the mixture loses its fluids.

(v) Compaction: Initial compaction (breakdown rolling) of the laid material

shall be carried out using a pneumatic tyred roller a weight 12 – 15
tonnes weight having nine wheels, with a tyre pressure of at least 5.6
kg/sqcm (or 15 – 25 tonnes weight having seven wheels, with a tyre
pressure of at least 7.0 kg/sqcm).

Intermediate rolling shall be done with 8 – 10 tonnes vibratory roller or

steel wheeled pneumatic roller.

Finishing rolling shall be done with 6 – 8 tonnes smooth wheeled tandem

roller.

(vi) Open to Traffic: Traffic shall not be allowed to run on new work until the
water or volatile in the mixture have evaporated.

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