CIR Project Example

Mike Marshall

Wirtgen GmbH

Cold Recycling / StabilisationCold Recycling / Stabilisation

Edn: March 2011

Strong brands, innovative products and applications know-how

Strong companies united under one roof

The Wirtgen groupThe Wirtgen group

Vögele America Inc.Chambersburg, USA

Ciber Ltda. Porto Alegre, Brazil

Company locations in more than 40 countries

SALES AND SERVICE COMPANIES

Largest plant for the series production of cold milling & recycling machines

Wirtgen Headquarters in WindhagenWirtgen Headquarters in Windhagen

Location: between Cologne and Frankfurt

Employees: 1,000

Assembly plant: 17,000 m²

Annual production: 1,400 machines

��Range of Recycling Equipment & World CoverageRange of Recycling Equipment & World Coverage

��Typical uses of Recyclers / StabilisersTypical uses of Recyclers / Stabilisers

��Key features & Spray SystemsKey features & Spray Systems��Key features & Spray SystemsKey features & Spray Systems

��Foamed Bitumen overview as an alternative binderFoamed Bitumen overview as an alternative binder

��Recycling Project ExamplesRecycling Project Examples

Wirtgen EquipmentWirtgen Equipment

Soil Stabilization / Cold Recycling

WS 2200/2500 WR 2000 WR 2400 WR 2500 S

2200 CR WR 4200 WM 1000 KMA 200

>>1400 Recycler/Stabilisers Worldwide

> 780 Wirtgen Foam Recyclers

Foamed Bitumen Foamed Bitumen recyclersrecyclers

Cement Stabilisation WMCement Stabilisation WM

Soil Stabilization

Stabilizing of the Stabilizing of the Subgrade and / or Subgrade and / or SubbaseSubbase

Soil Modification with Binding Agent

Binding Agent

+ =Lime / Cement

Modification and / or Stabilizing of soils

Lime-Spreader SW 10 TA / SW 16 TA

Tank capacity10 / 16,5 m³

Spreading with:2500 mm

Spreading quantity:2 – 50 l / m²

Spreading auger :manual operation

Lime and Cement Spreader SW 16 TC

Tank capacity16,5 m³

Spreading with:2460 / 3 x 820 mm


3 x Cellular wheel automatic operation

Lime and Cement Spreader SW 16 MC

Tank capacity16,5 m³

Spreading with:2460 / 3 x 820 mm


3 x Cellular wheel automatic operation

WS 2500WS 2500

Soil Stabilization in Germany

Soil stabilization of a new construction site, Industrial Area

WR 2500WR 2500

Soil Stabilization in Germany

Ground stabilization with Lime to a depth of 50 cm of a new highway exit

WR 2000WR 2000

Soil Stabilization in France

Soil stabilization on a high speed train to a depth of 420 mm

WR 2000WR 2000

Soil Stabilization in France

Homogeneous mixing of the lime with the heavy soil

WR 2000 (2.4 m wide cutter with no cab)WR 2000 (2.4 m wide cutter with no cab)

Soil Stabilization in Texas

Homogeneous mixing of the lime with the heavy soil

Cold Processing in situ

Construction ofConstruction ofBase layersBase layers

Cold Recycling in situ

Binding Agent

+ =emulsion water

foamed bitumen water

cement wateremulsion

watercement foamed bitumen

watercement

Bound granularbase course

Asphalt coursewith Granular base

Milled material

Binding Agent


Bound granularbase course

+ =Unbound granular material

Cement Water

WR 2400WR 2400WR 2000WR 2000 WR 2500WR 2500

Full Depth RecyclingFull Depth Recycling

Stabilizer / RecyclerStabilizer / Recycler

Working width: 8ft 0ins

Working depth: 0 – 20ins

Engine output: 570 HP

Weight: 56,540 lbs




Weight: 49,060 lbs




Weight: 63,000 lbs

Full Depth RecyclingFull Depth Recycling

Stabilizer / RecyclerStabilizer / Recycler

WR2000 VariantWR2000 Variant

Working width:Working width: 8ft 0ins8ft 0ins

Working depth:Working depth: 0 0 –– 20 ins20 ins

Engine output:Engine output: 422 HP422 HP

Weight:Weight: 48,690 48,690 lbslbs

WM 1000

Cement slurry mixer

165 kW / 225 PSPower station

2,900 gal

Weighing auger for accurate cement dosage

Schematic of the mobile cement slurry mixer

2,900 galWater tank

25 cu ydCement tank

260 gal/minSlurry mixer

Pumps for cement slurrySlurry to Recycler via a flexible hose

Twin-shaft mixer:200 t / h

KMA 220KMA 220

Mobile Cold Recycling Mixing Plant

Aggregate Hopper:2 x 6 cu yd

Transport weight:30 t

Power Output:131 kW / 178 PS

Transport:44ft x 8ft x 13ft


UpperUpperPavement Pavement LayersLayers

Typical Pavement for Cold Recycling

Cold in situ Recycling: The Process

Milling and Pulverising

Binding agent dosage

Animation of the cold recycling process

Binding agent dosage

Mixing

Compaction

Wearing course overlay

Cold Recycling in situ – typically 4” – 6” USA

Binding Agent

+ =emulsion water




watercement

Bound granularcourse

Asphalt course

Milled material

Cold Recycler2200 CR

Cold Recycler WR4200Cold Recycler WR4200

Cold In Place RecyclingCold In Place Recycling

2200CR / 3800CR / WR42002200CR / 3800CR / WR4200

Cold Recycler3800CR

Working Width:7ft 2 ½ insRecycling Depth:8 ins

Power Output:671 kW / 900 HP

Operating Weight:49.7 t

Operating Wieght:approx. 75 t

Power Output:2 x (470 kW / 640 HP)

Recycling Depth:8 ins

Working Width:10ft 0ins – 13ft 9ins

Working width12ft 6ins

Recycling Depth6 insPower Output:671kW / 900 HP

Operating Weight:58 t


��Typical uses of Recyclers / StabilisersTypical uses of Recyclers / Stabilisers




The cutter

WR2000 158 teethWR2000 158 teeth

WR2400 178 teethWR2400 178 teeth

WR2500S 224 teethWR2500S 224 teeth

Changeable Toolholders HT 11

Lower part welded onto the drumUpper part exchangeable

Variable volume mixing chamberVariable volume mixing chamber

The rThe recycling ecycling pprocess, uniformrocess, uniformdispersion of binder across full widthdispersion of binder across full width

Double Spray SystemDouble Spray System


��Typical uses of Recyclers Typical uses of Recyclers \\ StabilisersStabilisers




Heated bitumen systemHeated bitumen system

During stops the system is kept at operating temper ature, e.g. waiting for bitumen, cement and water tankers

No cleaning or flushing of the bitumen lines requir ed at the end of the day‘s operation.

Cold in situ recycling Foamed Bitumen

Hot Bitumen

Water Air

The larger surface area allows the mixingof bitumen with cold and damp aggregate

Foamed Bitumen

Consistent Foamed Bitumen Quality


��Typical uses of Recyclers Typical uses of Recyclers \\ StabilisersStabilisers




WR 2500 S

Stabilizer / Recycler

Micro processor controlled pump for addition of water

Cement StabilisationCement Stabilisation

Schematic of the working method

Milling and mixing chamber

Cement pre-spread

Traditional Spreading Method

Inaccurate and difficult to mix

Traditional Spreading MethodInaccurate and difficult to mix

Traditional Spreading MethodInaccurate and difficult to mix

18 % CEMENT

Cement Spreading Alaska, prior to Stabilisation process, inaccurate & wasteful

Cement Spreading Maine, prior to Stabilisation

process, inaccurate & wasteful

Cement Spreading Iowa, prior to Stabilisation

process, inaccurate & wasteful

Cement spreading Edmonton Canada prior to stabilisation, windblown inaccurate, wasteful

Cement spreading Edmonton Canada, windblown cement hazard to traffic

WM 1000

Cement slurry mixer

165 kW / 225 PSPower station

2,900 gal

Weighing auger for accurate cement dosage

Schematic of the mobile cement slurry mixer

2,900 galWater tank

25 cu ydCement tank

260 gal/minSlurry mixer

Pumps for cement slurrySlurry to Recycler via a flexible hose

Injection of cement slurry into stabiliser mixing drum to achieve uniform dispersion in mix, to meet design criteria

Accurate, quality mix with no waste..

On board microprocessors provide total control of moisture content at all times

Speed: 6.2m / min

Water: 5.3%Water: 5.3%

Cement: 5.8%

Depth: 300mm

Width: 2.9m

Density: 1900kgs

Wirtgen WR2500S / WM1000 Slurry MixerCement Stabilisation

Cement stabilisation using latest technology:

- Accurate

- No waste- No waste

- Uniform dispersion

-Safe

-Cost effective

-QUALITY

Wirtgen WR2500S / WM1000 Slurry Mixer

Cement Stabilisation

12ins stabilisation depth with 5.8%

cement slurry

12” stabilisation depth with 5.8% cement slurry

Stabilised layer cut to level after compaction


Project Examples FDRProject Examples FDR

WR2000 WR2400 WR2500SWR2000 WR2400 WR2500S


Working Width:6ft 7ins

WR 2000WR 2000


Working Depth:0 – 20ins

Power Output:422 HP

Operating Weight:ca. 49,060 lbs

WR2000 Recycling Project

Example

Project example

WR2000 Job Application

Up to 5” Asphalt over crushed limestone base


Recycling depth 6”

2.5% foamed bitumen2.5% foamed bitumen


Average working speed 35ft/min



Traffic Lane Recycling Lane


Initial CompactionInitial Compaction

HAMM 3412P


After cutting levels

Final Compaction

HAMM 3412 V/O


Surface Finish

HAMM GRW15


Immediately open recycled lane to traffic



WR 2400WR 2400


Working Depth:0 – 20ins

Power Output:570 HP



Example

Project example

WR2400 Job ApplicationWR2400 Job Application

2” to 3” Asphalt2” to 3” Asphalt

Up to 10” binder courseUp to 10” binder course

ClayClay


Recycling depth: 7”Recycling depth: 7”

2.8% Foamed Bitumen2.8% Foamed Bitumen

2% stone dust2% stone dust

1% cement1% cement


Initial compaction Hamm 3516 Pad Foot rollerInitial compaction Hamm 3516 Pad Foot roller



Hamm 3410Hamm 3410

Steel DrumSteel Drum

Hamm 3516Hamm 3516

Pad FootPad Foot



Finished recycled Finished recycled base covered with base covered with fog seal prior to fog seal prior to overlay with 1 ¾” overlay with 1 ¾” asphaltasphaltasphaltasphalt


Example Cement, Lime & Foamed Bitumen

Project Example

Cement, Lime & Foamed Bitumen

Point Lisas Industrial Port ProjectPoint Lisas Industrial Port Project

Identify Areas of extreme base failure

Cement, Lime & Foamed Bitumen Area

Cement & Foamed Cement & Foamed Bitumen Area

Cement, Lime & Foamed Bitumen Area

Pre Milling Operation

Pre mill area to required depth

Retain millings on site for later use

Spread cement at required design rate of 1% by mass

Spread Lime at required design rate of 1% by mass on top of cement

Stabilise to a depth of 10 ins

Full depth compaction using vibratory pad foot rollers

Finish Compact with vibratory steel drum roller

Re – instate millings from stockpile over 10 ins cement & lime stabilised base

Foam Stabilise 7 inswith 2.5% foamed bitumen & 1 % cement

2 ins Asphalt

3 / 4ins Leveliing Course

Finished Pavement Stabilised Section

Foam Stabilised base 7 ins with 2.5% foamed bitumen & 1 % cement


WR 2500 SWR 2500 S


Working Depth:0 – 20 ins

Power Output:690 HP



Example

Project example

Highway 20 Colusa California

Typical condition of pavement prior to Foam Recycling

2001 Traffic, > 5000 vpd, 20% Heavy Trucks


Highway 20, State of California

20 lane miles reconstructed & repaved in 20 days


2 x Wirtgen WR2500s working in echelon

Recycling depth 9ins


14% Super Elevation


The Foam Recycled material is compacted with pad foot rollers, shaped with a motor grader and finish compacted with a steel drum

vibratory roller.

Recycling Results

Construction July 2001 April 2004

Estimated Traffic:

Construction 2001 to

Recycling Results

April 2004

4,350,000 vehicles

(20% truck traffic)

Estimated Traffic:

Construction 2001

Recycling Results

Construction 2001

August 2006

6,750,000 vehicles(20% truck traffic)

Estimated Traffic:

Construction 2001

Recycling Results 2008

Construction 2001

July 2008

10,080,000 vehicles(20% truck traffic)

Recycling Results

June 2000 April 2004

Recycling Results

August 2006 – 5 years after construction


July 2008 – 7 years after construction

Recycling Results

Construction July 2001 April 2004

Recycling Results

August 2006 – 5 years after construction


July 2008 – 7 years after construction

California Dept Transportation

Highway 20 Report

Conclusions:

�After 5 years the project is performing better than expected

�Other projects that have been constructed utilizing conventional methods typically have remedial work done at the 3 year point.the 3 year point.

�To date no maintenance activities have been performed on the Highway 20 rehabilitated pavement

�Detailed investigations by the Marysville Materials staff in July 2006 showed no signs of thermal cracking, or other distressed areas.

California Dept TransportationHighway 20 Report

“This project should be considered a success for the following reasons”

�It has exceeded its design life and is performing very well

�During the design life, no maintenance activities have been required

�The roadway was rebuilt in place with minimal impacts to traffic

�The roadway was rebuilt in less than one season, conventional methods would have required multiple seasons

�The reclamation process utilizes fewer ingress/egress of construction vehicles, making it safer for works and the public

�100% of existing roadbed material was recycled,

�The project was accomplished for approximately the same cost as a grind and place of 80mm of HMA.

Information supplied California Dept Transportation

Cold Processing in Plant

Project Examples Base Layer ConstructionProject Examples Base Layer Construction

KMA200KMA200


emulsion water

Cold mixing plant - KMA 200 Binding agent dosage

=+

watercement




=

Bound base layer

+

Starting aggregate- Milled Asphalt- Crushed concrete

Cementitious and/or Bituminous Binders

Twin-shaft mixer:200 t / h

KMA 220KMA 220

Mobile Cold Recycling Mixing Plant

Aggregate Hopper:2 x 6 cu yd

Transport weight:30 t

Power Output:131 kW / 178 PS

Transport:44ft x 8ft x 13ft

Material hoppers

178 HP Motorstation

Cabin in working position

Injection system for water, bitumen emulsion and foamed

bitumenCement auger

Cold mixing plant - KMA 220 Components

Loading belt

Twin shaft pugmill mixer

Transfer conveyor with scale

4500 l Water tank

All components on one low-bed trailer

Mineral aggregate (2 Hoppers)

Cementitious and/or bituminous binding agent

dosage

Loading belt

Aggregate dosage openings

Cold mixing plant - KMA 220 Material- and/or binder dosage

Binding agent dosage depends on belt scale values

Weighing by means of a belt scale

Transfer conveyor

Cold mixed material conveyed onto a stockpile or transferred into tip trucks

Mixing in a twin shaft pugmill

mixer

Cold mixing plant - KMA 220 Aggregate hoppers

Twin hoppers for the possible dosage of two different mineral aggregate sizes

Aggregate feed with a min. 135 kW Payloader

KMA 220KMA 220

Recycling in plant

Cold recycling of milled asphalt with cement and foamed bitumenKMA 200; bitumen tanker; cement silo; payloader; tip trucks

Cement siloCement silo

Cold mixing plant Cold mixing plant KMA 200KMA 200

10 t tip trucks10 t tip trucks

approx. 65 ft

approx. 65 ft

approx. 100 ftapprox. 100 ft

Cold mixing plant Cold mixing plant -- KMA 220 KMA 220 Mixing plant yardMixing plant yard

20 t Bitumen tanker20 t Bitumen tanker 5000 gal 5000 gal Water tankerWater tanker

Front end loaderFront end loader

approx. 65 ft

approx. 65 ft

Example of a mixing plant yard with min. space requirementsExample of a mixing plant yard with min. space requirements

Cold mixing plant Cold mixing plant KMA 200KMA 200

350 kW Payloader350 kW Payloader

ca. 130 ftca. 130 ft

Cold mixing plant Cold mixing plant -- KMA 220 KMA 220 Mixing plant yardMixing plant yard

30 t Bitumen tanker30 t Bitumen tanker

5000 gal5000 galWater tankerWater tanker

20 t 20 t Cement siloCement silo

15 t tip 15 t tip truckstrucks

ca. 130 ft

ca. 130 ft

Example of a mixing plant yard with ideal space requirementsExample of a mixing plant yard with ideal space requirements

Recycling RAP with Foamed Bitumen & Flyash Blend

UK

KMA200 Application UKKMA200 Application UK

++++

Pre Pre –– BlendedBlended

Coarse millings 1” minusCoarse millings 1” minus

+ PFA+ PFA

Fine Millings 0 Fine Millings 0 –– 3/8 ins3/8 ins


Blended material & Fine Millings Blended material & Fine Millings loaded into KMA200loaded into KMA200

Material foam stabilisedMaterial foam stabilised

3.0% Foamed bitumen3.0% Foamed bitumen

2.0% Cement2.0% Cement


Foam stabilised material delivered in Foam stabilised material delivered in conventional dump truck to paver.conventional dump truck to paver.

Material to form new base in pre Material to form new base in pre milled lane.milled lane.

Foam stabilised material paved in two Foam stabilised material paved in two 4 ins lifts4 ins lifts


Foam stabilised base layers Foam stabilised base layers compacted with conventional Asphalt compacted with conventional Asphalt RollerRoller

Compacted foam stabilised base, Compacted foam stabilised base, ready for;ready for;

2 3/8 ins binder course2 3/8 ins binder course

1 ½ ins wearing course1 ½ ins wearing course

Maine DoTMaine DoT

KMA200 ProjectKMA200 Project

100% Recycled RAP100% Recycled RAP

Example Recycled RAP with Foamed BitumenExample Recycled RAP with Foamed Bitumen

KMA200 set up in RAP siteKMA200 set up in RAP site

Existing RAP StockpilesExisting RAP Stockpiles

Existing RAP stockpile in Existing RAP stockpile in reasonable conditions, no reasonable conditions, no excessive “chunks” of asphaltexcessive “chunks” of asphalt

Screened RAPScreened RAPWater tankWater tank

Position KMA200Position KMA200

KMA200KMA200

Insulated asphalt tankerInsulated asphalt tanker

LoaderLoader

RAP ScreeningRAP Screening

RAP from original stockpile RAP loaded into screen hopper oversized ejected to truRAP from original stockpile RAP loaded into screen hopper oversized ejected to truckck

screened RAP stockpile screened RAP loaded into KMA200 hoppers fitted with additional scscreened RAP stockpile screened RAP loaded into KMA200 hoppers fitted with additional screensreens

Process RAP through KMA200Process RAP through KMA200

Production / Stockpiling ExampleProduction / Stockpiling Example

As an example on As an example on this project an this project an average daily average daily production rate of production rate of production rate of production rate of 1475 tons was 1475 tons was achievedachieved

Foamix RAP stockpileFoamix RAP stockpile

Laying foamix RAP ExampleLaying foamix RAP Example

Existing pavementExisting pavement

Foamix RAP overlay, Foamix RAP overlay, paver laidpaver laid


Compaction equipmentCompaction equipment

1 x Tandem steel drum roller1 x Tandem steel drum roller

1 x Pneumatic tyred roller1 x Pneumatic tyred roller


Following compaction the Following compaction the foamix RAP can be foamix RAP can be immediately traffickedimmediately trafficked

Foamix RAP overlay should Foamix RAP overlay should be sealed, typically hotmix be sealed, typically hotmix asphalt or chipsealasphalt or chipseal

Foam Stabilised base with 50mm HMA overlay, 1st Winter Jan 2005Foam Stabilised base with 50mm HMA overlay, 1st Winter Jan 2005Temperature at time of Photo Temperature at time of Photo –– Minus 12 deg CMinus 12 deg C

View Route 138 August 2006, after 2 freeze thaw cyclesView Route 138 August 2006, after 2 freeze thaw cyclesNo evidence of any pavement cracking or failureNo evidence of any pavement cracking or failure

Foam Stabilised Base used as base and shoulder backing to support Foam Stabilised Base used as base and shoulder backing to support HMA overlay August 2006HMA overlay August 2006

Recycling RAP with Foamed Recycling RAP with Foamed BitumenBitumen

Louisiana DOTDLouisiana DOTD

Road 190 Road 190 –– Port Allen, LouisianaPort Allen, Louisiana

Existing Pavement, 12” Existing Pavement, 12” –– 14” Asphalt over 8” Concrete14” Asphalt over 8” Concrete

Existing Pavement removed, Asphalt Milled off, Concrete Broken on siteExisting Pavement removed, Asphalt Milled off, Concrete Broken on site

Base stabilised to a depth of 12” with 9% limeBase stabilised to a depth of 12” with 9% lime

RAP Stockpile from existing pavement adjacent to projectRAP Stockpile from existing pavement adjacent to project

RAP to be Recycled with Foam Bitumen and to be used as base materialRAP to be Recycled with Foam Bitumen and to be used as base material

KMA Cold Mix Plant KMA Cold Mix Plant –– Site SetupSite Setup

Site setup to allow easy movement of trucks and loadersSite setup to allow easy movement of trucks and loaders

(Note: Water supplied via underground piping)(Note: Water supplied via underground piping)

KMA Recycling ProcessKMA Recycling Process

3. Cement, 1.5% added via weigh cell3. Cement, 1.5% added via weigh cell

4. RAP with cement added entering pug mill4. RAP with cement added entering pug mill

Recycled RAP delivered to site and loaded into Recycled RAP delivered to site and loaded into conventional paverconventional paver

Paving width 13.5 ft x 4ins liftPaving width 13.5 ft x 4ins lift

40ft wide stabilised base paved with 3 lanes of recycled RAP40ft wide stabilised base paved with 3 lanes of recycled RAP

2 lifts per lane, total thickness of recycled RAP 8”2 lifts per lane, total thickness of recycled RAP 8”

Steel drum vibratory roller used for compactionSteel drum vibratory roller used for compaction

Excellent compaction and surface finish achievedExcellent compaction and surface finish achieved

The recycled RAP surface is lightly wateredThe recycled RAP surface is lightly watered

A tight surface finish is achieved by final rolling of the moist A tight surface finish is achieved by final rolling of the moist RAP with a Pneumatic Tyred rollerRAP with a Pneumatic Tyred roller

A tight surface finish provides a smooth running surface for A tight surface finish provides a smooth running surface for site traffic as well as preventing ravelling of the surface.site traffic as well as preventing ravelling of the surface.

As an alternative to paving the recycled RAP it is possible to As an alternative to paving the recycled RAP it is possible to dump the material and spread to a nominal thickness.dump the material and spread to a nominal thickness.

Recycled RAP spread to nominal thickness with dozer blade, Recycled RAP spread to nominal thickness with dozer blade, prior to compaction.prior to compaction.

A pad foot roller is best suited for initial compaction of the A pad foot roller is best suited for initial compaction of the “dumped” material “dumped” material

Final compaction of the recycled Rap is again achieved with a Final compaction of the recycled Rap is again achieved with a steel drum vibratory rollersteel drum vibratory roller

Finished full width (40’) recycled RAP baseFinished full width (40’) recycled RAP base

The first lane (right) has fully dried back and is being used for site trafficThe first lane (right) has fully dried back and is being used for site traffic

The recycled RAP base was laid an nominal 1” over required thickness.The recycled RAP base was laid an nominal 1” over required thickness.

This allowed for a final trimming operation to establish finish grade.This allowed for a final trimming operation to establish finish grade.

The recycled RAP was “trimmed” before it had completely dried back, The recycled RAP was “trimmed” before it had completely dried back, this allowed for the trimmed material to be loaded into trucks and be this allowed for the trimmed material to be loaded into trucks and be

used as base material further up the job site.used as base material further up the job site.

Recycled RAP base after trimmingRecycled RAP base after trimming

The trimmed surface was brushed clean with a sweeperThe trimmed surface was brushed clean with a sweeper

Recycled RAP base finished to correct thickness and grade.Recycled RAP base finished to correct thickness and grade.

Surface finish of recycled RAP after trimming and sweeping operations.Surface finish of recycled RAP after trimming and sweeping operations.

Recycling RAP with Foamed Recycling RAP with Foamed BitumenBitumen

Texas DOTTexas DOT

KMA plant set up at RAP stockpileKMA plant set up at RAP stockpile

Site setupSite setup

Phase 1. Widen existing road 3ft either side using Phase 1. Widen existing road 3ft either side using recycled RAPrecycled RAP

Phase 1. Road wideningPhase 1. Road widening

Phase 2. Overlay widened Phase 2. Overlay widened roadway with Recycled RAProadway with Recycled RAP

Paver laid recycled RAP overlayPaver laid recycled RAP overlay

View finished widened road View finished widened road with Recycled RAP Overlaywith Recycled RAP Overlay

Recycled RAP surface finishRecycled RAP surface finish

Recycling RAP with Emulsion

On site

California

KMA220KMA220

Emulsion Stabilised RAP Project CaliforniaEmulsion Stabilised RAP Project California

1.1. Mill existing 30 year old Mill existing 30 year old asphalt, 10cms to 12cmsasphalt, 10cms to 12cms

2. Stockpile RAP2. Stockpile RAP

3. Run RAP through crusher with twin 3. Run RAP through crusher with twin deck screen, 25mm minus deck screen, 25mm minus

4. Feed screened RAP directly to KMA220, 4. Feed screened RAP directly to KMA220, add 3.1% emulsion, 5% water, mixing rate add 3.1% emulsion, 5% water, mixing rate 280 t/hr.280 t/hr.

Note: On overcast days add 0.5% cement to accelerate emulsion breakNote: On overcast days add 0.5% cement to accelerate emulsion break

5. Pave back recycled stabilised RAP at 5. Pave back recycled stabilised RAP at depth of 70mmdepth of 70mm

Wirtgen Model KMA220

Roller Compacted Concrete Application Sept 08

Mike Marshall Wirtgen GmbHMike Marshall Wirtgen GmbH

RCC Mix Design

�19mm aggregate 45%

�Sand 55%

�Cement / Slag 9.5 %�Cement / Slag 9.5 %

(Cement / slag pre blended 80%/20%)

�Moisture added 1.5% to 2.1%

Aggregate

Sand

With close proximity of both sand & aggregate a single loader can maintain the KMA220 charge levels

Material Loading

Agg loaded into left hand hopper

Sand loaded into right hand hopper

Aggregate / Sand Blend

Using the proportional opening on the opening on the feed gates at the bottom of the hoppers a blend ratio of 45% agg to 55% sand is achieved

Aggregate / Sand Belt Feed

Agg / Sand Agg / Sand blend carried to pug mill via feed conveyor

Cement Feed

Cement added via feed auger @ 9.5% by @ 9.5% by mass.

Cement / Slag density 1000kgs/cum

Moisture Content

Added moisture content range 1.5% to 2.1% due to variation in in-situ in in-situ moisture of the sand & agg

As can be seen the in-situ moisture varies within the stockpile

RCC Loading

RH truck loaded with 22 tonnes mixed RCC @ rate of 155 rate of 155 tonnes/hr

Switch to LH truck to allow continuous production runs

RCC Loading

Loading switch from RH truck from RH truck to LH truck by means of conveyor swing

Production Rate

For this Mix:

A consistent high quality uniform mix was achieved at 155 t/hr

Maximum was found to be 180 t/hr

Mix19mm Agg 45% / Sand 55% / Cement 9.5%

15cms RCC Lift

15cms RCC lift15cms RCC lift

Vogele

Super 2100 Paver

15cms RCC Lift

Super 2100Super 2100

Paving Speed

2.0 – 2.5 m/min

15cms RCC Lift

Super 2100Super 2100

Paving width

3.8m

Compaction

Compaction:

Ave: 89% Ave: 89% behind screed

After rolling ave 96%

Vogele AB600 2TP2 Screed

Compaction

HAMM HD120VO Compactor

16.5 cms lift

RCC

16.5cms lift x 3.8m wide

Uniformity

Lifts drying back uniformly indicating a indicating a well mixed homogeneous blend of materials

Joints

20cms RCC Lift

20cms RCC Lift

Finished RCC Section


Project Examples CIRProject Examples CIR

2200CR 3800CR WR42002200CR 3800CR WR4200

UpperUpperPavement Pavement LayersLayers

Typical Pavement for Cold Recycling

Recycling Concept 2200CR / 3800CR

City Los Angeles 2200CRCity Los Angeles 2200CR









3800CR Cold In Place Recycling

Technical Specification – 3800CR

Cold Recycler 3800CR

Working width 12ft 6ins

Recycling Depth 0 – 6ins

Milling Depth Up cutting 13.75 insMilling Depth Up cutting 13.75 ins

Tool Spacing HT11 5/8 ins

Number of tools 294

Cutting Direction Up cut or down cut

Requires drum to be removed and turned

through 180 deg and fit either upcut or down cut

planetary drives

Technical Specification – 3800CR

Cold Recycler 3800CR

Engine CaterpillarEngine Caterpillar

Type C27 ATAAC

Cooling Water

No Cylinders 12

Output 708kW/950HP/963PS

Engine Speed 2100 rpm

Fuel consumption full load 49 gal/hr

Fuel consumption 2/3 load 32 gal/hr

Cold Recycler 3800 CRDouble pump for Water and Foamed Bitumen or Emulsion

WaterWater

Foam orFoam orFoam orFoam or

EmulsionEmulsion

supply of Watersupply of Water(out of 3800 CR tank)(out of 3800 CR tank)

Bitumen filter

Cold Recycler 3800 CR Foamed Bitumen or Emulsion with Waterinjection system, 2 Spray bars

Bitumen or Emulsion Bitumen pump Flow meter Test nozzle

Cold Recycler 3800 CR Foamed Bitumen or Emulsion with Waterinjection system 2 Spray bars

WaterWater

Flow meterFlow meter

Foamed BitumenFoamed Bitumen--test nozzletest nozzle

Hot Bitumen or EmulsionHot Bitumen or Emulsion

Bitumen filterBitumen filter

Cold Recycler 2200 CR Foamed Bitumen or Emulsion with Waterinjection system 2 Spray bars

Metered injection of foamed bitumen or emulsionand water via the 3800 CR

3800CR3800CR

drum for up / down cutdrum for up / down cut

Down cut mode fit down cut planetaryUp cut mode swing drum through 180 deg and fit up cut planetary

upcut 93 rpmupcut 93 rpmdowncut 104 rpmdowncut 104 rpm

upcut 73 rpmupcut 73 rpmdowncut 82 rpmdowncut 82 rpm

Bearing adaption

3800CR

Project Examples

38000CR CIR Project Example –Mason County Illinois

Project View – 35 year Pavement, 5ins to 6ins Asphalt


Pavement highly oxidized, major cracking with localised cold mix repair areas


Lane 1 pass 3 ½ ins depth, 2.5% Emulsion


Lane 1 View after Recycling CIR


Recycled Material Surface Finish / Mix


Recycled material at Auger before screed, well mixed and well graded material


Emulsion InletEmulsion Inlet


Screed end plate in open position Excess material run out for shoulderbacking


3800CR Compact Design features allow for traffic accommodation, even on narrow lane widths


Recycling width 12ft 6ins, depth 4ins, average speed 28ft/min


Speed 8.5 m/min (28ft/min)

Compaction water 2.6%Compaction water 2.6%

Emulsion content 2.7%

Approx 400 tons / hour


Compaction immediately behind recycler with HAMM Model HD120 Compactor



CIR Project Example –3800CR Urban Recycling, Toronto

Busy 4 lane through way

Kerb & gutter

Manholes & Side drains

Centre traffic islands

Turning lanes

Traffic Accommodation


Pre-Mill 4ins with Wirtgen Model W2100 Milling Machine


The CIR Train comprises 2 units, Wirtgen Model 3800CR & Bitumen Tanker


Recycle flush to Kerb as approaching Side drains


Recycle flush with drain


Steer recycler back to flush with kerb


Screed end plates in closed position


Hydraulically open screed end plate to allow sufficient recycled materialto flow around drain and fill taper both sides


Continue recycle pass flush to kerb


6 ins overlap at longitudinal joint




Traffic Accommodation -During the recycling operation it is possible to keep the traffic flowing, in this case either side of the 3800CR as the centre pass is being made


Average recycling speed for the project 27.5 ft/min.

This average speed at a depth of 6 ins and a width of 12.5ft equates to an hourly recycling tonnage of 610 tons per hours.


Finished foamed bitumen recycled material at screed


Pavement Recycled & Paved back to 2% slope, stabilized with 2.5% foamed bitumen using the 3800CR

3800CR

Project Examples

Municipal Recycling, Rte 9, Ontario

Lane width: 13ft 6ins

Std’ Cutter: 12ft 6ins

Pre-mill Centre with Pre-mill Centre with W50

Windrow millings

Speed: 26ft/min

Depth: 4ins

Foam: 1.5%

Water: 2.4%

Ave: 400 t/hr

Pave width: 13ft 6ins

Compaction:Compaction:

Hamm HD120

Hamm GRW18

Up to12,000 sq/yds to 15,000 sq/yds

Project End Cofax

Project Location

Project Examples CIRProject Examples CIRWR4200WR4200

80.8 kms (48.68 miles) Shoulder Recycling

40.4 kms (24.34 miles) Traffic lane Recycling

Project Start Bell Road

Existing pavement conditions

Typical pavement condition Eastbound Bell Road to Applegate

Existing pavement conditions

Typical pavement condition Westbound Cofax to Applegate

Traffic volumes in the project area range from:100,000 vpd in Auburn (3 lane section)

with 8.5 % trucks

Traffic Volumes

38,500 vpd in Colfax (2 lane section)with 16% trucks

1 truck per 10 seconds in Auburn1 truck per 15 seconds in Colfax

Data supplied by California Dept Transportation

Existing Pavement:150-200 mm HMA200 mm Concrete Treated

Base300 mm Aggregate Sub-base

Existing Pavement

Pavement Distress:• Block Cracking• Wheel Path Dig outs• Alligator Cracking• Potholes• Severe Oxidation• Exceeded Design Life

Why Recycle

• History of success on previous foam full depth reclamation projects (oldest is 5 years).

• Single Pass all in one Recycle Train, from milling to paving

• Trafficking in as little as 4 hours

Primary Reasons for Choosing Foam Recycling:

• Trafficking in as little as 4 hours

• Reduction in construction window traffic congestion.

• Less construction equipment on roadway.

• Fewer truck ingress/egress

• Preservation of natural resources.

• Significant potential cost savings.

–Shoulders: 60 mm recycle with

1.5 % Cement (added as slurry)

2.5% foamed bitumen

–Mainline: 100 mm recycle with

The foamed recycle design called for:

Mix Design Data

–Mainline: 100 mm recycle with

1.5% cement (added as slurry)

2.5% foamed bitumen

-Initial Seal: Application of 0.008 to 0.010

litres/sqm diluted emulsion

Recycling “train”

Recycling “Train” consists

Oil Truck + WM1000 Cement Slurry Mixer + WR4200 Recycler

WR4200 Recycler

WR4200 Recycler

2.80 m (9’ 2”) closed cutting width

WR4200 Recycler

4.2m (13’ 9”) maximum cutting width

Extension cutters

Position for foam barWorking direction

WR4200 Recycler

Centre cutterTwin shaft pug mill

WR4200 Recycler

Centre cutter with adjustable breaker bar

WR4200 Recycler

PugmillFoam recycled material

Recycling operation

Recycling Shoulder

Width, average 3.20m (10ft 6ins) x 70mm (2 ¾ins) Depth

Recycling operation

Recycling operation

Recycling operation

Extension cutters

Left hand extension cutter, cuts overlap into

Direction of work

cutter, cuts overlap into adjacent traffic lane

Extension cutters

Right hand extension cuts

Direction of work

Right hand extension cuts works flush with guard rail

Extension cutters

Recycled pavement with lane overlap and flush cut to guard rail

Extension cutters

Integral AB500TV Paving Screed

WR4200 fitted with integral Vogele

AB500Tamping & Vibrating Paving Screed


Recycled pavement material immediately after paving screed


A high level of compaction is achieved at the paving screed

Compaction

A flush joint between the recycled pavement and the adjacent traffic lane can be consistently achieved

Compaction

A tightly compacted surface finish is achieved using a pneumatic tyred roller

Compaction

Finish compacted recycled pavement

Cofax to Applegate example

Recycling No 1 Lane

Width, average 3.86m (12ft 8ins) x 100mm (4ins) Depth

Width includes 100mm (4ins) overlap into each adjacent lane

Cofax to Applegate example

Recycling train kept to minimum width to accommodate traffic

Finish fog seal

Full lane width fog spray seal

Finish fog seal

No 1 Lane Cofax to Applegate Recycled Pavement

after Fog Seal

Completed example sections

Bell Road Bridge

Recycled Original Recycled Recycled

Shoulder Pavement No 1 & 2 Lanes Shoulder

Fog Seal Only

No2 lane mill & fill No 1 lane recycled Inside shoulder recycled

with fog seal only with fog seal only


Westbound Cofax to Applegate

October with 40mm overlay


Westbound Cofax to Applegate

Recycled Recycled Mill Fill RecycledShoulder No 1 Lane No 2 lane Shoulder

Picture taken 4 hours after completion of the Recycled No 1 laneThe traffic is running on the recycled mat with a fog seal, no asphalt overlay

Note: the tracking lines are tyre tracks through the fresh sand seal

October with 40mm overlay


Eastbound Applegate to Cofax

Recycled Mill & Fill Recycled Recycled

Shoulder No 2 & 3 Lanes No 1 Lane Shoulder

October 2005 with 40mm overlay

June 2007

January 2011

100,000 vpd, 8.5% trucks Caltr ans 2005 Figures

Construction 2005

Traffic Volume since Cold In Place Recycling

Photo January 2011

5.5 Years Traffic (250 days / year) 137,000,000 ve hicles

11,500,000 trucks

No Calls for Maintenance

Why Recycle

It saved:101,909 metric tons

aggregate2,545 metric tons bitumen9,200 truck trips 9,200 truck trips

@ 80 Km round trip

736,000 truck traveled Km204,000 liters of diesel fuel

7200 Kg of NOx emissions

Bitumen @ $600/ton = $ 1.5 million Diesel @ $3/ gallon = $ 161,000.00

Reference Reports

�Project Example Concrete In -Situ Recycling�Project Example Concrete In -Situ Recycling

Cold Recycling in Romania

Cracked concrete pavement with chip seal


Concrete pavement pre-milled with W 2200 to a depth of 10 ins


Granulated concrete is pre-profiled with a dozer

WR 4200 + WM 1000WR 4200 + WM 1000


Recycling of concrete granulate with foamed bitumen and cement slurry

WR 4200WR 4200


Placing the recycled material with Vögele screed AB 500 TV with tampers and vibration

WR 4200WR 4200


Lifting the concrete granulate, mixing and paving a full 12ft 6ins wide traffic lane


Recycling carried out under traffic.After final compaction the traffic is diverted on to the recycled lane.

�Project Example China Expressway�Project Example China Expressway

Cold Recycling Jinghu Expressway, Tianjing China

1.0 Remove 20 cms existing asphalt by milling

22 cm milling of asphalt in the right laneRecycled layers in the left lane open for traffic


Existing asphalt and CTB milled outSubgrade stabilized soil



Milled Asphalt recycled and stabilised with KMA200 Cold Mix Plant,

2.4% foamed bitumen & 1.5% cement

KMA 200: Mixing of milled asphalt with 2,4 % foamed bitumen and 1.5 % cement


Pave back the recycled millings onto the new stabilised base

Paving the recycled asphalt on top of the recycled base



Placing of the cold mixed material by Vögele PaverFinal compaction by Hamm Roller HD 120


Overlay with 4 cms polymer modified asphalt wearing course

Recycled layer open for traffic before overlay with asphalt

II--81 Virginia DoT Recycling Alternative81 Virginia DoT Recycling Alternative

Wirtgen Developed Project Example

ALTERNATE FOAMED BITUMEN ALTERNATE FOAMED BITUMEN STABILISED BASE PROPOSALBASE PROPOSAL

Material StructuralCoefficient

Thickness S.N

SMA 0.44 2 0.88

Material StructuralCoefficient

Thickness S.N

SMA 0.44 2 0.88

Current Design Proposed Recycling AlternativeCurrent Design Proposed Recycling Alternative

SMA 0.44 2 0.88

IM-19.0D 0.44 2 0.88

BM-25.0 0.40 10 4.00

DGAB 21B 0.12 6 0.72

OGB 0.05 12 0.60

Total 32 7.08

SMA 0.44 2 0.88

IM-19.0D 0.44 2 0.88

FBSB 0.30 12 3.60

LSSB 0.15 12 1.80

Total 28 7.16

FBSB FBSB –– Foamed Bitumen Stabilised BaseFoamed Bitumen Stabilised Base

LSSB LSSB –– Lime Stabilised BaseLime Stabilised Base

Mill existing asphalt layers (Mill existing asphalt layers (±±12”) of the slow lane and slow shoulder to stockpile.12”) of the slow lane and slow shoulder to stockpile.

Spread 5% lime after millingSpread 5% lime after milling

InIn--situ recycle 12” of exposed existing pavement in the slow lane and slow shoulder, situ recycle 12” of exposed existing pavement in the slow lane and slow shoulder, whilst simultaneously stabilizing with nominal 5% lime. Shape and compact to whilst simultaneously stabilizing with nominal 5% lime. Shape and compact to

minimum 97% of modified AASHTO compaction or refusal densityminimum 97% of modified AASHTO compaction or refusal density

Stabilize the RAP material in Stabilize the RAP material in stockpilestockpile using a static foamed bitumen plant using a static foamed bitumen plant with nominal 2.2% foamed bitumen and 1% cement.with nominal 2.2% foamed bitumen and 1% cement.

KMA 220: Mixing of milled asphalt with 2,2 % foamed bitumen and 1.0 % cementKMA 220: Mixing of milled asphalt with 2,2 % foamed bitumen and 1.0 % cement


Stabilise base with foamed bitumen 3% and cement slurry 2%

-- Place 2” IMPlace 2” IM--19.0D across the full road width.19.0D across the full road width.-- Surface the mainline pavement and inside shoulder with 2” SMASurface the mainline pavement and inside shoulder with 2” SMA--12.5(7012.5(70--22)22)-- Surface the outside shoulder with 2” SMSurface the outside shoulder with 2” SM--12.5A12.5A

Recycled layer open for traffic before overlay with asphaltRecycled layer open for traffic before overlay with asphalt

�Project Example City Puebla Mexico�Project Example City Puebla Mexico

14 Oriente

Application ExampleApplication Example

Road WideningRoad WideningRoad WideningRoad Widening

Fort McMurray, AlbertaFort McMurray, Alberta

Existing (nominal) 24ft pavement to be extended to 44ftExisting (nominal) 24ft pavement to be extended to 44ft

Cut existing shoulder and vergeCut existing shoulder and verge

Compact with pad foot rollerCompact with pad foot roller

Mill existing pavement and CTB base with W2200 windrow material to new widthMill existing pavement and CTB base with W2200 windrow material to new width

Mill asphalt pavement and CTB base to depth of 10”Mill asphalt pavement and CTB base to depth of 10”

Blade windrowed millings level to width, add 6” to 8” crushed base materialBlade windrowed millings level to width, add 6” to 8” crushed base material

Spread cement at rate 1.5% across extended lane widthSpread cement at rate 1.5% across extended lane width

Stabilise extended lane with WR2500S, 2.5% foamed bitumen to depth of 11”Stabilise extended lane with WR2500S, 2.5% foamed bitumen to depth of 11”

Widened pavement out to 44ftWidened pavement out to 44ft

Recycler and Soil Stabilizer

600

800

1000

Num

ber

of

Col

d R

ecyc

ler

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

0

200

400

600

Num

ber

of

Col

d R

ecyc

ler

Year

Increasing market

** total included CIR units & plant mix units** total included CIR units & plant mix units

Gradation

Gradation Specification Requirement

100% passing 37mm

90% passing 25mm

Statistical Analysis of

Sieve size

Field results

Gradation

Analysis of Percent Passing 37mm 25mm 19mm

Mean 100 96 92

Standard deviation 0 1.69 2.68

Highest value 100 99 96

Lowest value 100 91 81

Coefficient of variation 0 1.8 2.9

2.1 Visual Assessment

The section of Avenida 14 Oriente extends from Cadete Vicente Suarez to the Municipal limit. The road starts as single carriageway and changes to dual carriageway towards the Municipal limit. The existing surface is asphalt that is severely cracked

14 Oriente Investigation / Design

existing surface is asphalt that is severely cracked and loss of surfacing is evident in many places. Areas of block cracking indicate a stabilised base layer.

The block cracks in most areas have degenerated into crocodile cracks and pumping of fines from the base is evident.

This is an indication that the base layer in these areas of pumping has reverted to its granular state .

Table 1: Summary of Asphalt Thickness

The thickness of the asphalt ranged from 9cm to 25cm. The 25cm measurement was taken close to the Municipal limit and can be considered an outlier since the

other 5 measurements and the 4 measurements from the test pits range from 9cm to 13.5cm as shown in Table 1 below. The average thickness of the asphalt can be

taken as 10cm.

Existing Asphalt

Table 1: Summary of Asphalt Thickness

Nucleo No

Thickness (cms)

Test Pit No

Thickness (cms)

1 25.0 PCA 1 10.0

2 9.0 PCA 2 10.0

3 10.5 PCA 3 9.5

4 10.0 PCA 4 9.5

5 10.2

6 13.5

Test Pits

2.3 Test PitsFour test pits were excavated during the September 2006 investigation.

The test pits allowed the pavement profile to be identified and samples of the pavement materials were tested in order to classify the pavement materials.

The base layer was found to have an average thickness of 20cm.

The only indication that this material could have been stabilised is the description of sample (muestra) 3 which reads “GRAVA CEMENTADA”. The CBR of this material ranges from 77% to 108% and only 1 sample showed any plasticity with recorded a linear shrinkage of 4.6%.

The other samples showed zero shrinkage.

3.1 Stabilisation DesignSamples of the asphalt were taken at 2 positions along the road to a depth of 10cm as this is the minimum recommended depth for cold recycling.

Foamed bitumen mix designs were undertaken to determine the application rates for foamed bitumen to achieve optimal strengths and to determine the strength characteristics for use in the structural design exercise. Foamed bitumen was added at between 2.0 and 3.0% foamed bitumen by mass of sample. The foamed bitumen stabilised samples were then compacted using “Marshall” effort and placed on an oven at 40 deg C for 3 days to cure.

Stabilisation Design

Table 2: Foamed Bitumen Mix Designs

BlendFoamed Bitumen (%)

Bulk Density

Average ITS dry

Average ITS

soaked

TSR (%)

Sample 1100% RAP

2.0 1854 335 422 > 100

2.5 1872 343 477 > 100

3.0 1865 360 470 > 100

Sample 2100% RAP

2.0 1782 260 138 53

2.5 1793 278 153 55

3.0 1799 257 162 63

The briquettes were then tested for dry and soaked Indirect Tensile Strength (ITS). A summary of the tests can be found in Table 2 below.

Table 5: Traffic calculations Northbound Southbound

Traffic count per carriageway (9 hour count) 7989 7241

Approximate 24 hour count ( 9 hour count x 1.2) 9600 8700

Average daily truck count ( 4% of total traffic) 384 348

Traffic

Average daily truck count ( 4% of total traffic) 384 348

Average daily axle count (1.7 axles per truck) 655 590

Lane distribution ( 0.9 for slow lane) 590 530

Average daily axle count per carriageway 560

Design traffic for 5 years 1.8




Table 4: Structural Numbers with seal surfacing

Material

Structural

Coefficient (per

cm)

Depth of Recycling

10 12 15 17 20

Recycled layer 0.140 10 12 15 17 20

SN with Seal Only

Recycled layer 0.140 10 12 15 17 20

Existing base 0.055 20 18 15 13 10

Existing subbase

0.040 30 30 30 30 30

Required Structural Number

3.34 3.44 3.59 3.68 3.83

Traffic estimate (million axles)(8 ton axle load)

2.8 3.4 4.5 5.3 7.0


1.2 1.4 1.9 2.2 2.9

Table 3: Structural Numbers with asphalt surfacing

Material

Structural

Coefficient (per cm)

Depth of Recycling

10 12 15 17 20

Asphalt (new) 0.165 4 4 4 4 4

SN with Asphalt Overlay

Recycled layer 0.104 10 12 15 17 20

Existing base 0.055 20 18 15 13 10

Existing subbase

0.040 30 30 30 30 30

Achievable Structural Number

4.00 4.10 4.25 4.34 4.49


9.4 11.2 14.5 16.8 21.4


3.9 4.7 6.0 7.0 8.9

Diagonal Boulevard Investigation / Design

2.1 Visual Assessment

The 3.36km section of Diagonal Ave.that is to be rehabilitated is a dual-carriageway facility with three traffic lanes per carriageway. The existing surface is asphalt that is severelycracked in many places . cracked in many places .

Areas of block cracking indicate a stabilised base layer . The block cracks in most areas have degenerated into crocodile cracks and pumping of fines from the base is evident.

This is an indication that the base layer in these areas of pumping has reverted to its granular state. No rutting or deformation due to pavement failure was noted.

Existing Asphalt / Coring

Table 1: Core Thickness

Northbound Southbound

Distance (from 18 de Noviembre

Blvd)

Thickness (cm)

Base Condition

Distance (from 18 de Noviembre

Blvd)

Thickness (cm)

Base Condition

0+300 6.0 Cemented 0+300 7.0Strongly

cemented

0+600 5.5Strongly

cemented0+600 6.5

Strongly cementedcemented cemented

0+900 8.8 Cemented sand 0+900 9.5 Cemented sand

1+200 5.5 Weakly cemented 1+200 7.8 Weakly cemented


1+800 8.5 Weakly cemented 1+800 5.5Strongly

cemented

2+100 8.0Strongly

cemented2+100 10.5 Weakly cemented




3+300 10.3Strongly

cemented

Test Pits

2.3 Test Pits

Two 1m x 1m test pits were excavated to a depth of 0.8m.

Representative samples from each different layer encountered were retained for laboratory testing, including bulk samples from the asphalt and base including bulk samples from the asphalt and base layers for foamed bitumen mix designs.

The asphalt found in the test pits was dry and brittle.

The base material comprised a crushed rock in a sandy matrix. This material was previously stabilised but has reverted to its natural granular state.

The thickness of the base was 23 and 27cm.

Underlying the crushed rock material was residual silty to clayey sands.

Stabilisation Design

Table 2: Foamed Bitumen Mix Designs

BlendFoamed Bitumen

(%)

Cement (%)

Average ITS dry

Average ITS

soaked

TSR (%)

100% RAP

2.0 0 604 187 31

2.5 0 595 263 44

3.0 0 561 179 323.0 0 561 179 32

50% RAP : 50% BaseDiagonal

2.5 1 374 272 73

3.0 1 519 365 70

3.5 1 535 408 76

50% RAP : 50% Base5 de Mayo

2.5 1 646 450 70

3.0 1 638 357 56

3.5 1 629 425 68

25% RAP :75% Base

2.5 1 595 306 51

3.0 1 697 263 38

3.5 1 603 298 49

Table 3: Structural Numbers with asphalt surfacing

Material

Structural

Coefficient (per

cm)

Depth of Recycling

10 12 15 17 20

Asphalt (new) 0.165 4 4 4 4 4

SN with Asphalt Overlay

Recycled layer 0.140 10 12 15 17 20

Existing base layer

0.055 25 23 20 18 15


3.43 3.61 3.87 4.06 4.29


5.6 7.9 12.8 17.9 26.4


2.3 3.3 5.3 7.5 11.0

SN with Seal Only

Table 4: Structural Numbers with seal surfacing

Material

Structural

Coefficient (per

cm)

Depth of Recycling

10 12 15 17 20

Recycled layer 0.140 10 12 15 17 20Recycled layer 0.140 10 12 15 17 20

Existing base layer

0.055 25 23 20 18 15


2.77 2.95 3.21 3.40 3.63


1.4 2.1 3.6 5.3 8.3


0.6 0.9 1.5 2.2 3.5

Documents

CIR Project Example