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Recycled Asphalt Program & Environmental Stewardship Program ( Post Consumer Content). Robert C. Rea Nebraska Department of Roads WASHTO – Omaha, Nebraska April 2014. Average RAP Contents (Overall). 39.2%. 37.3%. 34.4%. 28.6%. 27.3%. 6.9%. RAP Savings ($ millions). 43.6M. 41.7M. - PowerPoint PPT Presentation
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Recycled Asphalt Program&
Environmental Stewardship Program(Post Consumer Content)
Robert C. ReaNebraska Department of RoadsWASHTO – Omaha, Nebraska
April 2014
Average RAP Contents (Overall)
2007 2009 2010 2011 2012 201305
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6.9%
27.3% 28.6%
34.4%37.3% 39.2%
RAP Savings ($ millions)
2007 2009 2010 2011 2012 201305
1015202530354045
3.6M
23.3M19.8M
41.7M
35.3M
43.6M
How did we get to 39.2% average RAP ?
Design and Specifications to optimize RAP
RAP Incentive for binder savings
RAP Incentive for binder savings
1. Binder Cost Subsidiary to Mix (36 States)
• Not Needed -- Incentive is already there to use less contractor purchased ‘new’ binder• SPECIFICATIONS2. Binder Paid Separately as Bid Item
(14 States)• Needed -- No incentive for the Contractor
to underrun an established item, so we must place incentive on the net binder savings• SPECIFICATIONS and INCENTIVE
15% of Binder SavingsFor Contractor
35% of Binder SavingsFor Contractor
50% of Binder SavingsFor Contractor
DOT Millings from ‘ON’ project DOT Millings from ‘OFF’ project
Contractor ‘Owned’ Millings
90% of our projects are this 8% of our projects are this 2% of our projects are this
85/15 Incentive Split 65/35 Incentive Split 50/50 Incentive Split
Example 40,000 Ton Project( 5 M ESAL Design – Typical SPR mix )
MILLINGS FROM ON PROJECT85/15 Incentive Split
• Mill 2” – Fill 3”• Hot Mix = $ 30 per ton• Binder PG 64-34 = $650 per liquid ton• Design is for 5.4% Binder Content
Total Cost = $2,604,000Recycle Savings to DOT = $0.00Recycle Incentive to the Contractor = $0.00
Total final Cost Realized by DOT $2,604,000
Virgin Mix (No RAP)• Hot Mix = 1,200,000• Virgin Binder = $1,404,000• Binder from RAP = $0 Total Cost = $2,604,000
Pre-incentive 2008 (6.9% RAP)• Hot Mix = 1,200,000• Virgin Binder = $1,307,124• Binder from RAP = $96,876
Total Cost = $2,507,124
Current w/Incentive (45% RAP)• Hot Mix = 1,200,000• Virgin Binder = $772,200• Binder from RAP = $631,800
Total Cost = $1,972,200
Total Cost = $2,604,000Recycle Savings to DOT = $96,876Recycle Incentive to the Contractor = $0.00
Total final Cost Realized by DOT $2,507,124
Total Cost = $2,604,000Recycle Savings to DOT = $537,030Recycle Incentive to the Contractor = $94,770
Total final Cost Realized by DOT $2,066,970
Virgin Mix (No RAP)
Total final Cost Realized by DOT $2,604,000
Pre-incentive 2008 (6.9% RAP)
Current w/Incentive (45% RAP)
Savings from optimizing RAP
$440,000 to $550,000Total final Cost Realized by DOT
$2,507,124
Total final Cost Realized by DOT $2,066,970 On one 40,000 ton hot mix project
REASONS RAP USE MAY BE LIMITED
1. Agency limits use of RAP or says ‘I want the new stuff, not the used stuff ’
2. Stigma of lesser quality, Engineered Design a must 3. Plant Superintendant says ‘The plant won’t run that much’4. Design must optimize mill and fill strategies or ‘Road
Mining’5. Requires binder grade bumps/dumps when higher amounts
are used6. Restrictive in the specification, i.e. dust/asphalt maximum7. Limits the RAP #200 amounts and therefor rejects the RAP8. Voids and VMA and other properties restrict the amount of
RAP
SPR – Mix Design• CAA
o 83 Allows for RAP Variation, typically 90+
• FAAo Allows for RAP Variation, typically 44+o FAA Sp. Gravity slightly lowers true FAAo Binder Grade and Volumetrics provide added
Rutting Resistanceo Overshoot FAA – Increased Cracking
• Voidso Allow more dust & binder, better field density
• Min. Bindero Used as Factor for VMA
• #200o Typically around 4-6%, D/B around 1.0-1.2
APA Testing of SPR Mixes
• 8000 Cycles• 100 PSI Pressure Load• 64 degrees C• Max of 12 mm Rutting
APA Testing of SPR Mixes
02468
101214
APA Testing of SPR vs SP-4SP-4 SPR
Rutt
ing
(mm
)
44.7%
Approach to a 50% RAP Project1. Pick a 20,000 to 40,000 Ton Project 2. Use a ‘tried and true’ mix that you know works and has been a
workhorse for your state 3. Specify the quality and type of virgin aggregate that you want to use,
in other words, the ones that you like and are of good quality4. Use softest base oil you can get either -34 or -28 if you can 5. Specify a minimum Binder Content if you don’t pay ac separately6. Specify minimum 40 % RAP7. Have the RAP come from the road…….fresh processed millings8. Be flexible with the #200 material9. Lower voids and no VMA spec, effects of burnoff oven – another all
day presentation to discuss this control by voids and binder content10. Place it in all lifts, especially surface, we want to monitor this material
(No RAP) (20% RAP) (50% RAP)05
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BinderAggregate
$ 12
Type ‘R’ Asphalt
$ 36
$ 24
$ 12 - $ 20$ 44
RAP Savings Potential $ 12 to $20 per Ton x ?? Million Tons $ 10 to 40 Million
Annual Savings realized every year, over and over and over again .
Not to mention, Better on the environment, Green Technology, Recycling, Less Raw Materials, Less Hauling, Less Transportation and consumption of fuels ……..
Post Consumer Content
On Project Plan Sets in 2014
Thank You!
