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Recycled Asphalt Pavement

Gavin SowardQDTMR Principal Engineer Road Surfacings

Rob VosAAPA Queensland Executive

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Benefits of RAP

• Benefits– Reduced energy

consumption

– Conserving raw materials

– Reduced cost

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The Findings

• RAP increased resilient modulus

• RAP increased creep resistance

• RAP can be readily manufactured to a nominated design

• Fragmenting and screening required

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The Recommendations

“Provision should be made within Departmental documentation for RAP material to be able to be incorporated into production mix used on Main Roads works”

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MRTS30 and 31 – RAP Requirements

• RAP permitted up to 15%

• Required to be fragmented and screened

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The Future

• Research on fatigue properties

• Use of higher percentages of RAP

• Use in surfacings???

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Gold Coast

Sunshine CoastGladstone

Mackay

HMA producer’s view

• Changed Main Roads specification welcomed

• Production based focus simplifies changes to mix approval

• Is common practice in local municipal asphalt - 10 to 20 years experience

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Portable RAP crushing and screening plant Portable RAP crushing and screening plant

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Portable RAP production plant with stockpilesPortable RAP production plant with stockpiles

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RAP valuable and locked upRAP valuable and locked up

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Fixed RAP production facilities

Uniformity of gradation & binder content

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RAP into Batch Plant Pug Mill

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Three covered stockpile bins Three RAP cold feeders

Covered collector belt

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Screen

Screen & delivery belt

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Easy expansion

Difficult upgrade

RAP capability will varyacross HMA plants• space considerations• extra capex to upgrade• plant age vs investment• size of market for RAP• availability of RAP

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RAP & Sustainability

• Reduces material consumption – binders / aggregates

• Energy saving – carbon saving

• Warm Mix Asphalt – extra advantages

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RAP is Worth the Virgin Material it Replaces

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RA

Road Project with RAP available

Waste dump siteA

ggregate quarry

Asphalt Plant

At least 15% RAP* saves haulage “waste”* reuses bitumen (reduces mix requirement)

* reduces aggregate (haul & volumes)

Bitumen $800 / tonne 5.5% $44 materialsAggregate $38 / tonne 93.5% $35 $81 / tonneLime $230 / tonne 1% $2 plusHaulage $0.50 / tonne / km ???? haulageRAP at 15% ( 3.5% bitumen, 96.5% aggregate)= 0.15x($800 x .035 +$38 x .965) - processing – haulage= $9.70 less processing less haulage cost (not 15% $81)

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RAP potential

Availability• Major projects high volumes (>75Kt p.a.)

• Collection & management on smaller works (>25Kt p.a.)

• Need to develop collection capabilities

Usage• Current 15%, Cl320 DG14 & 20 in bases – good start

• Limited in effectiveness – limited demand

• Wearing course not included Long term savings expect $2 to $5 per tonne

for 20% Business as usual = $1.25 million budget saving= $2.88 million resource saving

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RAP members capacity

• All new plant in SEQ can handle 25% to 50% RAP

• Projects are being undertaken with up to 30% RAP

• Stockpiles of more than 6 000 tonnes ready to be used Gold Coast

Sunshine CoastGladstone

Mackay

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RAP next steps

• Get going on major projects

• higher percentages >30% possible– Would increase rut resistance / modulus

– Binder stiffening CL320 towards CL600

– Cost savings on cheaper binder (~10%)

• in wearing course– Currently used for municipal areas along coast

– Should be suitable in low skid demand areas

– Overlays, milling & shape correction in future

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RAP - vision• Valuable product

– savings possible up to $8 / tonne (after capex)

• Ongoing improvements & energy efficiency

• Commercial drivers best for implementation

• Even better when used with Warm Mix Asphalt – C02, worker friendly, energy saving

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