NCAT Test Track ConstructionCCPR & CIR, US280 MP 132 Location

September 2015

Updated: 22.09.15Mike Marshall

Pre-mill US280, Wirtgen W200i Milling Machine

Pre mill depth 5 ins, to accommodate 4 ins of Recycling RAP (including fluff) with provision for 1ins HMA overlay

Screened ¾ ins RAP at NCAT Yard

KMA220 Cold Mix Plant Production, Foam RAP Mix

Foam CCPR

30 t Bitumen tanker

5000 gal Water tanker20 t

Cement silo

Cold mixing plant KMA 200

350 kW Payloader

20 t tip trucks

Typical KMA220 CCPR Site Set Up

KMA220 Cold Mix Plant Control Panel

Foamed Asphalt Mix Design Inputs1.5% Cement, @.0% Compaction Water, 2.5% Foamed Asphalt

Foamed Asphalt Test Nozzle KMA220 Plant Mix

As the cement requirement was low, cement loaded into feed hopper manually

KMA220 discharge conveyor, 100% Recycled RAP directly to truck

Foam RAP Mix delivered to Roadtec Paver, fitted with Carlson Screed

Foamed Asphalt RAP at Paver Screed

Paving Foamed Asphalt RAP, Compacted to 4ins depth

Foamed Asphalt RAP Compaction

Completed Foam CCPR section prior to tack coat

application.

Emulsion Tanker & Cement Feed Connection Positions

Emulsion CCPR

Emulsion Mix Test, determine optimum moisture %age addition

Paving Emulsion RAP after compaction 4ins depth Mix design, 3.0% Emulsion, 1.5% cement & 3.0% Compaction water

Emulsion RAP Compaction

Completed Emulsion CCPR section prior to tack coat application

Tackcoat application to both Foam & Emulsion CCPR sections following compaction

Application Rate 0.050 gal/sqyd

Both CCPR Sections, Foam & Emulsion opened to full traffic after tackcoat application

Sections were trafficked 4 hours after placing recycled RAP

Foam RAP CCPR Section Emulsion CCPR SectionView both sections after overnight unrestricted speed high truck traffic

Emulsion CIR

CIR Section Pre-milled to depth of 1.4ins, 1.5% cement pre-spread on milled pavement

Wirtgen 3800CR, recycling depth, 4ins, emulsion binder, rear load directly to paver

Emulsion recycled material loaded directly into following Roadtec paver hopper

Paving Emulsion CIR Material

3800CR Control panelEmulsion mix design, 3.3% emulsion, 3.3% added compaction water

Emulsion CIR Compaction

Completed Emulsion CIR Section

Foam CIR