V.V.P.

ENGINEERING COLLEGE
CIVIL ENGINEERING DEPARTMENT

Semester – 5TH
Subject : Pavement Design and Highway Construction (3150613)
 Chapter : 5
Introduction to New Technology
Syllabus
 Recycle aggregate Pavements
IRC : 120 (RAP)
➢ Recycling of pavement is the process in which the existing pavement
materials are reclaimed and re-used after reprocessing for either (a)
resurfacing, or (b) repaving, or (c) reconstruction of pavement
depending upon the condition of the existing pavement, the nature of
the reclaimed materials, the method of reprocessing, and the
treatment that the pavement requires.
➢ The justification for reclaiming the pavement materials, consisting
mainly of aggregates and bituminous binders, is both environmental
as well as economic.
 Different Aspect of Recycling
1. Cold in-place recycling
2. Hot in-place recycling
3. Hot in-plant
4. Cold in plant
 1. Cold in-place Recycling
✓ In this process, milling and mixing are simultaneous processes
accomplished by a single equipment or a train of equipment capable of
milling and conveying the milled material to be fed to a pug mill, with
parallel supply line for feeding fresh aggregates also, and separate feeding
lines to the pug mill for bitumen emulsion, and rejuvenator.
✓ Where foam bitumen is to be used, there has to be separate feeding line for
hot bitumen and water to produce the foam bitumen and then feed into the
pug mill. The mixed material is discharged into the paver hopper closely
following the recycling equipment or train of equipment, then paved and
compacted.
✓ This type of recycling is considered suitable for depth upto 150 mm and
the use of reclaimed material is also of the same order (typically 30 to
50%) as in HIP.
✓ Another variant of cold in-place recycling is Full Depth Reclamation,
where the thickness of pavement to be recycled is greater than typically
150 mm. The pavement is ripped, the material pulverized and stabilized
with lime, cement or cementitious materials and compacted into base layer
of the required strength.
A Cold in Place Recycler should be equipped with :

a) Cold milling equipment to mill the existing pavement.

b) A system to carry the milled materials to vibrating screens with a
separate line for fresh aggregates.
c) A system for proportioning and weigh batching of different size
fractions.
d) A Pug mill for mixing with separate material feed lines for
aggregates, binder and rejuvenators.
e) Vibrating screeds for tamping and profiling the mixed materials
discharged from Pug mill.
f) Compaction equipment for compacting the mix.
g) Appropriate arrangements for controlling dust and noise pollution.

https://www.youtube.com/watch?v=gSvCcrnbaKs
https://www.youtube.com/watch?v=0ZXyt_oq6qg
https://www.youtube.com/watch?v=NIdSWB0pJz8
Schematic arrangement for CIR with emulsion
 2. Hot in-place Recycling
✓ In this method, a train of equipment is used with capabilities to perform
different functions such as infrared heating of the pavement surface to soften
it, milling the softened hot pavement surface, transferring the milled
materials into Pug mill mixer of the Recycling equipment through a belt
conveyor, adding fresh mix/binder/rejuvenator as per requirements of design
into the pug mill, discharging the remixed materials into integrated paving
screeds for paving the re-mixed output, rolling and compaction of the paved
material.
✓ 100 per cent of the reclaimed material is utilized. However, its limitation is
that no more than 50 mm thick bituminous layer can be satisfactorily
recycled (maximum 75 mm if softer binder was used in the original
construction).
✓ If the pavement needs to be overlaid from structural consideration, a second
layer of Hot mix overlay may have to be done on top of the recycled surface
and in such situations (also called repaving), HIR has to be done in two
layers (or multiple layers).
✓ In Hot in-place recycling the existing pavement is heated and softened, and then
scarified/milled to a specified depth.
✓ The critical issues involved in HIR plants and processes are the heating of the
pavement surface, scarification, collecting and conveying the RBM (Reclaimed
Bituminous Materials) to the mixer, addition of rejuvenators and fresh mixes into
the mixer, proper mixing of all the ingredients, laying and paving of the mat and
compaction.
✓ The HIR plants, therefore, should have all these facilities in one plant or should
have a train of equipment performing different functions in a synchronized
manner.
✓ Heating, material feed, mixing and laying are the processes to be strictly
controlled. For example, heating of the surface has to be uniform and for that the
number of preheating units is not as important as the length of the heating
areas/hoods on each preheater.
✓ Similarly, the rejuvenator doses have to be metered and controlled. Where fresh
mixes are added, its input quantities have to be controlled.
✓ HIR can be a single pass or multiple pass process. In single pass operation, the
scarified in-place material is compacted and that is the end of the process. In
multiple pass operation, the compacted mix is overlaid by fresh mix. The depth of
treatment varies between 20 to 50 mm and the temperature of the mix in the range
of 110-150 0C.
https://www.youtube.com/watch?v=0nxYEjl30RA
https://www.youtube.com/watch?v=PzjpFKvkj10
 3. Hot in-Plant Recycling
✓ This process involves production and laying of hot mix materials but not
with virgin aggregates and binder but with a combination of reclaimed
stockpiled aggregates already coated with binder and additional virgin
aggregate and fresh binder to meet the requirements of the design.
✓ Usually, some rejuvenator is used to soften the old hardened binder in the
reclaimed aggregates.
✓ Heating the reclaimed binder coated aggregates may release unacceptable
fumes while feeding them cold directly into the pug mill may reduce the
mixing temperature.
✓ The hot mix production process, therefore, has to be suitably modified. In
all other respects, hot in-plant recycling is just like normal hot mix
construction.
✓ Not more than 50% of the reclaimed material is used, though a widely
accepted percentage is only 30% and the thickness in which it can be laid
is typically 100 mm.
https://www.youtube.com/watch?v=coj-e5mhHEQ
 4. Cold in-Plant Recycling
✓ The process involves production of the mix in a plant using either emulsion
or foam bitumen and laying and compaction in the usual manner.
✓ A rejuvenator is to be added in the mixing process to soften the hard binder
in the reclaimed material.
✓ The application range in terms of depth of recycling and use of reclaimed
materials is typically the same as for cold in-place recycling.

https://www.youtube.com/watch?v=fT_2hcEzzgE
 Cold Mix Technology as per IRC SP-100
✓ A cold mix is defined as a mixture of bitumen emulsion and aggregate that
is mixed together at ambient temperature. Bitumen emulsion being liquid
at room temperature, there is no need to heat or dry the mineral aggregate.

✓ Cold mix is useful in the areas, where there is long distance between the
job site and plant and temperature of climate is low and moderate (<40°C).
Further, the versatility of cold mix allows it to be mixed in-place at the job
site as well as at a plant site and then subsequently transported to the job
site.

✓ Cold mix may be used in bituminous base (BM), binder course

(BM/SDBC) as well as wearing course (SDBC) of flexible pavement.
 Construction :
✓ CMBM (Cold Mix Bituminous Macadam) shall not be laid during
raining or when the granular base course is wet or when the
atmospheric temperature in the shade is below 8°C.
✓ The underlying surface on which CMBM is to be laid shall be prepared,
shaped and conditioned to a uniform grade and camber. Depressions,
ruts or potholes shall be repaired in advance at least before the day of
laying. The surface of underlying course shall be thoroughly swept,
made clean free from the dust and foreign materials.
✓ It is imperative to prepare cold mix of proper and uniform quality by
using a cold mix plant.
✓ It is recommended that the plant shall have (1) a twin shaft pug mill,
(2) a tank for emulsion storage, (3) metered pumps for emulsion
transfer to pug mill and water, valves and spray bars, (4) aggregate
feeder bins, (5) conveyor belts for moving aggregate and mix, and (6) a
power source.
✓ The ingredients shall be mixed for about one minute to achieve the
uniform coating of bitumen on mineral aggregates. Excessive mixing
may un-coat the aggregates.
✓ For an open-graded mix like the CMBM, the breaking of bitumen
emulsion usually occurs quickly. With open-graded mixes, rolling may
normally begin immediately behind the paver. Vibratory rolling for
open-graded mixes is not recommended because fracture of aggregate
and bitumen debonding may occur.
✓ The spreading of cold mix will be done preferably by means of a self
propelled mechanical paver at a suitable speed capable of spreading,
tamping and finishing to the proper grade, line and cross-section. The
mix shall be spread in such a manner that, after compaction, the required
thickness of surfacing layer is achieved.
✓ The paver laid cold mix shall be thoroughly and uniformly compacted
by a set of rollers at a speed not more than 5 km per hour. The break
down rolling shall be done with 8-12 tonne three wheel steel roller and
the final rolling shall be done with 8 to 10 tonne tandem roller. Before
finishing rolling by tandem roller, break down rolling shall preferably be
followed by an intermediate rolling with smooth wheel pneumatic roller
of 15 to 30 tonne capacity having a tyre pressure of 7 kg/cm2
✓ Traffic shall be allowed after 2-3 hours, when the cold mix is well set
and is not picked up by thevehicles.