Cold In-Place Recycling
Cold In-Place Recycling Dan Schellhammer, P.E.
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Overview • Right Tool, Right Time, Right Place • Cold Mix - It is NOT hot mix! • Cold Mix - How is it made? • Economics • Additives • Best Practices: Project Selection and Construction
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Right Tool, Right Place, Right Time • • • • • • •
Save Money Save Time Extend the Life of Pavement Reduce Maintenance Costs Improve Ride Reduce Carbon Emissions Recycle and Re-Use Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
COLD MIX -It’s NOT hot mix! Looks black and smooth
Coarse graded and sensitive
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Multi-Unit Cold In-Place Recycling Train
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Single Unit Train Photo Credit: Dunn Company
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Cold Central Plant Recycling (CCPR)
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
COLD MIX -How is it made? • CIR (Cold In-Place Recycling) • Multi-Unit • 75% of the Cold Mix Market in the Midwest
• CIR (Cold In-Place Recycling) • Single Unit • 24% of the Cold Mix Market in the Midwest
• CCPR (Cold Central Plant Recycling) • Less than 1% of the Cold Mix Market in the Midwest Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Economics • Many Scenarios, Many Options to Consider • Price of Cold Mix Asphalt placed and compacted • Less than $30 per TN • Closer to $18 per TN in a competitive Cold Mix Market
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Additives • Emulsion, 3% by Weight • Types: CSS-1H, HFMS-2S, Engineered
• PG Graded Binder (Foam), 2% by Weight • Types: PG 49-34, PG 52-34, PG 58-28, PG 64-22
• Modify Cold Mix Performance by Adding Other Materials • Portland Cement • Quicklime/Hydrated Lime • Lime Slurry • Add Rock Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Tricks of the Trade
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Project Selection
• Good Candidates • Structurally Sound • Stable Subgrade • Well Drained (No Cattails in the Ditch)
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Bad Candidates • Wet or Weak Subgrade • Shallow Depths of Existing Asphalt • Inconsistent Asphalt Depths • 100% RAP mix • Steady mixture of RAP vs. Agg Base
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Depth of CIR • 3 to 4 inches is the Sweet Spot, 5 inch max • Less than 3 inches, Resistance to Reflective Cracking is Reduced • 4 to 5 inches Increases the Size of the Windrow • SFDR should be considered when going over 5 inches (Economy and Compaction)
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Profile and Cross Slope Corrections • Condition of Existing Roadway • Percent Improvement (Profile) • 0.5% Cross Slope Corrections • Alternatives • Wedge/Level with HMA • Profile Mill (3D Milling) • Consider use of other pavement rehab technique Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Traffic Control • Roads that are Closed and Only Open to Local Traffic are Safest • Manage Time Lapse of Traffic on Fresh Mat • Work Zone 2 Miles or Less • Train Moves Against Traffic to Prevent Vehicles from Being Parked on New CIR Mat • Pilot Car and Flaggers Needed if the Road Remains Open to Traffic • Keep your Head on a Swivel Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Quality Control • Mix Design • Establish a Rolling Pattern • Perform Gradations and Compare Field RAP Size to Mix Design RAP Size • Nuke Gauge • Timely Reporting of Test Results • Foaming Characteristics • Monitor Moisture of the CIR Layer to Ensure Cure Prior to Surface Treatment • Enforce Specifications • Allow Input from Experienced Contractors Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Curing of the Cold Mix • Rolling Traffic is our Friend • Self Healing • Stop Signs • Frequent Turning can Tear the Mat • Limit Haul Routes • Hot, Sunny Days will Accelerate Cure • When the Water is Out, Cover It Up • Do NOT Apply a Surface Treatment on a Mat that has not Cured Out Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Surfacing Options • Dependent on Traffic Count and Axle Loading • • • • •
Chip Seal Double Chip Seal MicroSurface Single Lift of HMA Double Lift of HMA
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Other Applications • Interstate • I-680 in Iowa outside of Council Bluffs, IA
• Local Airports • CIR over Concrete • Throughout Iowa
• Suburban/Urban Areas • Shoulders • Interstate
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Summary • Use the Right Tool, Right Time, Right Place for a successful Cold In-Place Recycling project • Cost Savings • Roadway Maintenance • Smoother Ride • Reset the Service Life of your Existing Roadway System
• Shorter Construction Durations than a Reconstruct • Safer for Traveling Public and Construction Workers
• Green • Recycle 100% of the Roadway
• Reduced Environmental Impact (Mining of Virgin Aggregate Eliminated and Lower CO2 Footprint) Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Questions? Dan Schellhammer, P.E. Midstate Reclamation and Trucking 21955 Grenada Avenue Lakeville, MN 55044 Email: [email protected] Office: 952-985-5555 Mobile: 612-490-3835
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Overview • Right Tool, Right Time, Right Place • Cold Mix - It is NOT hot mix! • Cold Mix - How is it made? • Economics • Additives • Best Practices: Project Selection and Construction
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Right Tool, Right Place, Right Time • • • • • • •
Save Money Save Time Extend the Life of Pavement Reduce Maintenance Costs Improve Ride Reduce Carbon Emissions Recycle and Re-Use Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
COLD MIX -It’s NOT hot mix! Looks black and smooth
Coarse graded and sensitive
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Multi-Unit Cold In-Place Recycling Train
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Single Unit Train Photo Credit: Dunn Company
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Cold Central Plant Recycling (CCPR)
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
COLD MIX -How is it made? • CIR (Cold In-Place Recycling) • Multi-Unit • 75% of the Cold Mix Market in the Midwest
• CIR (Cold In-Place Recycling) • Single Unit • 24% of the Cold Mix Market in the Midwest
• CCPR (Cold Central Plant Recycling) • Less than 1% of the Cold Mix Market in the Midwest Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Economics • Many Scenarios, Many Options to Consider • Price of Cold Mix Asphalt placed and compacted • Less than $30 per TN • Closer to $18 per TN in a competitive Cold Mix Market
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Additives • Emulsion, 3% by Weight • Types: CSS-1H, HFMS-2S, Engineered
• PG Graded Binder (Foam), 2% by Weight • Types: PG 49-34, PG 52-34, PG 58-28, PG 64-22
• Modify Cold Mix Performance by Adding Other Materials • Portland Cement • Quicklime/Hydrated Lime • Lime Slurry • Add Rock Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Tricks of the Trade
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Project Selection
• Good Candidates • Structurally Sound • Stable Subgrade • Well Drained (No Cattails in the Ditch)
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Bad Candidates • Wet or Weak Subgrade • Shallow Depths of Existing Asphalt • Inconsistent Asphalt Depths • 100% RAP mix • Steady mixture of RAP vs. Agg Base
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Depth of CIR • 3 to 4 inches is the Sweet Spot, 5 inch max • Less than 3 inches, Resistance to Reflective Cracking is Reduced • 4 to 5 inches Increases the Size of the Windrow • SFDR should be considered when going over 5 inches (Economy and Compaction)
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Profile and Cross Slope Corrections • Condition of Existing Roadway • Percent Improvement (Profile) • 0.5% Cross Slope Corrections • Alternatives • Wedge/Level with HMA • Profile Mill (3D Milling) • Consider use of other pavement rehab technique Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Traffic Control • Roads that are Closed and Only Open to Local Traffic are Safest • Manage Time Lapse of Traffic on Fresh Mat • Work Zone 2 Miles or Less • Train Moves Against Traffic to Prevent Vehicles from Being Parked on New CIR Mat • Pilot Car and Flaggers Needed if the Road Remains Open to Traffic • Keep your Head on a Swivel Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Quality Control • Mix Design • Establish a Rolling Pattern • Perform Gradations and Compare Field RAP Size to Mix Design RAP Size • Nuke Gauge • Timely Reporting of Test Results • Foaming Characteristics • Monitor Moisture of the CIR Layer to Ensure Cure Prior to Surface Treatment • Enforce Specifications • Allow Input from Experienced Contractors Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Curing of the Cold Mix • Rolling Traffic is our Friend • Self Healing • Stop Signs • Frequent Turning can Tear the Mat • Limit Haul Routes • Hot, Sunny Days will Accelerate Cure • When the Water is Out, Cover It Up • Do NOT Apply a Surface Treatment on a Mat that has not Cured Out Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Surfacing Options • Dependent on Traffic Count and Axle Loading • • • • •
Chip Seal Double Chip Seal MicroSurface Single Lift of HMA Double Lift of HMA
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Other Applications • Interstate • I-680 in Iowa outside of Council Bluffs, IA
• Local Airports • CIR over Concrete • Throughout Iowa
• Suburban/Urban Areas • Shoulders • Interstate
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Summary • Use the Right Tool, Right Time, Right Place for a successful Cold In-Place Recycling project • Cost Savings • Roadway Maintenance • Smoother Ride • Reset the Service Life of your Existing Roadway System
• Shorter Construction Durations than a Reconstruct • Safer for Traveling Public and Construction Workers
• Green • Recycle 100% of the Roadway
• Reduced Environmental Impact (Mining of Virgin Aggregate Eliminated and Lower CO2 Footprint) Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
Questions? Dan Schellhammer, P.E. Midstate Reclamation and Trucking 21955 Grenada Avenue Lakeville, MN 55044 Email: [email protected] Office: 952-985-5555 Mobile: 612-490-3835
Midwestern Pavement Preservation Partnership (MPPP) | Traverse City, MI | August 29th, 2017
