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Innovative Methodologies
for Road Surface Maintenance in Japan;
HIR (Hot In-place Recycling),
Hot In-place Thin Overlay and
Hot In-place Transforming
National Conference on Highways Construction Technology
at Hyderabad
July 15, 2016
HIR Target Work Fields (Red-Framed)
Type of Activity Increase
Capacity
Increase
Strength
Reduce
Aging
Restore
Serviceability
New Construction ○ ○ ○ ○
Reconstruction ○ ○ ○
Major (Heavy)
Rehabilitation ○ ○
Structural Overlay ○ ○
Minor (Light)
Rehabilitation
Preventive
Maintenance ○
Routine
Maintenance
Corrective
(Reactive)
Maintenance
Catastrophic
Maintenance
Pavement Preservation Guidelines
○
Pavement
Preservation
Table Source : US FHWA
○
○
○
○
○
○
○
○
2
Green Technology for Sustainable Highway Reconstruction
Hot In-place Recycling
•Economics Including Construction Cost & Long Life
• Resource Saving
• Safety Improvement
• CO2 Emission Reduction
Innovative Method beyond the Conventional Method
3
Very Poor
Poor
Fair
Good
Very Good
Optimum Rehabilitation Point
Accumulated Axile Loads
Rehabilitation with Thin Overlay by HITO
Pavement Condition Sharply Drops
Will Cost 2 to 3 times as much as at Optimum Rehabilitation Point
Original Condition
Pavement Life
Reconstruction or Major Rehabilitation
Existing Pavement
Pavement Life-Cycle Prolongation through Keeping Condition Approach
Pavement Condition
Rehabilitation with Thin Overlay by HITO
Pavement Management System for Sustainable Road Construction
Features of asphalt mixture; Recyclable,
Easily softend by heater at 60 to 80 ℃ with aggregates not damaged.
What is HIR?
Heating to Soften Milling of Heated
Asphalt Mix
Adding
of New
Ad-Mix
Mixing Laying
down Compacting
Resource Saving Reuse 100% of existing asphalt mixture (Usually 70%
reduction of new asphalt mixture compared with
conventional method)
Economics More economical than prevailing conventional Mill & Fill
method
Environment No smell, no smoke, no fire under usual operation
Reduction of CO2 emission (40% reduction compared with
conventional Mill & Fill method)
Work Speed 5m/min on average
HIR Mill & Fill CIR
○ ○ ○
○ ○ -
Alligator ○ ○ ○
Longitudinal ○ ○ ○
Transverse ○ ○ ○
○ ○ -
○ ○ -
○ ○ -
Loosening Hard Milling or Excavation Hard Milling
Not Crushed Crushed and Disposed Crushed
100% Onsite Reuse Replace 100% Onsite Reuse
Unchanged - Changed
Not Required Tack Coat Cleaning and Tack Coat
Not Required By Truck Not Required
Bleeding
Slipperiness
Existing Asphalt Mixture
Aggregate in Use
Re-habilitation Method
Ty
pe
of
Pav
emen
t D
istr
ess
Ch
arac
teri
stic
s
Mixture Gradation
Pre-Treatment Under Layer
Transport Reclaimed Materials to Plant
Cracking
Rutting
Unevenness (Corrugation)
Raveling
Mico Surfacing
(Slurry Seals)
△
×
×
×
×
○
△
○
-
-
-
-
Cleaning and Tack Coat
Not Required
Why HIR Preferred?
- Usually not used Suitable × Unsuitable
* *
*: depending on the damaged condition
Superb Hot Air Heating System developed by Green ARM
Hot Air Heating System;
Easy Supply of Fuel on Site for Surface Heating,
Diesel: Much Safer Fuel than Propane,
Hot Air Heating; Gentle and Even Heating,
Step-less Adjustment of Heating Width HEATER (Green ARM’s Heater)
Surface Temperature after Heating
(Patent No. JP 4024293)
Heating
Advantages with Hot Air Circulation Heater
The performance has been confirmed through road heating work in Japan and California, US.
Smoke
Fire
Difference in ignition point
(Due to lower oxygen content)
0 2 4 6 8 10 12 14
400
300
200
100
tem
pera
ture
[℃]
Time[minute]
Surface
Smoke
Surface
The hot air circulation system The hot air circulation system
Fire
-20mm
-20mm
Infrared Burner Hot Air Circulation Heater
Road surface
Road
surface
1. Gentle Heating; No Overheating of Road Surface.
2. Homogeneous Heating of Road Surface.
3. No Smoke, No Fire, No Odor.
FIRE
SMOKE
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Hot In-place Thin Overlay
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Hot In-place Thin Overlay; New Easy Preservation Method
Crack
Rutting
Structural Profile
Patching
Light Distress
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Method of Hot In-place Thin Overlay (HITO)
Heating Scarifing Paving Compaction
Scarifier
New Hot Asphalt Mixture to be added
Existing Mixture
New Thin Overlay
Strong bonding
HITO Method
Road Heater
+
Scarifier
Delivery Truck
Asphalt Finisher
Steel Roller
Tire Roller
• Simple Repavement
• Short Train Composites
• Good Performance
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Key Technology of HITO
KAJIMA RO AD
Hot Air Circulation Scarifier
Existing Road Surface
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Characteristic Features of HITO Method
1. Combination of Efficient Heater & Conventional Paving Machine
2. Advance Mix Design Work Not Required ;
Ordinary Asphalt Mixture Available in the Market ready to be used for New Hot Asphalt Mixture to be added
Simple Work;
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HITO Work; Evaluation of Increase in Strength
Loading Test
Loading Test
with Wheel Tracking
Overlay
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HITO Work; Loading Test Result
Overlay (t=3cm)
Seal Infusion +
Overlay (t=2cm)
HITO Scarifying 2cm
Filling 2cm
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HITO Work; Cost Reduction
0
10
20
30
40
50
60
70
80
90
100
HITO (scarifing=2cm,filling=2cm)
HIR (milling=3cm,filling=2cm)
Overlay (t=5cm) Mill & Fill (t=5cm)
%
Construction Cost
Material Cost
+ R
eju
venato
r
51%
68%
84%
100%
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0
10
20
30
40
50
60
70
80
90
100
HITO HIR Mill & Fill (t=5cm)
%
Prduction of Asphalt Mixture
Material Delivery
Construction
Waste Delivery
HITO Work; CO2 Reduction
68%
100%
61%
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HITO Work; Summary
1. Life Extension
・ Sound conditions confirmed in more than 3 years
2. Cost Reduction
・ 49% Less than Mill & Fill
3. CO2 Reduction
・ 39% Less than Mill & Fill
4. Riding Quality Improvement
・ Elimination of Rutting
・ Elimination of Cracks
Site National Highway Route 77 in Okinawa
Hot In-place Transforming; Invented by Green ARM and Patented
Before(Dense) After(Porous)
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Binder
Rejuvenator
New Porous Asphalt Mixture
Compaction
Milling of Surface
Heating
Mixing for Lower
Layer
•More than 13mm
•Less than 5mm
Sieve
Mixing for
Porous Layer Mastic Layer
Dense Surface Course
Binder Course
13-5mm
Porous Layer
Hot In-place Transforming (Dense to Porous)
Dense Surface Mixture sieved, then transformed to Porous Mixture and
Mastic Mixture on Site by Double-lay Paver
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Site; National Highway Route 126 in Chiba prefecture, Japan
Construction Volume; 3,000㎡ (Length:400m×2Lane)
Construction Speed; 2.0m/min
Hot In-place Transforming Work done (Dense to Porous)
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HIT Work; Reduction of CO2 Emission
0
4000
8000
12000
16000
20000
kg-CO2
HI-T工法 従来工法
Pre-Heater
Heater-Miller
Separator
Mixer-Paver
Compaction
Producing & deliveries
of new aggregate
Cleaning + Removing
Milling
Manufacturing & delivering of new asphalt mixture
Hot in Place
Transforming
Conventional
Method
16,756
11,688
30%down
do
Compaction
Tack coating
Kg-CO2
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Green ARM offers Green and Cost Saving Technologies
for Road Surface Maintenance and together with Terpl
Private Co., Ltd., India is ready to contribute
to Road Infrastructure Improvement in India
Thank you.
To be followed by NICHIREKI, which introduces its
bridge life prolongation technology.