innovative uses for rap in road construction and repair
TRANSCRIPT
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Innovative Uses for RAP in Road Construction and Repair
Amanda Hufft
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Outline
• RAP Availability• FDOT’s Research
RAP in Florida: A Call for Innovation
Introduction to ReCharge™
• 100% RAP Surface Paving• 100% RAP Base Construction• Pothole Patching
Construction of Cold Mixtures
Outline
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RAP Availability
February 25, 20213
→ Reported tonnage of stockpiled RAP represents roughly 1½ years of inventory nationwide
→ About 94% producers reported having stockpiled RAP
NAPA’s Asphalt Pavement Industry Survey on Recycled Materials & WMA Usage (2019)
What can you do with a surplus of RAP??>>
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High RAP Asphalt Mixes forLow Volume Roads
BACKGROUND
→ 1.8 million tons of RAP produced each year from FDOT yearly maintenance and rehabilitation
→ Agency representatives expressed interest in economical solutions for:→ Paving unpaved roads→ Resurfacing existing low volume roads
February 25, 20214
BE 194 (FDOT and TTI, Nov. 2018)
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High RAP Asphalt Mixes forLow Volume Roads
February 25, 20215
BE 194 (FDOT and TTI, Nov. 2018)
21,780
84,320 106,100
14,728
1,563 16,291
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Rural36,508 mi
Urban85,883 mi
Total122,391 mi
Mile
s
Paved and Unpaved Proportions forRural and Urban Roadways in Florida
(Table HM-51, FHWA 2014)
UnpavedRoadsPavedRoads
Length by Functional System with Less than 1,000 ADT in Florida
(Table HM-57, FHWA 2014)
Functional System Rural Urban Total % ADT
< 1,000 (mi) (mi) (mi) Principal Arterials 20 --- 20 0.3 Minor Arterial 105 14 119 1.9 Major Collector 1,210 232 1,442 13.8 Minor Collector --- 118 118 2.3 Total (mi) 1,336 363 1,699 % of Total Length 3.7 0.4 1.4
COMMON DRAWBACKS OF UNPAVED ROADS→ Require frequent maintenance
→ Higher risk of rutting and washboarding
→ Requires routine dust control treatments
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Cold Recycled Mixtures
February 25, 20216
→ Cost comparison indicated savings of 20-50% with cold recycling
→ LCCA concluded the most favorable option was 100% RAP foamed cold recycled mixture
→ Cold recycled mixtures generally did not meet strength requirements and experience accelerated rutting at early load cycles
Conserve Resources
Low Cost(40-50% less than other methods)
Ease of Use(commonly used with emulsified or foamed asphalt)
BE 194 CONCLUSIONS
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ReCharge™ — An advanced cold mix additiveReCharge™ allows for easy blending, spreading, and compaction of 100% RAP material by activating the aged binder on the surface of RAP withoutheat and no additional asphalt.
→ Allows for resurfacing dirt roads at minimal cost
→ Ideal for cold-mix/pothole and patch repairs
→ Job site mixing or off-site pre-mixing
→ No special equipment required
→ Remains workable for several hours
→ Allows traffic within hours of construction
February 25, 20217
KEY BENEFITS
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ReCharge™ — Laboratory Study
SPECIMEN PREPARATION
→ Dose RAP with ReCharge™ and compact to 150 gyrations
→ Place specimen in front of fan for 30 minutes
→ Cure in 60°C oven for 48 or 72 hours
February 25, 20218
Laboratory Study on Curing
2378
2800
Min. 1,250lbtested @ 40°C
0 1 2 3 4
0
500
1000
1500
2000
2500
3000
48 72
Mar
shal
l Sta
bilit
y (lb
)
Curing Time @ 60°C (hr)
Marshall Stability vs. Curing Time @ 60°C
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100% RAP Cold Mix — Surface PavingPROJECT OVERVIEW
February 25, 20219
Location: Gulf Point Rd, Santa Rosa Beach, FL
Traffic: residential road with mostly car traffic
Objective: pave a 100% RAP road using existing RAP stockpileon top of an existing RAP aggregate base
Construction Dates: 07/31/19 to 08/02/19
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100% RAP Cold Mix — Surface Paving
February 25, 202110
Additive Dosing
Mixture Blending Final Product
MIXPRODUCTIONSanta Rosa Beach, FL
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100% RAP Cold Mix — Surface Paving
February 25, 202111
CONSTRUCTIONSanta Rosa Beach, FL
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100% RAP Cold Mix — Surface PavingINITIAL PERFORMANCE
→ Cars were able to drive on roadway within minutes of compaction
→ No visible signs of rutting
→ Hardness comparable to HMA after placement
→ No significant tenderness→ Edge compaction is crucial to performance
February 25, 202112
Santa Rosa Beach, FL – 08/02/19
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100% RAP Cold Mix — Surface PavingFIELD SURVEY – 02/12/20
→ Ride quality: light vibrations with no speed reduction necessary
→ No rutting or cracking
→ Some weathering and raveling mostly along edges
February 25, 202113
Santa Rosa Beach, FL – 02/14/21
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100% RAP Cold Mix — Base ConstructionPROJECT OVERVIEW
February 25, 202114
Location: Riverview Park Rd, Hannibal, MO
Traffic: park road leading to a water treatment plant, low traffic
Objective: mill existing over-crowned asphalt pavement and usemilled RAP to create a stable base for an asphalt overlay
Construction Dates: 09/29/20 and 10/01/20
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100% RAP Cold Mix — Base Construction
February 25, 202115
MIX PRODUCTIONHannibal, MO
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100% RAP Cold Mix — Base Construction
February 25, 202116
BASE CONSTRUCTIONHannibal, MO
Spreading Mix
Compaction
Finished Product
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100% RAP Cold Mix — Base Construction
February 25, 202117
OVERLAY PAVINGHannibal, MO
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100% RAP Cold Mix — Pothole PatchingPROJECT OVERVIEW
February 25, 202118
Location: City of Ridgeland, MS
Traffic: all city roads with varying traffic
Objective: use existing RAP stockpile to patch potholes on cityowned roads
Construction Dates: Ongoing since early 2020
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100% RAP Cold Mix — Pothole PatchingMIX PRODUCTIONCity of Ridgeland, MS
February 25, 202119
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100% RAP Cold Mix — Pothole Patching
February 25, 202120
POTHOLE PATCHINGCity of Ridgeland, MS
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References
February 25, 202121
→ Arambula-Mercado, E., Chavarro-Munoz, S.J., Hu, S., Epps, J., Sug Park, E., and Epps Martin, A. (2018). High Reclaimed Asphalt Pavement (RAP) Asphalt Mixes for Low Volume Roads. Florida Department of Transportation, Tallahassee, FL.
→ Cox, B.C. and Howard, I.L. (2015). Cold In-Place Recycling Characterization Framework and Design Guidance for Single or Multiple Component Binder Systems. Report No. FHWA/MS-DOT-RD-15-250 Vol. 2, Mississippi Department of Transportation, Jackson, MS.
→ Williams, B.A., Willis, J.R., and Shacat, J. (2020). Asphalt Pavement Industry Survey on Recycled Materials and Warm-mix Asphalt Usage: 2019. Information Series 138 (9th
edition). Federal Highway Administration, Washington, DC.
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Questions?