Utilization of

Recycled Asphalt
in Cold Mixes and Cold In-Place
Recycling Processes

Guidelines

Commissioned by: Communities of Tomorrow August 2012

Leveraged Municipal Innovation Fund

Prepared by: Clifton Associates Ltd.

Sponsoring
Municipalities: Moose Jaw, Saskatoon
 Utilization of
Recycled Asphalt in Cold Mixes and
Cold In-Place Recycling Processes

GUIDELINES

Commissioned by:
Communities of Tomorrow
Leveraged Municipal Innovation Fund
June 2012

Prepared by:
Allan Widger, M.Sc., P.Eng.
Frank Skilnick, P.Eng.
Elena Zabolotnii, Engineer-In-Training
Clifton Associates Ltd.
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EXECUTIVE SUMMARY
There are two common sources of reclaimed asphalt: reclaimed asphalt
concrete (RAP) and recycled asphalt shingles (RAS). RAP comes in
the form of lumps and millings. RAS can be obtained as construction
waste or manufactured ends. Any of these materials can be crushed
and blended, with or without the addition of virgin aggregate, to create
blends. Reclaimed asphalt is used as a source of two materials:
aggregate and bitumen.

RAP can be processed to produce a well-controlled material or used

as is.

Rejuvenating agents are used to restore the aged bitumen by restoring

the original ratio of asphaltenes to maltenes. This decreases the
percentage required of new bitumen, cutback or emulsion for the new
mix by reusing the binder already present in the reclaim asphalt
material.

Testing of the reclaimed asphalt is required to determine its following

engineering characteristics: gradation of RAP, gradation of extracted
aggregate, binder content and binder properties. It is also important to
identify any contaminants, impurities or additions, and establish their
impact on the new mix as well as handling requirements.

The design methods for mixes with reclaimed asphalt are generally
similar to conventional methods, with adjustments to best incorporate
the old binder content. Suitable design methods used for cold mixes
include: the modified Marshall Method, ASTM D4215, the modified
Hveem Method, the Oregon Estimation, Chevron Mix Method and the
Asphalt Institute Design Method. In testing the designed mix, it is
critical to eliminate cutback and water content prior to compaction
tests.

For base course design with reclaimed asphalt, the RAP % in the
aggregate blend is determined by testing CBR values for different
mixes. The bearing capacity of the base mix can be improved through
the addition of emulsion, cutback, asphalt or rejuvenator, producing
asphalt-bound base. There is potential to improve the stability and
gradation of the mix by adding Portland cement, fly ash and sawdust
ash.

The AASHTO “Guide for Design and Pavement Structures” is suitable

for structural design using mixes with reclaimed asphalt content, with
the structural capacity of these being considered equivalent to that of
conventional structures.
4

Applications of reclaimed asphalt include:

• Asphalt concrete surfaces:

o Using hot mix design methods with RAP content
below 30%, for surface layers on roadways;
o Using hot, warm and cold mix design methods with
RAP content up to 100% on low volume roads,
parking lots, back alleys, bicycle paths and driveways.
• Granular base:
o In plant-processed mixes with RAP content below
30% used as base and subbase on primary roadways;
o In mixes with 50% RAP content, stabilized with the
use of hot asphalt, emulsified asphalt or foamed
asphalt;
o Using the full-depth reclamation process, and
increasing the RAP % by decreasing the mixing depth
and vice versa;
o Improving the bearing strength of the base with
Portland cement.
• Shoulder base with RAP content up to 100%.
• Fill for embankments, trenches and utility cuts.
• Dust control on gravel roads.
• Slurry seals and chip seals.
• Backfill for temporary earth walls.

Asphalt recycling processes are divided into two major groups: central
plant processes and in-place processes. Central plant processes involve
transporting the reclaim offsite to a processing facility, and provide
better control over the output quality. In-place processes include cold
in-place, hot in-place, and full depth reclamation approaches. Each of
these processes employs distinct equipment. Some equipment
producers have developed proprietary equipment and processes similar
to HIP, CIP and FDR.

The benefits of reclaiming asphalt include recycling aggregate and

binder. Cold processes decrease energy input requirements, and in-
place processes decrease hauling needs. With rising binder costs and
increasing aggregate scarcity, there is a strong argument for economic
benefit and sustainability in using reclaimed asphalt.

Training will allow the assessment of RAP properties and

determination of appropriate uses.
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TABLE OF CONTENTS
1. Introduction 7
2. Definitions and Clarifications 8
3. Types of Reclaim Asphalt Mix 9
3.1 Lumps of Reclaim 9
3.2 Millings 9
3.3 Blends 9
3.4 Cold In-Place Recycled Material 9
3.5 Asphalt Shingles 10
4. Processing of Reclaim Mix 12
5. Rejuvenating Agents 14
6. Testing of Reclaim Mix and Design Methods 15
6.1 Testing Needs and Procedures 15
6.2 Mix Design Methods 16
6.3 Structural Design 19
7. Safety Considerations 20
8. Uses of Reclaimed Material 21
8.1 Production of Cold Mix with RAP 21
8.2 Hot and Warm Mixes 21
8.3 Granular Base 22
8.4 Shoulder Base 23
8.5 Fill 23
8.6 Dust Control on Gravel Roads 24
8.7 Slurry Seals and Chip Seals 24
8.8 Backfill for Temporary Earth Walls 25
8.9 Other 25
9. Process and Equipment 27
9.1 Central Plant Mix Process 27
9.2 In-Place Recycling 29
9.3 Full Depth Reclamation 31
9.4 Recyclers 31
10. Assessment of Best Practices 32
10.1 Economic Benefits 32
10.2 Other Considerations 33
11. Areas of Future Research 34
12. Training 36
13. Conclusions and Recommendations 37
References 40
Photo Credits 45
Appendices 47
Material Specifications
Equipment
Survey Summary
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1. INTRODUCTION
This report has been commissioned by the public-private partnership
Communities of Tomorrow on behalf of a number of Saskatchewan
urban communities with the goal of developing a set of guidelines
reviewing existing applications of reclaimed asphalt in cold mixes and
cold in-place recycled processes. The scope includes materials,
processes and equipment. The guidelines focus on the utilization of
existing reclaim that has been stockpiled.

The anticipated end users of these guidelines comprise municipal road

preservation administrators and supervisors, as well as municipal
council in charge of road maintenance decision-making processes.
While engineering input was necessary to develop the technical
content of these guidelines, a significant effort was made to keep the
information understandable and usable by the intended reader.

To provide the Saskatchewan municipalities with current guidelines on

the matter, worldwide practices on the issue were reviewed, with
special interest for places with similar climate.
8

2. DEFINITIONS AND CLARIFICATIONS

The utilization of reclaimed asphalt is a relatively new field of
practice. As a result, many new terms and acronyms related to the
various aspects of this practice have entered the language. The terms
are individually defined and explained later in these guidelines. A list
of their acronyms and synonyms is provided below.

CIR Cold In-Place Recycling or Cold In-Place

Rehabilitation (interchangeable terms). Sometimes
referred to as CIPR.
CIPR Same as CIR
HIR Hot In-Place Recycling
FDR Full Depth Reclamation
RAP Reclaimed Asphalt Pavement
RAS Recycled Asphalt Shingles
Remixing See “rotomixing”
Rotomixing Also “mixing” or “remixing,” this term describes a step
within the FDR process consisting of milling the
pavement surface and, optionally, the top layer of
subgrade to a specified depth in order to obtain a
granular base material. In the industry, this term is
sometimes used interchangeably with FDR.
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3. TYPES OF RECLAIM ASPHALT MIX

3.1 LUMPS OF RECLAIM

Lumps of reclaim are obtained when ripping the asphalt concrete road
surface with equipment discussed in Section 9.1. Lumps are loaded
and hauled to a central site for storage and processing. Recycling
asphalt concrete material as lumps allows a good control over the size
and gradation of the final aggregate during processing (Kandhal et al,
1997 chap. 12). Crushing of RAP results in a minimal breakdown of
the original aggregate, and the lumps are less likely to set up in
stockpile. Crushing operations resulting in blending of materials from
stockpiles and splitting crushed material also improves uniformity.

3.2 MILLINGS

Millings are the recycled asphalt material obtained as a result of

removal by milling or planning with the use of equipment discussed in
Section 9.2. The asphalt concrete surface material is milled to a
relatively small size, resulting in the aggregate being degraded. The
advantage of recycling asphalt concrete as millings is that it is fast and
done in-place using equipment described in Section 9.2; the drawback
is that there is poor control over gradation and size, often resulting in
oversized particles (Kandhal et al, 1997, chap. 12) and non-uniformity
due to patching materials. Unlike lumps, millings have a tendency to
set up and harden in stockpile, making future processing difficult.

3.3 BLENDS

Crushed reclaimed asphalt lumps, millings and virgin aggregate can be

combined to create a blend with the gradation required to produce a
new mix.

Blended material does not set up as much in the stockpile. However,

blended material that has been stockpiled for a considerable amount of
time, particularly in warm weather, may harden and require re-
crushing (FHWA 2) or reworking.

3.4 COLD IN-PLACE RECYCLED MATERIAL

Due to a very specific production process, the cold in-place recycled

millings or remixing are classified as a separate material category.
Produced by milling equipment which pulverize the existing pavement
surface and then deposit it in place, this material is distinct from
millings, discussed in Section 3.2, in that it is immediately
reincorporated into the road structure with or without additives, rather
than stored off-site and reprocessed. Cold in-place recycling material
may conform to the same property requirements as any other reclaimed
10

asphalt material; however, the in-place processing often results in

lower quality control over the particle gradation. Existing base gravel
is typically incorporated in the pulverized asphalt.

Additives to cold in-place recycled material are as follows:

• Water is mixed thoroughly together with the milled material

to bring it up to its optimum compaction moisture content
(Lewis et al);
• Cement: typically, 2 - 4% (w/w) of cement is added during the
recycling process. The cement can be added in three different
ways: spreading it onto the surface of the road ahead of the
recycler; mixing it with water in a specially designed slurry
mixer to form a slurry that is introduced directly into the
mixing chamber; and using a specialised cement spreader
incorporated in the recycler’s frame (Lewis et al);
• Bitumen emulsion: containing approximately 60% of bitumen
and 40% of water, when used in the cold in place recycling
process, bitumen emulsion is transported in a tanker that is
pushed ahead of the recycling machine (Lewis et al). 0.5 –
3.0% of bitumen emulsion is added to granular road building
materials (Kandhal et al, 1997, chap. 14);
• A combination of bitumen emulsion and cement: in many
cases, combining bitumen emulsion with cement is found to
be effective. The percentage of cement that is added may
typically vary from 1% to 3%. It is introduced into the
recycled mixture together with the bitumen emulsion
(Lewis et al);
• Foamed bitumen: In the case of granular materials, 3 - 5% of
foamed bitumen (w/w) is normally added. When the recycled
material contains a high proportion of asphalt, a reduced
content of foamed bitumen of 2 - 3% is common (Lewis et al).

3.5 ASPHALT SHINGLES

In North America, it is estimated that recycled asphalt shingles (RAS)

constitute 8% of the total construction waste; recycled asphalt shingles
can be used in paving applications, as aggregate for road construction,
as dust control on gravel roads, in cold patch asphalt, and as
feedstock/fuel for cement kilns and coal-fired boilers (NERC).

The primary use of recycled shingles has been in hot mix asphalt
(NERC) in an attempt to reclaim the asphalt. Because of the high
asphalt binder content in RAS (19-36%), even small percentage
additions replace significant quantities of new asphalt binder. RAS can
work in all asphalt mixes provided that all specifications are followed.
Where virgin binder constitutes at least 70% of the total binder, no
 11

change in binder grade is required; otherwise, a softer binder may be According to the NorthEast Recycling Council
(NERC), approximately one million tons of scraps
needed (CAPA).
from asphalt shingle manufacturers are produced
annually in US. A list of North-American shingle
Some manufacturers have developed processes to recycle asphalt producers is provided below (from NERC).
shingles into manufactured shingles, used as a substitute to bitumen in
asphalt concrete pavement, and process engineered fuel used in Producer: Web Site:
Atlas Roofing Corporation (GA,US) atlasroofing.com
industrial burners (Gemaco). Building Products of Canada (QC) bpcan.com
CertainTeed Corporation (PA, US) certainteed.com
EMCO (QC) emcoltd.com
Waste management practices are the primary barrier to effectively GAF/ELK Materials Corporation gaf.com
using asphalt shingles; waste and landfill administration practices can (NJ, US)
IKO Production Inc (ON) iko.com
be locally adapted to collecting shingles for their recycling as opposed Malarkey Roofing Products (OR, malarkeyroofing.com
US)
to disposal in the landfill. The US Environmental Protection Agency Owens Corning (OH, US) roofing.owenscorning.
com
has developed a web site, shinglerecycling.org, as a comprehensive Pacific Coast Building Products, paccoast.com
resource to such management practices. Inc. (CA, US)
W.R. Grace and Co.
TAMKO Building Products, Inc. tamko.com
Sources of asphalt shingles include landfills, shingle production plants
and construction sites. Currently, there is no known effective way of
processing used shingles from landfill sites. The City of Saskatoon
allows asphalt shingle manufactured ends to be incorporated into the
asphalt concrete mix. This eliminates the issue of separating shingles
from nails, improves material uniformity and eliminates issues related
to binder aging.
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Crushers for Central Plant Crushing

Operations (Section 4) 4. PROCESSING OF RECLAIM MIX
Reclaimed asphalt processing pertains to crushing RAP and RAS
Screen Machine Industries material to the desired gradation in order to use it as aggregate and also
(www.screenmachine.com) is a producer of to increase the contact surface area of bitumen so that it can be
crushing plant equipment. ScreenMachine 5256T
softened and reincorporated into the new mix. Crushing can be done
is an example of a stationary impact crushing unit.
See Appendices E1 to E9 on this producer’s on-site for in-place and full depth reclamation processes, and off-site
processing equipment. for central plant cold mix processes.

Central plant crushing operations involve crushing equipment,

screening equipment, and conveyors. The input materials include
lumps (Section 3.1), millings (Section 3.2) shingles (Section 3.5), as
well as virgin aggregate. The output material is a RAP aggregate of
desired gradation. Central plant crushing is done best in winter
conditions, as low temperatures render the bitumen fraction brittle,
ScreenMachine 5256T
making it easier to process.

There are three main types of crushers, listed in order of preference:

Screening Equipment for Central Plant Crushing
Operations • Impact crushers: the aggregate is crushed by the force of
impact as it moves through the machine vertically or
horizontally, depending on the model (SBM).
ELRUS Aggregate Systems (www.elrus.com) are
• Jaw crushers: these are equipped with two sets of vertical
a producer of crushing plant equipment. See
Appendices E9 to E10 for more information on this jaws, one of which is fixed and the other being movable. The
producer’s equipment. aggregate is crushed by the pressure applied by the jaw plates
as it travels downward (Ambica).
• Cone crushers crush aggregate by means of a gyrating spindle
as it travels downward.

These types of crushers can be both stationary and mobile.

Screening equipment includes screens with square openings, slotted

openings and vibrating wire.

In-place processes either use mobile crushing and screening units

discussed above, or incorporate crushing operations into the material
reclamation step, as the material is pulverized during mixing. The
ELRUS 6'x20'-2 Deck Splitting Screen Plant
latter approach generally provides less quality control over the
aggregate gradation as compared to mobile unit crushing operations.
This process produces the cold in-place recycled material (see Section
3.4) as output, which is a RAP aggregate of desired gradation, with or
without additives. The key difference between this output graded
aggregate and the graded aggregate obtained through central plant
crushing processes is that the blending and quality control over
gradation in the latter process is much better. On-road operations can
only process and blend the material across the width of the cut and not
along the surface.
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Cold Milling Machines for Cold In-Place

Reclamation (Section 4)
The in-place pulverizing of the material is done with milling
equipment. Equipment producers offer both basic milling machine
Wirtgen Group produces the full range of cold
models which simply pulverize the top layer of the asphalt concrete,
milling machines suitable for cold in-place
and more sophisticated models which allow the addition of water, processes. See Appendix E24 for details.
cement, foamed asphalt, etc. There are also milling and mixing
attachments available for other equipment.

When selecting the appropriate milling machine, the direction of

rotation of the mixing drum must be considered. Machines with the
mixing drum rotating in the same direction as the wheels tend to
pulverize the road surface and deposit it behind without significant
mixing, whereas machines with the mixing drum rotating in a direction According to the manufacturer, the Wirtgen
W2200 cold milling machine (above) mills to a
opposite to the wheels tend to pulverize, uplift and mix the material.
depth of 330 mm, and as such can be used for
Therefore, the first type is more suitable for shallow depth cold in- processing the asphalt in both cold in-place
place recycling and the latter is more appropriate for deeper cold in- recycling and full depth reclamation.
place recycling works. See graphic insert for Sections 9.2 and 9.3
(page 31) for equipment examples.

Full depth reclamation: in full depth reclamation processes, the asphalt

concrete is milled, or pulverized in place, with the use of a rotomixer.
Rotomixers generally have a mixing drum rotating in the direction
opposite to the wheels, ensuring full depth turnover and better material
breakdown.

In the industry, the terms “milling,” “remixing,” “rotomixing” and

“mixing” are used interchangeably with “full depth reclamation” to
refer to the pavement and base milling process. The Wirtgen 2200 CR cold recycler (above)
mixes pre-spread cement, bitumen emulsion and
Aggregate degradation: it is important to note that all of the water while recycling the asphalt concrete
processing approaches discussed above result in the degradation of the surface.
RAP aggregate. While the main purpose of the crushing, pulverizing
and milling processes is to break down the cohesive pavement into
aggregate-sized material, a portion of the aggregate is invariably Rotomixers for Full Depth Reclamation
crushed to a smaller size. This means that the RAP aggregate gradation
is finer than the original gradation of the aggregate used in the original Asphalt Zipper (R) (www.asphaltzipper.com)
asphalt concrete mix. produces equipment intended for full depth
reclamation. The Asphalt Zipper (R) FDR
attachment (below) are used with front loaders (in
There are some processes developed by equipment producers which
the picture), backhoes and skidsters to pulverize
minimize the degradation of aggregate. These processes involve: the road surface as the first step in the full depth
reclamation.
• Using heat to soften the binder in the RAP lumps to break
them down. See Section 9.2 for examples of this type of
equipment employing this process;
• Using the heat in hot in-place processes to soften and rework
the asphalt concrete pavement surface without milling it (see
Section 9.2 for examples of equipment).
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5. REJUVENATING AGENTS
Rejuvenating agents are intended to restore aged (oxidized) asphalt
binders by restoring the original ratio of asphaltenes to maltenes. As
most of these products are proprietary, there is no defined formula for
them. However, their primary components are bituminous; a
rejuvenating product must contain maltenes in order to improve the
asphaltenes to maltenes ratio (Boyer). When used properly,
rejuvenating agents will decrease the proportion of new asphalt,
cutback or emulsion required in the mix; because of this ability,
rejuvenators are considered more environmentally sustainable
(Brownridge).

A number of studies have tested and compared various proprietary

brands of rejuvenators. A summary of their findings is presented in the
table below. It is important to note that, since rejuvenator formulae are
proprietary, they may change in time. It is therefore beneficial for
transportation agencies to share information on their own experience
with these products; this can be achieved through such means as
approved product lists.

Product: Notes: More information:

AR2000 Tested with positive results by US Army Corps of Engineers (Shoenberger). Appendix E17
APR 100 and Produced by Mariani Asphalt Company. Successfully tested by US Army Corps of www.marianiasphalt.com
SBRT SO Engineers (Shoenberger).
BCR2000 Successfully tested by US Army Corps of Engineers (Shoenberger). See Shoenberger Appendix A
BCR3000
CPR Produced by Reeves Enterprises Inc. of Selkirk, NY. Successfully tested by US Army See Shoenberger Appendix A
Corps of Engineers (Shoenberger).
CRF Restorative Produced by Tricor Refining, LLC, CA. Inconclusively tested by US Army Corps of www.tricorrefining.com
Seal Engineers (Shoenberger). Available in SK from Pounder Emulsions in Saskatoon
(306.934.1500).
GSB-series Successfully tested by US Army Corps of Engineers (Shoenberger). www.asphaltsystemsinc.com
LAS-320 Limited tests by US Army Corps of Engineers with acceptable results (Shoenberger). www.enviroseal.com
PAS Limited tests by US Army Corps of Engineers with acceptable results (Shoenberger). www.marianiasphalt.com
PASS(R) A polymer-modified asphalt rejuvenator suitable for application at ambient temperatures Appendix E18, E18-1
Emulsion between 7 and 49°C. California Transportation successfully used the product for a cold in-
place recycling project to rebuild a section of Interstate 10 (Main Street Materials et al).
Reclamite Tested by Air Force Weapons Laboratory (US) in 1970 with positive results, determining Appendix E16
that manufacturer claims are correct (Rostler et al). Later studies have confirmed these
findings. Available in SK from Pounder Emulsions in Saskatoon (306.934.1500).
RejuvaSeal Produced by Echelon Industries Inc., TX. Successfully tested by US Army Corps of www.rejuvaseal.com
Engineers (Shoenberger). www.echeloninc.com
 15

6. TESTING OF RECLAIM MIX AND

DESIGN METHODS
6.1 TESTING NEEDS AND PROCEDURES

A Minnesota DOT study has concluded that the key engineering

properties of recycled asphalt pavement – hydraulic conductivity,
drainage, gradation, stiffness, strength – are similar or better than those
of virgin aggregate, allowing the substitution of the latter with RAP in
base, subbase and other materials in road construction. In addition,
RAP was found not to leach substantial amounts of inorganic
chemicals into the surrounding environment (Gupta).

To produce a good mix design, the recycled asphalt material must be

tested in order to establish its engineering characteristics. The main
characteristics of interest are:

• Gradation, which tends to be somewhat finer in RAP as

compared to virgin aggregate;
• Asphalt content, which usually varies from 3 to 7% by weight
and 10 to 20% by volume;
• Asphalt penetration and viscosity: depending on pavement
age, RAP binder penetration values are known to range from
10 to 80, and absolute viscosity values at 60°C range from
2,000 to 50,000 poise (Thurston County, WA).

For testing, a minimum of five or six representative samples must be

collected, and the following properties are determined (Kandhal et al,
1997, chap. 14):

• RAP gradation using AASHTO T27 sieve test (Appendix S1);

• Binder content, % using AASHTO T 164-93 test;
• Gradation of extracted aggregate using AASHTO T27-93
sieve test; and
• Aged asphalt binder properties using AASHTO TP2-94,
AASHTO T49 and AASHTO T202.

Where reclaimed asphalt is known to contain steel slag, it renders to

the recycled mix a number of desirable properties such as increased
friction (hence increased strength) in aggregate (Deniz).
16

6.2 MIX DESIGN METHODS

The design process for hot or cold mix asphalt has two main aspects:

• The mix design defining the types and quantities of RAP and
virgin aggregates, and of virgin AC binder, cutback, emulsion
and/or additives; and
• The structural design defining the thickness of the new layer as
a function of traffic loading.

According to the American Association of State Highway and

Transportation Officials, the main challenge in the application of
current mix design methods is that an assumption is made that the aged
binder is fully reincorporated into the mix (AASHTO 1). However, lab
tests indicate that the aged binder does not fully re-activate. This
problem is exacerbated for mixes with high RAP content.

There are four distinctive mix design categories, based on the mix type
and output material: cold mix design, hot mix design for low RAP
content, hot mix design for high RAP content and base course mix
design.

Mix design
The mix design methods for central plant hot or cold mix recycling and
cold in-place recycling are generally the same. For both methods,
samples of RAP are obtained to determine their characteristics and
develop a suitable mix design. Following are the conventional design
mix methods using RAP that are suitable for the two methods:

• Modified Marshall Method (Appendix S2): suitable for both

CIR and central plant cold mix recycling processes, it allows
design mixes with RAP content range of 0 to 100% (Hussain).
It has been shown that, for CIR processes, the addition of
20-25% virgin aggregate decreases porosity and improves
stability (Murphy et al). Also for CIR, the optimum content of
recycling agent is 2-3% of dry RAP weight (Castedo).
• ASTM D4215: these design specifications are suitable for
central plant cold mix recycling processes where used as
surface, base or subbase course.
• Modified Hveem Method (Appendix S2).
• Oregon Estimation: for 100% RAP mixes (Appendix S2).
• Chevron Mix Method: allows up to 100% RAP use
(Appendix S2).
• Asphalt Institute Design Method (Appendix S2).

In testing design mixes with RAP content, it is critical to correctly

adjust asphalt concrete content for cutback and water. Specifically, it is
 17

important to eliminate, through drying or other means, the cutback and

water prior to compaction in lab tests.

Conventional asphalt hot mix design (RAP content from 5 to 30%)

Once the properties of RAP are known, the desired aggregate
gradation of the new mix can be selected. Using various blends of
RAP and virgin aggregate, this new gradation must be obtained. The
fraction of RAP in the total aggregate can be as high as 30% without
impacting the properties of the new mix (NCAT). In the lab, testing
has shown that RAP mixes designed using the conventional Marshall
Mix Design method perform the same or better than conventional
mixes, but that for mixes with RAP percentage above 45% the flow
properties were decreased below requirements (Hussain et al).

For a hot mix, the percentage of RAP in the final aggregate blend that
is to be added determines the binder grade. For RAP content between
15 and 25%, select virgin binder one grade softer than normal to
counter the stiffening effect of the aged binder in RAP; for RAP
contents above 25%, use AASHTO M 323 testing procedures to
determine binder type (Kandhal et al, 1997, chap. 3). Conversely, the
RAP percent can be determined based on binder grade and percent of
binder in RAP. As RAP may contain high percentages of fines, this
could limit the percent of RAP in total aggregate.

For cold mixes, emulsions are the most common, and cutbacks are
used less commonly. Cement, fly ash, lime and other chemical
stabilizers can be used with the emulsions (Kandhal et al, 1997,
chap. 14) for in-place applications.

The choice of rejuvenating or recycling agent depends on how it

interacts with the aged binder; the softening of the binder is dependent
on its properties, the mixing time and ambient temperatures. Some of
the aged asphalt content will not soften and will act as aggregate. The
coating of the aggregate can be tested as a measure of how compatible
the recycling agent is with the aggregate mix (Kandhal et al, 1997,
chap. 14).

Conventional asphalt hot mix design with high RAP content (RAP
content from 30% to100%)
Once the design gradation of the aggregate is obtained, through
crushing and screening, as well as blending with virgin aggregate if
necessary, the type and quantity of new binder must be determined.
For aggregates with high reclaim asphalt percentage, proprietary
emulsion agents may be more effective than conventional emulsions or
cutbacks, as they contain rejuvenating agents designed to restore aged
asphalt (Kandhal et al, 1997, chap. 14). For 100% RAP aggregates, a
small amount of recycling (rejuvenating) agent can be added to soften
18

the aged binder without increasing binder content; however, it may be

very difficult to disperse the binder if an insufficient amount is used
(Kandhal et al, 1997, chap. 14).

When using conventional emulsions as new binder, 0.5 to 3.0% of new

binder is required, with higher RAP content requiring less new binder.
For design purposes, aggregate-binder mixes with new binder contents
of 0.5, 1.0, 1.5, 2.0, 2.5 and 3.0% are prepared and tested (Kandhal et
al, 1997, chap. 14) for workability and other relevant parameters. The
percentage of residual asphalt in the emulsion should be used in the
calculation of new asphalt percent.

While it is possible to design asphalt mixes with RAP content higher

than 45%, the mix properties are impacted and the mix is not expected
to perform as well under traffic loading. Generally, mixes with high
RAP content are as stable as or more stable than mixes with virgin
aggregates; however, they do not flow as well, indicating that aged
binder is not participating well and the mixtures are under stress during
loading (Hussain), making them less resistant to cracking. The water
from emulsion and cutter from cutbacks tend to improve the
workability of recycled mixes during laying and need to be released
prior to final compaction.

A study by the Belgian Road Research Center has shown that, when
using sound design procedures, it is possible to design high quality hot
mix asphalts with high percentages of reclaimed asphalt. The
performance related laboratory tests showed no relevant differences
between the mixes with “common” percentages of reclaimed asphalt
and those with “high” percentages of reclaimed asphalt, and that the
amount of reclaimed asphalt used in hot asphalt mixes can be
increased without affecting the performance of these mixes (Perez et
al, 2004).

Base course design

The key design parameter for incorporating processed RAP into
granular base material is the blending ratio of RAP to conventional
aggregate that is needed to provide adequate bearing capacity. The
ratio can be determined from laboratory testing of RAP aggregate
blends using the CBR test method or previous experience (FHWA 1).
Some US agencies are using up to 30% RAP content in the final base
aggregate blend. In UK, the Waste & Resource Action Programme
advises a RAP content of up to 50% in base courses (AggRegain).
Bottom lift bases may incorporate up to 100% RAP content. Testing
procedures are the same as for regular base materials.
 19

There is potential to use higher percentages of RAP with a small

amount of emulsion, cutback, asphalt or rejuvenator in order to
produce black base or asphalt-bound base.

Testing: The following engineering properties of RAP and other

reclaimed asphalt material are of interest when using it as base
material:

• Gradation;
• Compacted density (which is usually lower than that of sand
due to the presence of binder);
• Permeability (FHWA 1). The US Federal Authority specifies
that the base permeability should be in the same range as sand,
and that the material should be free-draining. In Saskatchewan,
dense graded or soil stabilized base with generally low
permeability has been used.

Shear strength and bearing strength (CBR value) are also properties of
interest, and should fall in the acceptable ranges of regular aggregate.
For a sample of draft specifications for RAP aggregate base, see
Appendix S4, p.20.

6.3 STRUCTURAL DESIGN

The AASHTO “Guide for Design of Pavement Structures” is suitable

for the structural design of CIR and central plant RAP asphalt mix
recycling processes as the structural capacity of these can be
considered equal to that of conventional asphalt mix structures, with a
recommended structural layer coefficient of 0.25 to 0.35 (Thurston
County, WA). CIR and central plant high RAP asphalt mix recycling
processes are not recommended for use as a wearing course in high-
traffic areas. Saskatchewan Ministry of Transportation and
Infrastructure has successfully used cold mix layers as wearing course
on low volume roads but has found that:

• Thin layers do not properly accommodate the maximum size

of the RAP aggregate. This may result in poor compaction
and lack of interlocking between aggregate particles in the lift.
The rule of thumb is that the thickness of the asphalt concrete
layer must be equal to or exceeding the size of the maximum
aggregate size multiplied by 2.5.
• Cold Mix layers with a thickness above 35 mm tend to rut.
This would also be the case for RAP cold asphalt mixes which
may also require a seal of some kind. Therefore, cold asphalt
mixes with RAP should be used in locations where some
rutting can be accepted.
20

7. SAFETY CONSIDERATIONS
Prior to working with any recycled asphalt materials, consideration
must be given to the composition of these materials. Depending on
use, time of placement and location, recycled asphalt materials could
contain asbestos, slag (used in pavements around Regina), glass,
sulphur, etc. Any non-standard component (e.g. beside the granular
aggregate and asphalt fractions) must be considered, primarily for
reasons of handling safety. Also, the effect of these components on the
mix performance must be considered.

Recycled asphalt shingles always contain some minor contaminants,

notably asbestos. With proper screening and testing procedures, the
risk of exposure is extremely low (CAPA).
 21

8. USES OF RECLAIMED ASPHALT

8.1 PRODUCTION OF COLD MIX WITH RAP

Cold mixes generally fall into two categories: low ratio and high ratio,
as a function of the RAP percentage in the total aggregate. Mixes with
RAP content below 30% are considered low ratio recycled cold mixes,
and mixes with RAP content above that are considered high ratio
recycled cold mixes. While this classification is not strictly scientific,
the two categories are differentiated for reasons of (a) mix
characteristics,
(b) applications and (c) associated levels of risks. Generally, low ratio
cold mixes are considered to match all characteristics of regular cold
mixes and are used in the same applications, whereas high ratio cold
mixes may have characteristics that are different from the regular cold
mixes, such as flow and workability, and are generally considered to
pose a higher risk of failure due to durability concerns.

Cold mixes – low ratio: RAP that has been crushed to a specified
gradation and blended at low ratios with new aggregate can be
processed to produce cold mixes using standard process. The cutter in
the cutback will tend to soften the asphalt in the RAP, improving the
workability and compaction. This new cold mix may set up quicker
than regular mixes because the fines in RAP will absorb some of the
cutter. Similarly, in emulsions, the water in the mix will improve
workability and compaction, but the fines in RAP will cause the
emulsion to break quicker.

Cold mixes – high ratio: Processed RAP blended at high ratio with
new aggregate can be used to produce cold mixes using standard
processes. At high ratios, a rejuvenator will likely be required to
improve workability. This material should be used immediately after
mixing and should not be stockpiled.

8.2 HOT AND WARM MIXES

Hot and warm mixes – low ratio: Hot mixes with RAP ratios below
30% can be used for the same applications as virgin hot mixes. From
an economic point of view, it makes the most sense to use these mixes
as pavement material for intermediate and surface layers.

A recent survey has shown that in the US, due to performance

concerns, transportation agencies tend to have a restricted use of hot
mixes with RAP in surface layers, with less than 5 states allowing up
to 29% RAP in the surface course as compared to 10 states allowing
the same RAP content in the intermediate layers. Generally, it was
determined that states allow 10% to 20% of RAP in the surface courses
22

for medium and heavy traffic roads (meaning 3 to over 30 million

ESALs for a 20-year design). A comment was made that even in states
allowing usage of higher RAP percentages, contractors typically did
not submit mix designs with RAP content above 25% (Copeland
2011). The Ontario Ministry of Transportation uses 20% to 50% RAP
content for base and binder courses.

Hot and warm mixes – high ratio: 30 - 100% RAP mixes, although not
generally used on main highways, are being implemented in urban and
residential applications such as driveways, parking lots and small to
medium size road repairs. The hot in-place 100% RAP mixes are
suitable for pothole patching, utility cut repairs, curbing, railway
crossing repairs, all-winter patching jobs, etc. (Bagela).

100% RAP mixes have been successfully used on shoulders and could
be used in alleys. Hot mixes with RAP ratios above 30% can be used
for the same applications as virgin mixes on lower pavement surface
lifts, but are not recommended as a surface course where some ravel or
pick-out is not acceptable. A surface flush, seal or slurry seal can be
used to protect the surface in traffic areas.

Whereas low ratio hot and cold mixes have been extensively used
throughout North America and are fairly well-studied, high ratio hot
and cold mixes are rarely used and are not normally recommended for
areas where performance is a priority.

8.3 GRANULAR BASE

According to a recent survey, RAP content of up to 29% in the base

course of a conventional road design is used by 10 transportation
agencies, with over 20 more considering it (Copeland 2011). In
Canada, the City of Hamilton allows the use of up to 30% RAP in its
base course (Appendix S3).

While the conventional way of incorporating RAP into base courses is

by blending RAP aggregate with virgin aggregate (see Section 6),
there is the full-depth reclamation process, consisting of breaking and
crushing the existing AC road surface and underlying granular base
layers up to a typical depth of 100 mm (and up to a maximum depth of
200 mm) and mixing them (FHWA 1). Other sources suggest, for low
volume roads, a mixing depth of up to 300 mm (Koch). Increasing the
mixing depth decreases the RAP % and vice versa.

Conventional granular aggregates do not bond well with RAP or

blended granular material containing RAP. Consequently, raveling
can occur if thin layers of conventional base are placed over material
containing RAP (FHWA 1). Construction methods are similar to
 Pavement Coatings Co., a part of Pavement
23 Recycling Systems, has developed a proprietary
process for preparing and placing chip seal and
chip slurry. The process consists of crushing the
RAP off-site, separating the finer aggregate for
conventional base course, although using little or no water improves the slurry from larger aggregate for chip (Ford).
compaction (FHWA 1). Performance is expected to be equivalent to Below are some company pictures of materials
that of conventional base material. and projects.

Portland cement addition: Portland cement can be added to base

aggregates with high RAP content in order to improve its bearing
strength. According to research performed at the University of Texas,
the optimum Portland cement content for base course containing 100,
75 and 50% RAP is, respectively, 4, 3 and 2% (Yuan et al). This will 1/4” RAP chip
produce a semi-rigid layer that will act like soil cement (see Section 6).
An increase in cement content results in higher structure rigidity and
shrinkage cracking.

Asphalt-treated bases (ATB): the stabilization of the base course

containing 50% RAP material with asphalt materials is commonly 3/8” RAP chip
used in Alaska as an alternative to the scarce granular base material.
The base can be treated with (i) hot asphalt, (ii) emulsified asphalt and
(iii) foamed asphalt. This treatment was found to be most effective
with hot asphalt; however, the emulsified asphalt treatment, a cold mix
technique, was found to be almost as effective (Li et al).
RAP slurry dust
Recent research indicates that RAP aggregate properties such as Below: El Rivino Rd. Chip seal, San Bernardino,
CA 2006
stability and gradation can be improved by adding sawdust ash when
using it as a subbase or base material (Osinubi et al).

8.4 SHOULDER BASE

To prepare shoulder base, RAP is put through a plant at a 100%

reclaim ratio and laid on shoulders as opposed to shoulder base. All
engineering properties for shoulder base are the same as for regular
base (see Section 8.3). Also, a high ratio recycled mix can be used on
shoulders.

In Ontario, the Ministry of Transportation allows 100% RAP in

shoulder aggregate material (OHMPA).
Below: Field test application of RAP slurry seal,
8.5 FILL Descanso Gardens, La Canada CA 2003.

US states with similar climate to Saskatchewan, such as Montana, are

using reclaim asphalt as an embankment additive, with reported
satisfactory results. The design requirements for RAP in embankment
construction are the same as for similar sized soil-aggregate blends,
conventional aggregates, or shot rock fill. When used as an
embankment or fill material, the undersize portion of crushed and
screened RAP, typically less than 50 mm (2 in), may be blended with
soil and/or finely graded aggregate or used unblended (FHWA 1). The
Ontario Hot Mix Producers Association claims that RAP fill stabilizes
soft subgrade (OHMPA); this property may be very useful in
24

Saskatchewan conditions, where plastic clays and tills constitute much

of the subgrade.

The City of Regina successfully uses RAP as trench backfill

(Kosolofski). The City of Saskatoon uses RAP as a bound or unbound
base to backfill utility cuts, as well as utility cut surfacing wet spring
conditions, and finds it to be more durable than regular aggregate
(Prang). RAP can be also used as a pipe bedding material and culvert
backfill.

Where pieces of broken asphalt pavement are used as embankment

base, size and placement restrictions should apply in the same manner
as for boulders and cobbles (NYSDOT). Due to the bituminous
content, asphalt millings are not considered clean fill and should not be
used in sensitive areas.

8.6 DUST CONTROL ON GRAVEL ROADS

A 2010 study (Koch et al) assessed the performance of RAP aggregate

as means of dust control on gravel roads. The study has found that
RAP aggregate, when blended with virgin aggregate used as traffic
gravel, decreases dust loss. The study also recommends:

• Blending the RAP and virgin aggregates in a pugmill rather

than in place to avoid segregation;
• Compacting the blend with a roller to improve serviceability;
and
• Adding CaCl to the RAP and virgin aggregate blend to further
improve dust control properties (Koch et al).

The fines generated from processing RAP can be used in this

application as they are not used in recycled mixes.

8.7 SLURRY SEALS AND CHIP SEALS

A number of cities and transportation agencies are implementing 100%

RAP chip seals and slurry seals. The Cities of Duartre (Missouri
Petroleum) and Colton (Udelhofen) in California are successfully
using the slurry seal material on roadway rehabilitation projects. For
City of Duartre slurry specifications, see Appendix S5, p. 3 and the
graphic insert on previous page for elaboration.

The use of RAP in slurry seals provides another application for RAP
fines. The incorporation of fines in slurry seals is likely more
beneficial from an economic perspective than their use for the purpose
of dust control (Section 8.6) as it makes better use of the binder.
 Schematic representation of an earth wall (Rathje
25
et al, p.9)

8.8 BACKFILL FOR TEMPORARY EARTH WALLS

Mechanically stabilized earth walls are vertical retaining walls built

with the use of face panels, engineered horizontal reinforcement
systems, and backfill. The backfill is usually made of common fill
earth which is free-draining, well-graded and has high frictional
strength. Clayey and other cohesive types of soil are not desirable as a
backfill due to their swelling potential and poor drainage properties
(Rathje et al). These materials are far more common in Saskatchewan
than free-draining soils.

Several test sections with RAP backfill that were built in Texas have
performed well. However, due to the creep potential in RAP,
especially for higher binder contents, it is recommended that RAP not
be used in permanent retaining walls. However, RAP use as a backfill
is possible in temporary walls with a service life no longer than a few
Lot No. 4 of the Dallas Cowboys Stadium (Swaner)
years (Rathje et al).

8.9 OTHER

Parking lots
Parking lots are increasingly being built and resurfaced using hot and
cold mixes with reclaim asphalt. Successful examples include the
Baylor Hospital parking lot in Dallas, Texas, the Las Vegas Motor
Speedway parking lot (LVMS), and Lot 4 of the Dallas Cowboys
Stadium (Swaner). The City of Regina has also had success using
100% RAP laid as gravel surface in a number of its parking lots.
100% RAP aggregate used as gravel surface on
Driveways trail: in 2007, the Clinton River Trail in Oakland
County, US, was commissioned to be resurfaced
Paving new or repaving old driveways with RAP is a growing
using 100% reclaimed asphalt pavement material,
application of reclaim asphalt, with the main driving force behind it grinded to ¾” size and rolled onto the trail; the
being the high and increasing cost of new asphalt concrete. In North costs of resurfacing the trail in this way
America, a number of private companies are offering the service of represented 1/3 of the initial estimate (Trailways,
repaving an old driveway or constructing a new driveway with 100% Spring 2007).

RAP aggregate.
100% RAP aggregate used as base course
There are two general approaches to laying the 100% RAP driveway: beneath asphalt concrete on trail: in 2007, the
Roaring Fork Transportation Authority (RFTA)
• Gravel-type driveway: the RAP aggregate is installed on a overseeing the Rio Grande Trail has decided to
graded, compacted subgrade with the use of graders, use RAP base course for the section of trail south
compactors or pavers. Optionally, the surface can be seal- of Glenwood Springs, Colorado. 150 mm of base
layer consisting of 100% RAP base material will be
coated. This type of surface is more stable than conventional supporting 75 mm of conventional hot mix asphalt
gravel surfaces and constitutes a good base for an AC surface concrete surface. Mike Hermes, director of
to be installed at a later date (CreativeAsphalt). properties and trails for the RFTA, said that
• 100% RAP asphalt concrete pavement surface: a conventional recycled asphalt doesn’t work well for the top layer
because it’s more challenging to get the
cold-mix or hot-mix process using a 100% RAP aggregate is
consistency and the heat right while laying it down
(Fowler, August 15, 2007).
26

built. Some companies suggest a 75 mm final AC thickness

placed in two lifts (CreativeAsphalt).

RAP has also been used as base under paving stones with only enough
sand placed on top to provide a smooth surface for laying the stones.

Bicycle paths and walking trails

A feasibility study for incorporating RAP materials into the trail
program (City of San Jose, 2007) concluded that RAP materials are
suitable for this application both as base and hot mix. The same study
states that Caltrans currently limits the fraction of RAP in base
materials to 50% and the fraction of RAP in hot mixes to 30%. In
Ontario, bicycle paths and trails can be built using hot mix asphalt
containing 30% reclaim asphalt material (OHMPA). However, the use
of higher proportions of RAP both in the base course and as a hot mix
on trails and bicycle paths is becoming increasingly common. See
insert on page 25 for details.
 27

Section 9.1
Step 2: Pulverizing the road surface
9. PROCESS AND EQUIPMENT The Maddock Corporation
(www.maddockcorp.com) is an example producer
Asphalt recycling processes are generally divided into two major of all three types of milling equipment:
groups: central plant processes necessitating the haul of reclaimed attachments, self-contained units, and tow-type
asphalt offsite and its processing at a central facility, and in-place units. These are shown below in the listed order.
processes, consisting of reclaiming, processing and placing the asphalt Their specifications are provided in Appendices
E13 to E15.
concrete material at the construction site using mobile equipment.
There are three general in-place recycling processes: cold in-place
recycling, hot in-place recycling and full-depth reclamation (Stroup-
Gardiner).

In order to choose the suitable type of treatment, the road surface

condition and type of damage must be identified. Refer to Appendix
S6, Table 6 on p.7, for guidance on choosing the correct type of
treatment based on type of pavement distress.

9.1 CENTRAL PLANT MIX PROCESS

This process is used where (i) high rates of production are required,
and/or (ii) the quality control of the output mix is very tight. This Maddock AM24 backhoe attachment
process is suited for the production of hot, warm and cold asphalt
mixes for the use in the surface and intermediate layers of asphalt
concrete pavement.

Regular drum mix plants can be used to produce RAP mixes.

Typically, the RAP material is fed in at mid drum in order to keep it
away from the flame and prevent the further oxidation of the binder.

Double drum plants work well with RAP and allow higher amounts of
RAP while maintaining temperatures. Continuous flow or batch plants
can utilize RAP which is fed into the pugmill without going through
the drum. These plants typically accommodate only low RAP ratios.
The use of a 15 m test section is recommended when implementing Maddock VT325, self-contained asphalt recycling
unit
any recycling mix, but especially for central plant process (NIBS).

The cold mix is stabilized with the following materials (Kandhal et al,
1997, chap. 12):

• Emulsified asphalt, with optional additives:

o Hydrated lime; or
o Portland cement.
Emulsified asphalt cold mix recycling should be performed at
temperatures above 10°C (Kandhal et al, 1997, chap. 12).
• Cutbacks can be effective in rejuvenating RAP as the cutter
Maddock 84E, tow-type asphalt recycler
tends to soften the aged binder. However, there has been a
decrease in the use of cutbacks as additives to asphalt mixes,
 28

mainly due to the environmental concerns related to high VOC

issues.

Following is the step-by-step central plant cold mix process:

1. Prepare the existing area by implementing traffic controls,
cleaning it, removing debris, etc.
2. Pulverize the road surface to the specified depth. This can be
achieved through the following means:
a. Ripping, loading and hauling the material to the plant
where it is crushed: this approach results in better
control of aggregate gradation.
b. Ripping, breaking and pulverizing in-place, then
Central Plant Mixing Processes (Section 9.1)
Step 4: Cold Central Plant Mixing loading and hauling it to a central plant: this method
Amman Group is a producer of the whole requires highly specialized equipment and stringent
spectrum of mixing plants. Its CMC plant traffic controls. It does not provide for good control
produces cold mixes using foamed asphalt and over the aggregate size, often resulting in oversized
emulsions. See Appendix E23 for more
information.
lumps.
c. Milling in place, then loading and hauling the RAP
material to a central plant: this is a very common way
of producing RAP; it is fast and efficient, but provides
less control over the aggregate size than option (a).
Step 2 is optional (unless the roadway is strictly inadequate),
as a road surface does not necessarily have to be pulverized
before placing a (previously stockpiled) cold mix course on it
(Kandhal et al, 1997, chap. 12).
3. Crushing and stockpiling: a crushing and screening plant is
used to create the aggregate gradation desired. A RAP
stockpile must be limited in height as RAP will stick together
under excessive pressure and moisture.
4. Mixing: the process of mixing the RAP, aggregate and binder
can be done as a batch, drum and continuous process. The
proportions of new aggregate, RAP and binder are controlled
by the feed rates. The option of adding water, modifiers or
Spreaders (Section 9.2)
rejuvenating agents to the mix is useful (Kandhal et al, 1997,
Streumaster SW 3 FC (below) is a binder
3
spreader attachment with a capacity of 3m . See
chap. 12). The coating of the mix is not always 100%, which is
Appendix E25 for more information on acceptable as further coating will be achieved during the
Streumaster binder spreaders. placement of the mix on the road. For particles passing US
sieve #4 (<4.75 mm), the coating should be 100% (NIBS).
5. Laydown, aeration and compaction: the process is similar to
the one used with conventional hot mix asphalt, and uses
similar equipment (Kandhal et al, 1997, chap. 12).
Construction should avoid rainfall periods. Densely graded
mixes should be placed in lifts no thicker than 75 mm, whereas
open-graded mixes should be placed in lifts not exceeding
100 mm; two to four days curing time should be allowed
between lifts.
 29

The equipment used in central plant cold mix processes varies by the
phase of the process.

Pulverizing of the surface (step 2) is done by milling equipment. There

are milling attachments suitable for use with motorgraders and
excavators, self-contained milling machines and tow-type machines. Cold In-Place Recycling (Section 9.2)
See graphic insert to the right for example. The picture below illustrates the cold in-place
recycling process in a project conducted on
The crushing of the material to the required size and gradation is done Marquis Drive in the City of Saskatoon,
Saskatchewan.
at a central plant facility and involves conventional crushers, screening
plants and auxiliary equipment such as conveyors. This process is A rotomixer pulverizes the pavement surface to a
reviewed in detail in Section 4. depth equal to or less than the asphalt pavement
thickness. Following that, asphalt emulsion and/or
a recycling agent are added, and the surface is
Central plant mixing is done with the use of a pugmill or an asphalt
recompacted.
plant. Cold mix plants are lower cost, lower emission, and easier to set
up than hot mix plants; the output material can be stockpiled (AEMA).
The material produced by a central plant is a bituminous asphalt
concrete material suitable for intermediate and surface layers on low
traffic roads, shoulder base (Section 8.4) parking lots and driveways
(Section 8.9). See graphic inset to the left for an example of a cold
mix plant.

The laydown, aeration and compaction step uses motorgraders and

compactors. The motorgrader is used to place mixed material into
windrow to aerate, then spread onto road. Aeration is done prior to
spreading and compaction to decrease the water content. Three
general types of compactors are used: the vibratory roller type, used in
the initial compaction step; the pneumatic tire type; and the static steel
wheel type, used for final compaction. Hot In-Place Recycling (Section 9.2)
HIR is offered as service or equipment by many
private companies. Following are typical
9.2 IN-PLACE RECYCLING examples of HIR processes currently offered on
In-place recycling includes a number of hot and cold processes which the North American market:
optimize the reuse of materials, haul distances, construction times, • RE-HEAT and SCARIFY HIR processes,
disruption to traffic, as well as minimizes the number of construction marketed as a service by Gallagher Asphalt
Corp., consist of heating the road surface,
vehicles and other truck traffic (Stroup-Gardiner).
dislodging or scarifying it, re-mixing it with the
addition of emulsion, and compacting it in
Cold in-place recycling is a self-contained, continuous train operation
place by a self-contained unit. The producer
that includes ripping or scarifying, processing (screening and claims that the process results in resurfacing
sizing/crushing unit), mixing of the milled RAP, and the addition of the asphalt concrete road surface with no
liquid rejuvenators. The output material of this process is a cold overlay required (Gallagher).
• Another proprietary process, marketed for
bituminous mix which serves as asphalt pavement surface. For cold
equipment sales by Pavement Recyclers,
in-place recycling, the pavement is removed by cold planing to a depth consists of preparing 100% RAP hot mix using
of 75-100 mm. The material is then pulverized, sized, and mixed with a portable, self-contained plant. The RAP
an additive. Virgin aggregate may be added to modify RAP chunks, millings and other RAP materials are
characteristics. An asphalt emulsion or a recycling agent is added. loaded into the unit, where they are heated up,
broken down and mixed (Bagela).
Once the gradation and asphalt content meet specifications, the
 30

Rotomixers for FDR and CIR processes

(Sections 9.2 and 9.3)
CAT RM350B reclaimer/mixer (pictured below) is material is placed and compacted. For low volume roads, an additional
an example of equipment suitable both for full- layer is optional, such as a chip seal or 25-75 mm of hot-mix asphalt
depth reclamation and cold in-place processes.
on top. A 3-piece “train” may be used. This consists of a cold-planing
machine, a screening and crushing unit, a mixing device, and
conventional lay down and rolling equipment. This train occupies only
one lane, thus maximizing traffic flow (Koch et al). Cold in-place
recycling can be used for repaving low volume roads, as well as
parking lots and driveways (Section 8.9).

Special asphalt-derived products such as cationic, anionic, and

This machine allows a bi-directional mixing polymer modified emulsions, rejuvenators and recycling agents have
capability (see mixing chamber drawing below) been developed especially for CIR processes. These hydrocarbon
and adjustable mixing height. A selection of
materials are sometimes, but not always, used to soften or lower the
specialized rotors is available for full-depth
reclamation, soil stabilization and cold in-place viscosity of the residual asphalt binder in the RAP material so that it is
recycling processes. See Appendix E26 for more compatible with the newly added binder (FHWA 1). CIR addresses
details on this piece of equipment. distress in the upper 50-100 mm of road surface (Stroup-Gardiner).

Hot in-place recycling includes three general processes: resurfacing,

repaving and remixing, and addresses shallow distress at the surface of
the pavement. As of 2011, 43 US state transportation agencies were
using HIR, with many of them implementing all three processes
(Stroup-Gardiner). The output material of a HIR process is an
improved asphalt pavement surface. This process can be applied as a
preservation or maintenance treatment for any asphalt pavement
surfaces exhibiting shallow distress.

The following equipment types are used for in-place recycling

processes: cold planers, a mobile screening and crushing unit, a cold
Asphalt Recyclers (Section 9.4) mobile or in-place mixing unit for CIR processes and a hot mobile
The Bagela Asphalt Recycler equipment line is an
mixing unit for HIR processes. Alternatively, the mobile screening and
example of hot mobile crushing and mixing
combination unit which allows the on-site crushing unit can be replaced with milling equipment (see Section 4),
preparing of the hot recycled mix. The breakdown and the mixing of the pulverized aggregate with new binder can be
of the RAP chunks is achieved through heating, achieved through the use of spreaders.
which causes the softening of the old asphalt
without degrading the original aggregate. The In addition, for HIR processes, heater-scarifiers can be employed for
producer claims virtually no emissions. See
the following applications (also see insert on the previous page):
Appendices E19 to E21 for more examples.

• As a surface treatment without additives to reprofile the road;

• As a surface treatment with additives for resurfacing; and
• As a treatment applied prior to an integral overlay to produce a
repaved asphalt pavement surface.

Bagela BA7000 mobile hot mixing unit.

 31

9.3 FULL DEPTH RECLAMATION Full Depth Reclamation (Section 9.3)

The two pictures below illustrate the full-depth
Full-depth reclamation is a process of recycling or remixing the reclamation process with the addition of emulsion
on Kenderline Road in Saskatoon, Saskatchewan.
existing asphalt concrete surface into a stabilized layer which may then
be overlaid with new asphalt concrete. The output material of an FDR In this 2009 project, the old asphalt pavement and
process is a base material, which may or may not be stabilized (see part of the underlying base are milled, and then
Section 8.3). FDR equipment consists of a miller or grinder capable of the emulsion is spread and mixed in on a second
pass.
grinding the existing asphalt concrete mat to a depth of 200 mm or
deeper. The equipment has the capability of injecting emulsion,
rejuvenator, foamed asphalt and water into the mixing area.

The process typically results in the grinding of the existing AC mat

with a portion of the underlying granular base layer. The depth of
treatment is dependent on the distress being treated, the mat thickness,
the underlying base thickness and the expected final surface. A
thickness and mix design is established and the amount of new binder
or rejuvenator is determined. Virgin aggregate or additional RAP can
be spread over the existing surface to be milled into the existing
material and modify the gradation.

Generally, if an emulsion is used, cement or lime is added in order to

reduce the liquid content and aid compaction. The finished surface is
compacted and flushed, then allowed to cure for several months prior
to placing a new wearing surface.

The equipment used in full depth reclamation processes includes a

rotomixer (see Section 4), a grader and a compactor. For stabilized
base, a spreader (see Section 9.2) can be used to spread binder, ash,
cement, or other material as determined by the mix design.

9.4 RECYCLERS

There are a number of recyclers or recycling attachments available to

use with reclaim. Most are pulvi-type mixers or grinders that can
break up the reclaim blocks or millings to workable size. The
equipment is then used to mix an emulsion, cutback or rejuvenator into
the reclaim which is then loaded and hauled to site for placement using
conventional equipment.

Other equipment types have the capability to heat up the reclaim to a

temperature where it becomes workable so that new material or
rejuvenators can be added.
32

10. ASSESSMENT OF BEST PRACTICES

10.1 ECONOMIC BENEFITS FOR USING COLD MIXES AND
COLD IN-PLACE RECYCLED MATERIALS

From an economic point of view, using RAP to replace the most

expensive commodity possible makes the most sense. Generally, it is
advisable to use RAP as a source of specialized aggregate or asphalt
mix. The rising price of bitumen makes RAP an attractive source of
bitumen. However, the increasing scarcity of aggregate sources in
Saskatchewan is turning RAP into an attractive source of this
commodity, both because of its availability and closeness to roads.

Generally, substituting RAP for asphalt and aggregate introduces cost

savings, as RAP is often already owned by the agency reusing it.
However, there are cases where the incorporation of RAP into
construction materials increases the final price of commodity and is
done for reasons other than economical (see Section 10.2). For
example, there are generally increased energy costs when producing
recycled hot-mix asphalt because it requires more heat to incorporate
the recycled material (City of San Jose, 2007).

Cold in-place recycling processes save 20 to 40% of the costs when

compared to conventional cold mixing techniques; if compared to hot
asphalt pavement processes, the savings are around 40 to 50% (Davio).
In areas with aggregate shortages or long hauls, RAP can be used in
place of new aggregate, reducing costs.

Base course: the cost of 100% virgin aggregate base averages at

$14/ton; the cost of base course containing 50% and 100% RAP
material is, respectively, $12.50/ton and $11.50/ton (City of San Jose,
2007). This represents a reduction in cost of 11% and 18%,
respectively. The City of Saskatoon “green streets” infrastructure
program evaluation suggests savings of 40-50% for base with at least
30% improvement in the mechanistic material properties than virgin
source counterparts (Berthelot et al).

Fill: This application of RAP does not represent the most effective use
for RAP. RAP as an embankment base may be a practical alternative
for material stockpiled for a considerable time period, or that has been
commingled from several project sources (Davio).

Dust control: Using RAP blends for dust control on gravel roads has
also proven cost-effective, with estimated cost savings of about 50%
when compared to conventional gravel/MgCl treatment (Koch et al).
Using the fines portion of processed RAP may further reduce costs.
 33

Driveways: It is estimated that 100% RAP driveways are 50% cheaper

than conventional asphalt concrete driveways (CreativeAsphalt).

Use of RAS: According to the Colorado Asphalt Pavement

Association, the savings generated by the reuse of asphalt shingles in
asphalt concrete mixes constitute $4.80-$6.80 per ton of binder where
binder costs are $400-600 per ton (CAPA).

10.2 OTHER CONSIDERATIONS

Aggregate scarcity: In Saskatchewan, gravel pits are rapidly becoming

depleted, with the price of this commodity increasing more than three
times over the last three decades, and with the hauling distances
increasing to over 100 km in some instances. Reclaimed asphalt,
composed of over 90% of aggregate per volume, is conveniently
located either directly at the construction site in the case of in-place
technologies, or nearby in stockpiles.

Reduction in damage to haul roads: an indirect benefit of using

reclaimed asphalt is that there is less damage to haul roads due to
reduced hauling distances. This can be considered both as direct cost
savings as well as indirect societal benefit due to improved quality of
service.

Rising bitumen costs: The increase in the price of petroleum products

has been a main reason behind the rising costs of infrastructure
construction and maintenance. Reclaiming asphalt from RAP,
containing up to 5.5% per volume of bitumen, and RAS, containing
19-30% of the same, can be a significant source of savings.

Sustainability: Both aggregate and bitumen are non-renewable

resources. Various environmental incentives such as environmental
credits in Ontario (OHMPA) or LEED credits in US (APA) can be
earned for RAP or RAS processes.

Energy use: processes involving the recycling of reclaimed asphalt

vary in their energy consumption needs. As discussed in the previous
section, the energy use in the production of hot mix with RAP is
higher than that of conventional hot mix. However, both cold and hot
in-place processes generally have lower energy requirements than
other conventional techniques to produce similar products.
34

11. AREAS OF FUTURE RESEARCH

While reclaimed asphalt has been used in pavement design for many
decades, no comprehensive design methodology exists to date, with
the current state-of-practice largely based on empirical knowledge and
field implementation. However, due to virgin aggregate scarcity and
increasing asphalt prices, RAP and other reclaimed asphalt is
increasingly regarded as a valuable resource, with a growing research
effort around it. The research areas related to reclaimed asphalt which
need to be followed are listed below:

1. Determine the long-term performance, and high volume roads

performance (NYSDOT), especially for mixes containing high
RAP percentages, as applied to Saskatchewan.
2. Investigate the use of RAP and, specifically, the use of RAP
fines, as means of dust control on gravel roads.
3. Study the use of RAP in temporary and permanent retaining
walls (Rathje et al) and its potential applications in
Saskatchewan.
4. A body of research suggests that RAP is not leachable.
Develop procedures and standards regarding storing reclaimed
asphalt in areas where groundwater or surface water
contamination may be an issue (FHWA 1).
5. Investigate the use of RAP in slurry seals or as a seal
aggregate under Saskatchewan conditions.
6. The effect of sawdust ash addition to RAP mixes has shown
potential to improve the mix properties such as stability and
gradation (Osinubi et al). In Saskatchewan, cogeneration
projects could be a source of sawdust ash. It is recommended
to further study the effect of adding this material to RAP
mixes.
7. Investigate warm mix technology to determine:
a. The potential to incorporate more RAP into mixes; and
b. Which warm mix products may be used in high ratio
recycling of RAP.
8. Research shows that hot mixes with RAP content up to 50%
can be designed under SuperPave specifications, and can
perform very well, provided the RAP properties are properly
accounted for in the material selection and mix design process
(McDaniel et al, 2002). Modifications to the Marshall Method
and other design approaches have been published to allow for
the incorporation of RAP materials both in hot and cold mixes
(see Oliver et al, 2004). One of the main challenges related to
the applicability of mix design methods to the RAP mixes is
the accurate determination of aged binder content that has
 35

been reincorporated into the mix. Currently, there are multiple

efforts to redefine the available mix design procedures to
effectively incorporate RAP into the mixes. Investigate the
current research to determine the most suitable RAP mix
design method under Saskatchewan conditions.
9. In order to encourage information sharing between urban
centres and municipalities, as well as to take advantage of the
province-wide experience, it is recommended to develop
approved product lists for such items as rejuvenators and
equipment.
36

12. TRAINING
The relevant competencies and respective training needs regarding
reclaimed asphalt uses, processes and equipment are dependent on the
individual’s role in the municipal organization. Three distinct
functions can be identified within a municipal authority, which have
impact on the implementation of reclaimed asphalt applications in the
organizational practices:

• Planning: senior management involved with strategic planning

and development should be knowledgeable about reclaimed
asphalt applications, extent of available resources, design and
cost considerations.
• The construction and maintenance managers must be
competent in matters of process implementation and
requirements, as well as structural design using reclaim asphalt
material. Individuals assuming this role should also determine
detailed training requirements for their crews, technicians and
operators both in terms of salvaging RAP and reusing it.
• Construction and maintenance crews, lab technicians and
equipment operators must be adequately trained in matters of
implementing specific processes assigned to them. Crews
need to know how to salvage and stockpile RAP, as well as
handle and place processed RAP in various applications; lab
technicians should be trained in all pertinent testing and mix
design procedures.

It is advisable to develop training packages suitable for each group and

provide, on a periodic basis, general workshops with the purpose of
reviewing the entire process in addition to specialized training for each
of the identified functions.
 37

13. CONCLUSIONS AND

RECOMMENDATIONS
It is recommended that reclaimed asphalt material is used to replace
the most expensive commodity that it is suitable for.

Applications: Reclaimed asphalt can be incorporated in cold mixes,

warm mixes, hot mixes, in-place recycling and central plant cold
processes for the following uses:

• High and low RAP ratio cold asphalt concrete mixes are
recommended for surfacing of roads with low traffic volumes.
To accommodate the maximum size of the aggregate in RAP
cold mixes while ensuring their proper compaction and
interlocking, it is recommended that the wearing course
thickness be in excess of 25 mm. Other uses of cold asphalt
concrete mixes include paving of cycling lanes, parking lots
and driveways.
• Wearing courses made of cold mix with RAP tend to rut,
especially when their thickness exceeds 35 mm. Therefore it is
recommended that:
o In areas where performance is a priority, the layer
thickness be limited to 30-40 mm; and/or
o Cold mixes with RAP be placed in areas with low
truck traffic or where some rutting can be accepted.
• Low ratio asphalt concrete hot mixes with RAP content up to
30% can be used as surface wearing course for all road
classifications. Where performance concerns exist, the use of
RAP can be restricted to bottom and middle lifts.
• High ratio asphalt concrete hot mixes with RAP content
between 30 and 100% generally are not used for roads with
high traffic; their typical applications include surface courses
for driveways, parking lots and small to medium size road
repairs.
• 100% RAP hot mixes are suitable for pothole patching, utility
cut repairs, curbing, railway crossing repairs and all-winter
patching applications.
• RAP aggregate is suitable for use as granular base for the base
and subbase layers of the road structures. RAP bases are
credited with equal or higher strength and durability as
compared to virgin aggregate bases. The granular material can
be prepared either using central plant or full-depth reclamation
processes.
38

• Portland cement, ash and various cold binders can be added to

bases with RAP to improve its engineering properties such as
gradation, strength, durability and cohesion.
• Base mixes with RAP content up to 100% can be used for
shoulder base on all roads. Central plant processes work best
for this application.
• The undersized portion of RAP, containing higher percentages
of binder, has limited applications as aggregate, but can be
successfully used as a stabilizer for subbase and subgrade.
Other suitable applications include trench backfill and utility
cut surfacing during wet spring conditions.
• Mixes of RAP and virgin aggregates can be used for dust
control on gravel roads and are cheaper than conventional
methods. RAP and virgin aggregate mixes can be prepared
either using central plant processes or by in-place rotomixing.
• It is recommended that RAP be tested as an aggregate for
slurry seals and chip seals tested in pilot projects to assess
performance in Saskatchewan climate. To ensure the best
quality control in the testing stage, it is recommended that
central plant processes are used for the mix preparation.
• RAP aggregate can be used as backfill for temporary earth
walls. It is recommended that the use of RAP aggregate mixes
be tested in pilot projects to assess performance in
Saskatchewan conditions.

A chart of processes involving reclaimed asphalt uses is provided on

page 39.

Historically, reclaimed asphalt materials has shown to have different

stockpiling requirements as compared to conventional aggregate.
These differences stem from the fact that the asphalt fraction,
especially in the presence of moisture, binds the aggregate. Following
is a summary of stockpiling recommendations (from Davio):

• Avoid low, horizontal RAP piles, which have a tendency to

hold water. Large cone-shaped stockpiles, originally thought
to cause re-agglomeration, are now thought to be better.
• Experience has proven that RAP tends to form a crust over the
exterior that is 20-25 cm thick. Avoid driving front-end
loaders and bulldozers directly on RAP stockpiles to minimize
compaction.
• Cover RAP stockpiles when feasible because RAP doesn’t
shed water or drain like other aggregates. However, tarps
should not be used because they cause condensation.
• Place RAP on a solid paved surface to improve drainage and
reduce soil contamination during loading.
 Asphalt Reclaim Sources: Applications:
Virgin Aggregate RAP: RAS: Recycled Cold Mix:
90%+ aggregate, up to 5.5% bitumen (v/v) 19-30% bitumen (v/v)
• RAP %: 0-100
• Applied as road wearing course or
Lumps Millings Shingle Manufactured Shingles from bottom lifts
5-7% bitumen Ends Construction Waste • Not recommended as wearing course
for roads with high traffic
Contaminant
Separation Recycled Hot and Warm Mix:
• For RAP % = 100%, used as wearing
course on parking lots, driveways, small
Blends to medium size road repairs
• For RAP <30%, used as wearing course
on all roadways

Storage: Structural Design: Granular Base:

• Store RAP in large, cone-shaped stockpiles. AASHTO Guide for Design of Pavement Structures • For RAP % < 30%, used as base for all
• Avoid driving heavy equipment onto RAP roadways
stockpiles. • Portland cement addition increases
• If possible, cover RAP stockpiles to prevent water bearing strength
from entering. Do not use tarps to avoid • Hot asphalt, foamed asphalt or
condensation. emulsions stabilize 50% RAP base
• Place RAP stockpiles onto a paved surface. material
Mix Design:
Hot Mix Design Cold Mix Design Shoulder Base:
• RAP % = up to 100%
not covered in the Guidelines For CIR and central plant processes

Fill:
39

• For base and subbase, the undersized

Modified fraction for RAP (<50mm) can be mixed
Modified Asphalt Institute in at any proportion
SuperPave Hveem Design Method • For subgrade, the RAP fines are
reported to improve stability
Modified Oregon Chevron • 100% RAP used as trench backfill,
Marshall Estimation Mix utility cut backfill.

Dust Control on Gravel Roads:

• Blended with virgin aggregate and
CaCl (optional)

Processing: Slurry Seal/Chip Seal:

In Place Cold Mix Plant Hot Mix Plant • 100% RAP
not covered in the • For chip seal, use the larger RAP
Guidelines aggregate fraction (3/8” to 1/4“)
• For slurry seal, use the undersized
fraction
40

REFERENCES
American Association of State Highway and Transportation Officials
“AASHTO M 323: Standard Specification for Superpave Volumetric
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Association of State Highway and Transportation Officials,
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Programme, UK, February 23, 2011.

Ambica CrushTech.PVT.LTD “Kohinoor Jaw Crushers”

http://www.kohinoorjawcrushers.com/jaw_crusher.pdf accessed May
2012.

Asphalt Emulsion Manufacturers’ Association (AEMA)

http://www.aema.org/index.php?option=com_content&view=article&i
d=81:the-basics-of-cold-mix-applications-with-asphalt-
emulsions&catid=7&Itemid=25 accessed May 2012.

Asphalt Pavement Association (APA)

http://asphaltroads.org/Environment accessed April 2012.

ASTM D4215 “Standard Specification for Cold-Mixed, Cold-Laid

Bituminous Paving Mixtures” American Society for Testing and
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Berthelot, C., Wandzura, C., Heichert, R., Taylor, B., Guenther, D.,
Praski, S.“Crushing and Processing Reclaimed Concrete for City of
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Conference of the Transportation Association of Canada
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Boyer, R. “Asphalt Rejuvenators: Fact or Fable”, Asphalt Institute

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Brownridge, J. “The Role of an Asphalt Rejuvenator in Pavement

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Preservation, Paper #47.
 41

Castedo, H. “Significance of Various Factors in the Recycling of

Asphalt Pavements on Secondary Roads” Transportation Research
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prepared by Callander Associates, July 11, 2007.

Colorado Asphalt Pavement Association (CAPA) “Best Practices for

the Use of Recycled Asphalt Shingles” The Asphalt RAP Vol. 11
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Copeland, A. “Reclaimed Asphalt Pavement in Asphalt Mixtures:

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Deniz, D., Tutulmuer, E., and Popovics, J. “Expansive Characteristics

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42

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Pavement (RAP) Under Superpave Specifications: A Regional Pooled
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 43

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Asphalt Pavement” American Society for Testing and Materials ISSN
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Perez, F., Rodriguez, M., De Visscher, J., Vanelstraete, A. and De

Bock, L. “Design and Performance of Hot Mix Asphalts with High
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Rathje, E., Rauch, A., Treho, D., Folliard, K., Viyanant, C., Esfellar,
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4177-3 March 2006.

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44

Udelhofen, G. “Using RAP in Slurry Seals”

http://www.forconstructionpros.com/article/10117475/using-rap-in-
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Shanghai Shibang Machinery Co., Ltd (SBM), “Impact Crusher”

http://www.stone-crusher.org/impact-crusher.html accessed May 2012.

Shoenberger, J. “Rejuvenators, rejuvenator/sealers and seal coats for

airfield pavements” US Army Corps of Engineers, February 2003.

Stroup-Gardiner, M. “Recycling and Reclamation of Asphalt

Pavements Using In-Place Methods” NCHRP Synthesis 421, 2011.

Swaner, K. “Dallas Cowboys Go Green with Warm Mix Asphalt”

Texas Asphalt Magazine Fall 2009.

Thurston County, WA “Reclaimed Asphalt Pavement User Guideline”

http://www.co.thurston.wa.us/planning/asphalt/notebook/section1/1.5
%20RECLAIMED%20ASPHALT%20PAVEMENT.pdf accessed
April 2012.

Trailways “Trail Surfacing Update”, A Newsletter from the Friends of

the Clinton River Trail, Spring 2007.

Waste and Resource Action Programme, UK (WRAP)

http://aggregain.wrap.org.uk/specifier/materials/reclaimed_asphalt.htm
l accessed Spring 2012.

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RAP Mixes for Roadway Bases” FHWA/TX-10/0-6084-1 October
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 45

PHOTO CREDITS:
Cover page: RAP central plant crushing operations, courtesy of City of
Saskatoon, 2012.

Section 4: picture of ScreenMachine 5256T Impact Crusher

reproduced from www.screenmachine.com.

Section 4: picture of Elrus 6'x20'-2 Deck Splitting Screen Plant

reproduced from www.elrus.com.

Section 4: pictures of Wirtgen W2200 cold milling machine and

Wirtgen 2200 CR cold recycler reproduced from www.wirtgen.de.

Section 4: pictures of the Asphalt Zipper (R) FDR attachment, attached

to a frontloader, reproduced from www.asphaltzipper.com.

Section 8.8: 3 pictures of RAP chip/slurry dust and two pictures of

RAP chip seal and RAP slurry seal application reprinted from Ford.

Section 8.8: Mechanically stabilized earth wall, reproduced from

Rathje et al, p. 9.

Section 8.9: Lot No. 4 of the Cowboys Stadium in Dallas, Texas.

Reproduced from Swaner, p. 3.

Section 9.1: 3 pictures of Maddock milling machines (Maddock

AM24, Maddock VT325 and Maddock 84E) reproduced from
www.maddockcorp.com.

Section 9.1: picture of Ammann cold mix plant reproduced from

http://www.ammann-group.com/en/home/asphalt-mixing-
plant/mobile-asphalt-mixing-plant/cmc-130-200-th accessed May
2012.

Section 9.2: picture of Streumaster SW 3 FC binder spreader

reproduced from
http://www.wirtgen.de/en/produkte/bindemittelstreuer_3/sw3fc/sw3fc_
detail.php.

Section 9.2: picture of CIR on Marquis Drive in Saskatoon,

Saskatchewan, courtesy City of Saskatoon.

Section 9.3: 2 pictures of FDR with addition of emulsion on

Kenderline Road in Saskatoon, Saskatchewan, courtesy of City of
Saskatoon, 2009.

Sections 9.2 & 9.3: 2 pictures of CAT RM-350B reclaimer/mixer

reproduced from CAT RM-350B brochure (Appendix E26).
46

Section 9.4: picture of Bagela BA7000 asphalt recycler reproduced

from http://pavementrecyclers.com/pavement-recycling-
equipment/ba7000/ accessed May 2012.
 47

APPENDICES
Appendices 24, 25 and 26 are available on the CD attachment only.