AEMA-ARRA-ISSA-PPRA Fall Meeting 2015

Recycling, Ayrton Senna Highway Brasil, & USA

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2012:

The Ayrton Senna Highway in Brazil was rehabilitated under challenging conditions by using the Wirtgen Cold Recycling technology in plant.

Sao Paulo:

a city with more than

20 million citizen.

CCPR (Cold Central Plant Recycling)

3• KMA 220 – Ayrton Senna Highway in Sao Paulo / Brazil

AYRTON SENNA HIGHWAY

CCPR (Cold Central Plant Recycling)

LOCAL BAR

Ayrton Senna Highway / Brazil:8-lane divided facility – Brazil’s most heavily trafficked highway

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CCPR (Cold Central Plant Recycling)

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Ayrton Senna Highway / Brazil: Pavementcondition after standard rehabilitation procedure “Mill and Fill”

CCPR (Cold Central Plant Recycling)

ADT > 250,000vpd (15% Trucks)(OUTER RECYCLED LANE > 15,000 trucks / day in each direction)

Milling & Replacing 4 ins HMA lasts < 3 months

Lane closure only between 21:00 – 05:00

Ayrton Senna Highway / Brazil: Traditional Rehabilitation / Traffic Loading

CCPR (Cold Central Plant Recycling)

8• Results of pavement investigations

HMA ± 4 ins

CEMENTED CRUSHED STONE (G2) ± 10 ins

CRUSHED STONE (G2) ± 8 ins

SELECTED COARSE GRAVEL (G6) ± 8 ins

EMBANKMENT (RIVER LEEVEE) (G7) Semi-infinite

CCPR (Cold Central Plant Recycling)

HMA ?13.75 ins

BSM-a 8 ins Nominal

BSM-b HMA2 ins

4 ins

Rehabilitation options

4 ins

Step 1 - mill off asphalt layers

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Construction sequence

Ayrton Senna Highway / Brazil:Milling of the asphalt layer (4 ins) at night

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Ayrton Senna Highway / Brazil:Crushing screened RAP – 1 ins minus

Construction sequence

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KMA 220 – Sized RAP loaded to CCPR (Cold Central Plant Recycler) BSM (Bitumen Stabilised Material) Mix Design: 2.5% Foamed Asphalt + 1.5% Cement

Construction sequence

10 ins

Step 2 - mill and remove CTB layer

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Ayrton Senna Highway / Brazil:Mill & Remove 10 ins CTB layer in one pass

Construction sequence

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Ayrton Senna Highway / Brazil:Paving of the first BSM layer with a thickness of 8 ins

Construction sequence

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Ayrton Senna Highway / Brazil: The BSM layeris levelled and pre-compacted with an asphalt paver

Construction sequence

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Ayrton Senna Highway / Brazil:Full depth (8ins) compaction of the BSM material with apadfoot roller

Construction sequence

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Ayrton Senna Highway / Brazil:Final compaction with a tandem steel drum roller

Construction sequence

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Ayrton Senna Highway / Brazil:Paving the second BSM layer 4 ins

Construction sequence

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Ayrton Senna Highway / Brazil: 4 ins BSM layer after final compaction. Ready for the asphalt overlay.

Construction sequence

2 ins HMA (gap-graded / fine mix)

Finish – Pave – 2 ins HMA

Rockfill where heavingwas detected.

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Ayrton Senna Highway / Brazil:A tack coat is applied between the BSM and the asphalt layer

Construction sequence

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Ayrton Senna Highway / Brazil:Pave 2 ins HMA

Construction sequence

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Ayrton Senna Highway / Brazil:

Construction sequence

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Monitoring

Ayrton Senna Highway / Brazil:two months under heavy traffic

Average: 0.45 mm 0.34 mm

Before rehab After rehab

• Deflection decrease from average 0.45 mm to 0.34 mm

Monitoring

Monitoring

June 2015 – 30 months after construction

Est traffic > 9.0 million trucks

Decision to Proceed

Confidence in Concept

I-81 Virginia DoT Recycling Alternative

FIRST MULTI RECYCLING/STABILISATION PROCESS IN N.AMERICA

Interstate I-81

30,000 VPD

8,000 trucks

Continual maintenance problem due to poor base materials

10 ins Asphalt layers

Poor Clay Support

Native

Mill & Fill Maintenance, limited successCracks reflecting back after 6 months

ALTERNATE FOAMED ASPHALT STABILISED BASE PROPOSAL

Material StructuralCoefficient

Thickness S.N

SMA 0.44 2 0.88

IM-19.0D 0.44 2 0.88

BM-25.0 0.40 10 4.00

DGAB 21B 0.12 6 0.72

OGB 0.05 12 0.60

Total 32 7.08

Material StructuralCoefficient

Thickness S.N

SMA 0.44 2 0.88

IM-19.0D 0.44 2 0.88

FBSB 0.30 12 3.60

LSSB 0.15 12 1.80

Total 28 7.16

Re-Construction Design Proposed Recycling Alternative

FBSB – Foamed Bitumen Stabilised Base

LSSB – Lime Stabilised Base

I81 Truck Lane

Milling 10ins depth Lime Stabilisation 12ins depth

100% Recycle Millings Pave Recycled Millings as Base

I81 Fast Lane

Phase 2: LH Fast Lane

Cold In Place Recycle

Depth 5”

Width 12’ 6”

2.2% Foamed Bitumen

Pave with attached AB375T screed

Concept Summary

Right Lane Traffic

7.8 million trucks

20.2 million cars

Left Lane Traffic(overtaking lane)

1.6 million trucks

3.8 million cars

August 2015 (4 years)

Economics of Recycling

Questions

Can we recycle and save $

Do we lose performance

YES SAVE $$

NO LOSS OF PERFORMANCEWELL ENGINEERED PRODUCT