AD-A264 436 ___

FEAP-UG-92/113
September 1992 FACILITIES ENGINEERING USER'S GUIDE
MP GL-92-30 APPLICATIONS PROGRAM

USER'S GUIDE: COLD-MIX RECYCLING

OF ASPHALT CONCRETE PAVEMENTS

DTIC
ELECTE
MAY 19 03.
by "Y s ~C co
James E. Shoenberger
US Army Engineer Waterways Experiment Station
Vicksburg, MS 39180-6199

_ 93-11112

Approved For Public Release; Distribution Is I -

U.S. Army Engineering and Housing Support Center

Fort Belvoir, VA 22060-5516

I -
Innovative Ideas for the Operation, Maintenance, S Repair of Army Facilities
 Destroy this report when no longer needed. Do not return
it to the originator.

The findings in this report are nnt !,I be construed as an official

Department of the Army position unless so designated
by other autho-ized documents.

The contents of this report are not to be used for

advertising, publication, or promotional purposes.
Citation of trade names does not constitute an
official endorsement or approval of the use of
such commercial products.
 Form Approved
REPORT DOCUMENTATION PAGE 0M8 No. 0704-0188

PupiiC reeortplo
r t1 t cOtk 'dnOflo n"faneal n
.td n for Il tefge I hou rroc r eiponse,
ettln'ate to ii ,mciudingthe ime for , uctontr t exsuC1 • data -,,;ur(t,.
gathernfg and mnaintaining the. da=%;Idad comnpleting and rCewcwngthe ltleiCrtiofl Of informnation send cosn,nttts regarding this WideCn est male o1any Other #U-*"( 0.!'s
collectont of Information.m to Washington
including suggestions tof reducing this bourdlen Orecorate
WloonesIrrices. formf~ornatto. Operationv and 'flecion) 1215 Irtteflio"
oavs HNghway. Suite )204. AsrngOn. VA 22201-4302. and to the Otfi(e of Managemnt and Budget, Pacerworm Reduc"on Pro0eCt (1)104-044,S WashingtOn, DC 2OSO

1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED
September 1992T Final report
T. TITLE AND SUBTITLE S FUNDING NUMBERS
User's Guide: Cold-Mix Recycling
of Asphalt Concrete Pavements

6. AUTHOR(S)
James E. Shoenberger

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION

REPORT NUMBER
Station
USAE Waterways Experiment
Geotechnical Laboratory Miscellaneous Paper
3909 Halls Ferry Road GL-92-30
Vicksburg, MS 39180-6199
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/ MONITORING
AGENCY REPORT NUMBER
US Army Corps of Engineers
Engineering and Housing Support Centpr FEAP-UG-92/13
Bldg. 2593
Fort Belvoir, VA 22060-5516
11. SUPPLEMENTARY NOTES

12a. DISTRIBUTION/ AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE

Approved for public release; distribution is unlimited

13. ABSTRACT (Maximum 200 words)

This guide provides the technical information required to implement the

application of cold-mix recycling of asphalt concrete pavements. Included are
details on areas on application, benefits/advantages, limitations/disadvantages,
and costs associated with this technology. Information is provided on two dem-
onstration sites at Fort Gillem, Georgia, and Fort Leavenworth, Kansas. Also
provided is information concerning funding, procurement, maintenance, and per-
formance monitoring. A fact sheet on recycling, contract specification example,
and references are provided in the appendixes.

14. SUBJECT TERMS 15. NUMBER OF PAGES

See reverse 29
16. PRICE CODE

17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT
OF REPORT OF THIS PAGE f•= ABSTRACT
Unc lasp I ff ed Unclassified Unclassified
NSN 7540-01-280-5500 Standard Form 298 (Rev 2-89)
Pescribed by ANSI Std 1)9.16
14. (Concluded).

Asphalt pavement recycling Emulsified asphalt cement

Cold milling In-place cold-mix asphalt recycling
Cold-mix asphalt recycling Recycling of asphalt
 CONTENTS
Pag~e
PART 1: INTRODUCTION ..................................................... 2
Description ............................................................ 2
Application ............................................................ 2
Benefits ............................................................... 2
Limitations ............................................................ 3
Costs .................................................................. 3
Recommendations for Use .............................................. 3
Points of Contact ..................................................... 4
PART I : PREACQUISITION .................................................... 5
Description of Cold-Mix Recycling ..................................... 5
Application..... ..................................................... 6
Limitations/Disadvantages ............................................. 6
FEAP Demonstration/Implementation Sites ............................... 6
Life-Cycle Costs and Benefits ......................................... 7
Costs .................................................................. 7
Advantages/Benefits ................................................... 8
PART III: ACQUISITION/PROCUREMENT .......................................... 9
Potential Funding Sources ............................................. 9
Technology Components and Sources .................................... 10
Procurement Documents ................................................ 10
Procurement Scheduling ............................................... 10
PART IV: POST ACQUISITION ................................................ 12
Initial Implementation ............................................... 12
Operation and Maintenance ............................................ 15
Service and Support Requirements ..................................... 15
Performance Monitoring ............................................... 15
aPPENDIX A: REFERENCES ..................................................... Al
APPENDIX B: FACT SHEET .................................................... BI
APPENDIX C: CONTRACT SPECIFICATION EXAMPLE ............................... Cl

8y J~ t :jt;n

i1strlbeton

1 j _odes_
 COLD-MIX RECYCLING OF ASPHALT CONCRETE PAVEMENTS

PART I: INTRODUCTION

Description

1. Asphalt pavement recycling involves reusing the asphalt concrete

pavement material to rehabilitate and/or strengthen the pavement structure.
The cold-mix recycling process involves first breaking up and pulverizing the
pavement in-place or removing the recyclable asphalt pavement (RAP) to a cen-
tral plant for crushing. Second, the RAP material is modified by the addition
of emulsified asphalt, water, and/or aggregates as required. The RAP material
is then placed and compacted to the specified density. The construction
equipment required is readily available within the pavement construction
industry.

Ap~plication

2. The use of cold-mix recycled asphalt concrete is applicable to any

pavement structure. Cold-mix recycled pavements have the capability to
decrease or minimize reflective cracking. A cold-mix recycled asphalt mixture
should be used as an intermediate course, requiring a wearing course or sur-

face treatment over it for most pavement applications. However, it can be

used as a surface course on low volume roads and similar applications. Areas
with load related pavement distress can be repaired prior to recycling or in

conjunction with the cold-mix recycling, provided the cause for the distress

is corrected.

Benefits

3. Cold-mix recycling allows the reuse of existing pavement materials

resulting in the conservation of existing resources. The resources conserved

include aggregate and petroleum resources, and fuels from reduced transporta-
tion and processing requirements (no heating of materials required). The
reuse of the existing asphalt concrete pavement materials also eliminates the

2
problem of disposal which can be an environmental as well as an economic
concern.

Limitations

4. A cold-mixed recycled pavement should, in most instances, have a

wearing surface applied to it. The recycled pavement will normally require
form 3 to 30 days to cure before a wearing surface or another recycled layer
is placed on top. The strength developed in the cold-mix recycled pavement
will typically be slightly less than that of a conventional new asphalt con-
crete pavement.

Costs

5. There is usually a cost savings associated with cold-mix recycling

versus conventional virgin asphalt concrete. Cost savings encountered have
ranged from 10 to 30 percent. The effective useful life of cold-mix recycled
asphalt pavements and those reconstructed with new materials should be almost
equal. The majority of the cost savings arp achieved during the construction
process as fuel and material savings.

Recommendations for Use

6. Cold-mix recycling of asphalt concrete pavements is recommended for

use in any location where an existing asphalt pavement requires reconstruc-
tion. It should be considered for both its environmental benefits and the
cost benefit advantage. The available Corps of Engineers guide specifications
should be followed closely, and quality construction methods should be fol-
lowed at all times.

3
 Points of Contact

7. Points of contact regarding this technology are:

a. Technical:
Director
US Army Engineer Waterways Experiment Station
ATTN: CEWES-GP-Q (Mr. James E. Shoenberger)
3909 Halls Ferry Road
Vicksburg, MS 39180-6199
Telephone: 601-634-3553
Facsimile: 601-634-3020
b. US Army Engineering and Housing Support Center:
Commander
US Army Engineering and Housing Support Center
ATTN: CEHSC-FB-P (Mr. Joseph Sicuranza)
Fort Belvoir, VA 22060-5516
Telephone: 703-704-1574
Facsimile: 703-780-5935
8. Points of contact at Fort Gillem, Georgia; Fort Leavenworth, Kansas;
and Fort Benjamin Harrison, Indiana wlere the Facilities Engineering Applica-
tions Program (FEAP) cold-mix recycling demonstrations occurred are:
a. Director of Engineering and Housing
ATTN: Mr. Grady Simms, Road Foreman
Fort Gillem
Forest Park, GA 30050-5000
Telephone: 404-363-5771
Facsimile: 404-363-5631
b. Chief, Engineering Division, DEH
ATTN: Mr Bob Mullen
Fort Leavenworth, KS 66027-5000
Telephone: 800-567-8262
c. Commander
US Army Soldier Support Center
ATTN: ATZI-FEP (Mr. Gene Springer)
Building 28
Fort Benjamin Harrison, IN 46216-5450
Telephone: 317-549-5417

4
 PART II: PREACQUISITION

Description of Cold-Mix Recycling

9. Pavement recycling involves reusing the in-place pavement material

to rehabilitate the pavement structure. The feasibility of pavement recycling
has been recognized for years, but its development and use greatly increased
after the 1973 oil embargo. The primary reason for this increase is econom-

ics. During and after the embargo, the price of oil increased significantly
causing the price of oil products such as asphalt cement, gasoline fuels, and
diesel fuels to increase. These and other cost increases caused the cost of
producing and hauling pavement materials to increase.
10. With the significant increase in the cost of pavement materials and
a growing shortage of good aggregates in some parts of the country, recycling
of pavements became a cost-effective alternative to be considered when reha-
bilitating a pavement structure. Even if pavement recycling is found not to
be cost-effective, recycling should be considered because of potential intan-
gible benefits such as conservation of natural resources, energy conservation,
and preservation of the environment.
11. The US Air Force specifies or allows as an alternative, recycling
techniques to rehabilitate and/or strengthen its pavements. The US Army Corps
of Engineers has published an Army Policy Letter on asphaltic concrete pave-
ment recycling (Headquarters, Department of the Army 1984) (see Appendix A)
dated 11 September 1984 which, in summary, states that recycling will be eval-
uated on all pavement projects which involve overlays, replacement of asphalt
concrete, or corrections of the pavement cross-section. This document also
states that the recycling evaluation must be included in the "Decision
Analysis" document submitted for MACOM or DA approval.
12. Cold-mix recycling involves reusing most or all of the existing
bituminous pavement structure by reducing it to a maximum particle size of
1 to 1 1/2 in. blending with virgin materials, if needed, and using the mix-
ture as a pavement material. Appendix B contains a fact sheet describing
pavement recycling.

5
 Application

13. Cold-mix recycling should be considered when a pavement has deteri-

orated to a point where its use is more economical than a conventional overlay
or where an overlay is prohibited by existing grades. Cold-mix recycling can
be used as a surface course on secondary roads and as a base course for high

quality pavements.

Limitations/Disadvantages

14. In most cases, cold-mix recycling will require or at least benefit

from the application of a wearing surface on top of the recycled material.
The wearing surface will prevent the recycled surface from raveling or eroding
under traffic or water drainage. The quality of the recycled mixture will
depend on the type and quality of the asphalt pavement and aggregates making

up the mixture.
15. Weather conditions such as temperature, humidity, and potential
rainfall are factors to consider when scheduling a cold-mix recycling paving
project. Another important consideration is the relatively long disruption to
the normal traffic flow during construction. Limited trafficking on a recy-
cled pavement during the cure period (usually 5 to 7 days) may be possible.

FEAP Demonstration/Implementation Sites

Installation Date Remarks

Fort Gillem, GA FY84 Flanker. Road, a two-lane road 24 ft
wide by 2,500 ft long serves as a com-
mercial vehicular truck entrance. It
was cold mix recycled to a depth of
8 in. Surfaced with 2 in. of hot mix
asphalt concrete 6 months after comple-
tion of recycling.

Fort Gillem, GA FY85 Recreation roads and warehouse roads

were cold-mix recycled and surfaced
with a double bituminous treatment.

6
 Installation Date Remarks

Fort Leavenworth, KS FY86 5th Artillery Road had 4 ix. of asphalt

concrete removed by cold-milling in two
2-in. lifts. The remaining pavement
structure was then cold-mix recycled.
The pavement was then surfaced with
2 in. of hot-mix asphalt concrete.

Life-Cycle Costs and Benefits

16. Pavement recycling provides a pavement rehabilitation or construc-

tion procedure which allows the optimum use of money and materials. This
often results in a significant cost savings in -ne range of 10 to 30 percent.

Cold-mix recycling is accomplished by the in-place recycling process or Ly

removing the old pavement materialr And transporting to a central plant for
processing. The in-place process has the advantage that minimal transporta-

tion of the material is required and greater cost savings are produced,
whereas the advantage of the central plant process is that a more consistent
mix is obtained. Both procedures have been used with success.

17. A tangible benefit of using the in-place cold-mix recycling process

is that a recycled quality base course can be produced which will be stronger

and more durable than the original. Also, by using the in-place recycling
process, the cracks in the old pavement are removed, reducing the possibility
of reflective cracking in the newly constructed pavement.

18. An intangible benefit of both processes is the elimination of dis-

posal of the old pavement in the local landfill. Another intangible benefit
is the conservation of natural resources by reusing the old pavement in the

construction of the new pavement.

Costs

19. The cost reduction or savings involved in cold-mix recycling will

vary with the location, materials, and contractor involved in the project. A
cost comparison of cold-mix recycling a s.ructurally failed pavement versus
removal and replacement with a new asphalt concrete pavement was developed for

the cold-mix recycling demonstraLion at Fort Gillem, Georgia. The cost for
the recycling option included cold-mix recycling 6 in. of asphalt concrete

7
pavement and base course material and overlaying with 4 in. of new hot mix for
$12.36 per sq yd. The cost for removing the low quality base course material
and providing a high quality 6 in. base course with a 4-in. new hot mix over-
lay was $15.55 per sq yd. This resulted in a savings of $3.19 per sq yd or a
21 percent cost savi-igs, using the cold-mix recycling option.

Advantages/Benefits

20. Some tangible benefits of using the cola-mix recycling process

include eliminating or minimizing the possibility of reflective cracking,
reestablishing the pavement surface to the desired grade, and minimal trans-
portation of materials. The intangible benefits included the elimination of
dumping the old pavement in local dumps and the conservation of natural
resources and energy by reusing the old pavement in the rehabilitation of a
new recycled pavement.
 PART III: ACQUISITION/PROCUREMENT

Potential Funding Sources

21. Typically, installations fund the implementation of pavements and

railroads technologies from their annual budgets. However, the installations
annual budget is usually underfunded, and the pavement and railroad projects
do not compete well with other high visibility or high interest type projects.
As a result, it is prudent to seek out additional funding sources when the
project merits the action. Listed below are some sources commonly pursued to
fund projects.
a. Productivity program. See AR 5-4, Department of the Army Pro-
ductivity Improvement Program for guidance to determine if the
project qualifies for this type of funding.
b. Facilities Engineering Applications Program (FEAP). In the
past, a number of pavement and railroad maintenance projects
located at various installations were funded with FEAP demon-
stration funds. At that time, emphasis was placed on demon-
strating new technologies to the Directorate of Engineering and
Housing (DEH) community. Now that these technologies have been
demonstrated, the installations will be responsible for funding
their projects through other s~urces. However, emphasis con-
cerning the direction of FEAP may change in the future; there-
fore, one should not rule out FEAP as a source of funding.
R. Special programs. Examples of th-se are as follows:
(1) FORSCOM mobilization plan which may include rehabilitation
or enlargement of parking areas and the reinforcement of
bridges.
(2) Safety program which may include the repair of unsafe/
deteriorated railroads at crossings and in ammunition
storage areas.
(3) Security upgrade which may include the repair or enlarge-
ment of fencing.
d. Reimbursable customer. Examples of this source are roads to
special function areas such as family housing or schools and
airfield pavements required to support logistical operations.
e. Special requests from MACOMS.
•. Year end funds. This type of funding should be coordinated
with the MACOMS to ensure that the funds will not be lost after
a contract is advertised.
z. Operations and Maintenance P'rmy. These are the normal funds
used for funding pavement ani railroad projects.

9
 Technology Components and Sources

22. Components of the technology which must be procured for the use of
cold-mix recycling of asphalt concrete pavement are section design (may be
in-house or contracted out) to include plans and specifications and a contrac-
tor to perform all phases of the recycling process. Cold-mix recycling uti-
lizes equipment which is widely available in the pavement construction
industry. Cold milling machines, graders, and rollers are widely available.
Many cold-mix recycling operations use portable pulvermixing units which are
used to break up and mix the recycled material uith any added materials. The
units are manufactured by several equipment makers and are widely available.
Many contractors have had at least some experience with some form of cold-mix
recycling. The Corps of Engineers has guide specifications and design and
construction manuals covering (TM 5-822-8 and TM 5-822-10) (Headquarters,
Departments of the Army and the Air Force 1987, 1988) the use of cold-mix
recycling of asphalt concrete pavement.

Procurement Documents

23. Applicable Specifications are listed below:

a. CEGS-02552, Bituminous Binder and Wearing Courses (Central
Plant Cold-Mix), August 1982.
b. CEGS-02554, Bituminous Road-Mix Surface Course, March 1983.
&. CEGS-02591, Cold Mix Recycling, September 1984.
d. CEGS-02598, Cold Milling of Bituminous Pavements, September
1984.
24. GSA Listing:
None
25. Vendors List and Recent Prices:
Local contractors who have the capability.

Procurement Scheduling

26. Normal construction contract schedules should be established that

allow adequate design and plan preparation time, design and review and
approval, contract preparation, advertising and award, and construction time.
A typical pavement project is designed 1 to 2 years before it is constructed;

10
however, relatively small projects that require limited plans and specifica-
tions can be prepared and ready to go within a few months.

11
 PART IV: POST ACQUISITION

Initial Implementation

Equipment
27. The equipment required for cold-mix recycling will depend on the
method used to remove/loosen, process, and place the recycled material. The
equipment used to remove/loosen the existing pavement can be either a cold
milling machine, pulvermixer, or conventional equipment used for ripping and
crushing the recyclable asphalt pavement (RAP). Processing and placement
equipment can include various combinations of central plants, mix-in-place
traveling plants, conventional pavers, graders, and pulvermixers. Conven-
tional paving equipment that is normally used with any method of recycling
includes water trucks, distributors, haul trucks, brooms, rollers, and front
end loaders.
Materials
28. The materials required for cold-mix recycling will vary according
to project conditions. The amount of each material required will depend on
the amount of RAP material to be used and final material properties desired in
the recycled pavement. Additional asphalt cement is normally added in the
form of an emulsified asphalt, although a cutback asphalt cement may be used.
Additional aggregates may be added, if required, with the gradation of the
aggregates added based on the final gradation desired for the recycled pave-
ment. The final gradation should meet the requirements given in TM 5-822-8
(Headquarters, Departments of the Army and the Air Force 1987) according to
pavement usage.
Personnel
29. Personnel involved in the construction of a cold-mix recycled
asphalt pavement will be the same as those normally involved in conventional
asphalt concrete pavement construction. The only additional personnel that
are used to produce and place a recycled mix versus a conventional virgin mix
are those employed on a milling machine or those on a break-up and crush oper-
ation along with transportation, when appropriate, to a central asphalt con-
crete plant. The quality control required for the recycling can be easily
handled by any commercial testing laboratory 4;Aalified for conventional
asphalt concrete testing. For the FEAP demonstrations, the quality control

12
testing was performed by personnel from the US Army Engineer Waterways Experi-
ment Station.
Procedure
30. Given the need for pavement rehabilitation, the option of cold-mix
recycling should be based on consideration of the following pavement
conditions:
a.
Extensive or large cracks in the existing asphalt concrete
pavement which would result in reflective cracking within 6 to
18 months of a conventional asphalt concrete overlay.
b. Existing curb and gutter system which can be maintained with
the use of cold-mix recycling.
c. Need to reestablish drainage pattern on roadways and around
structures.
d. Pavement structure containing isolated or extensive areas of
base failure.
e. A weathered/oxidized pavement surface that is experiencing
raveling.
f. The need to provide increased load-carrying capacity to a dis-
tressed pavement.
Z. The quality of the existing pavement material is lower than
that required for hot recycling.
31. With one or more of these conditions existing, the option of cold-
mix recycling may be a cost effective method of rehabilitation. The selection
of recycling versus a new asphalt concrete mix should be based on providing
pavement structures of equal capabilities with regard to preventing reflective
cracking and maintaining existing structures and drainage systems.
32. Cold-mix recycling can either be accomplished by in-place process-
ing or by removing the existing pavement and taking it to a central plant for
processing. Within these two methods there are various procedures and equip-
ment used to accomplish the same task.
33. The in-place cold-mix recycling method will involve the following
construction procedures:
a. The asphalt pavement can be broken up with a pulvermixer or
cold milled and left in place.
b. Any additives such as water, asphalt (normally emulsified
asphalt), or additional aggregates should then be added to the
RAP. These additives should be thoroughly combined, usually
with a pulvermixer or by blading with a grader.
c. The RAP material is then final graded as required and
compacted.

13
 34. The central plant cold-mix recycling method will involve the fol-
lowing construction procedures:
a. The asphalt pavement can be broken up as stated above or with a
dozer and ripper blade and then transported to a central plant.
b. If required, the RAP is reduced to the required particle size
by passing it through a crusher. The required additives are
then combined in the mixing plant and the material is trans-
ported back to the jobsite.
c. The RAP material is then placed at final grade with a paver or
with a grader as required and compacted.
d. The central plant should be used when large amounts (more than
10 percent) of new aggregates are required for the RAP mixture.
35. The mix design will be based on the properties of the RAP material,
additional binder required, and additional aggregates, if required. The mix
design involves first determining the total asphalt content required for the
recycled mix, when tested as a conventional asphalt hot mix. The additional
asphalt required is then the total required minus the existing amount in the
RAP. The final determination is the amount of water required to achieve the
highest possible density. The water contained in the emulsified asphalt added
to the mix must be considered as part of the water added or existing in the
recycled mixture.
36. The quality control and quality assurance methods used for cold-mix
recycled asphalt are different from that of other asphalt mixes in the follow-
ing ways:
a. The maximum theoretical density (MTD) is determined by the use
of ASTM D 2041. The field density required is based on a per-
centage of this MTD. The percent MTD required will normally
range from 84 to 90 percent, depending on the recycled mixture
and the pavement usage.
b. There is normally a curing period involved with a cold-mix
recycled pavement. This curing period will vary with the mate-
rial properties of the mix and the climatic conditions present
during the curing period. The curing period can vary from 3 to
30 days. This curing period should be completed before the
pavement is overlaid or sealed.
c. Obtaining field cores for density determination with a standard
coring drill may not be possible as the samples will tend to
fall apart. A nuclear gage can be used, provided that it has
been calibrated for the recycled material with a series of sand
cone or water balloon density tests. It may be possible to dry
cut block samples of the pavement for a density determination.
37. Appendix C contains an example of a specification used to cold-mix
recycle at Fort Gillem, Georgia.

14
 Operation and Maintenance

38. Operations and maintenance over a cold-mix recycled asphalt pave-

ment are no different than those over a pavement constructed on conventional
asphalt concrete intermediate courses. This is true in instances where the
recycled pavement is overlaid or receives a surface treatment.
39. Cold-mix recycled pavements used on low volume roads do not always
require an overlay. However, these pavements, depending on the materials
used, may be more susceptible to raveling from traffic and weather effects.
40. Cold-mix recycled pavements generally gain strength as they cure
and can produce strong and stable pavements. The material will provide a base
course material with improved properties over a conventional crushed stone
base course or a low volume road surface with lower maintenance requirements
than that of conventional aggregate surfaces.
41. Cold-mix recycled pavements can be trafficked until a wearing sur-
face can be applied. Minor maintenance may be required depending on traffic
levels and weather conditions.

Service and Support Requirements

42. No special services or support is required to implement or maintain

this technology.

Performance Monitoring

43. Installation personnel can monitor and measure the performance of

the cold-mix recycled asphalt concrete pavement by making periodic inspections
of the pavement for signs of distress (cracking, rutting, etc.). This
monitoring of performance would be no more than that required for any asphalt
concrete pavement. The performance monitoring can be adjusted to fit into
existing pavement management systems. Unusual traffic or climatic conditions
could adversely affect performance and should be noted.

15
APPENDIX A: REFERENCES
Headquarters, Department of the Army. 1984 (Sep). "Army Policy on Asphaltic
Concrete Pavement Recycling," Army Policy Letter, Office of the Chief of
Engineers, Washington, DC.
Headquarters, Departments of the Army and the Air Force. 1988 (Aug).
"Standard Practice for Pavement Recycling," Technical Manual TM 5-822-1O/AFM
88-6, Chap. 6, Washington, DC.
_ _ 1987 (Jul). "Bituminous Pavements Standard Practice," Technical
Manual TM 5-822-8/AFM 88-6, Chap. 9, Washington, DC.
Lynch, L. N. and Lewandowski, L. H. 1991 (Apr). "Tn-Place Cold Mix Recycling
of Asphalt Pavements," Video Report GL-91-2, US Army Engineer Waterways
Experiment Station, Vicksburg, MS.
Vollor, T. W. 1986 (May). "Pavement Recycling: Facilities Technology Appli-
cation Tests (FTAT) Demonstration, FY84, Fort Gillem, Georgia," Technical
Report GL-86-4, US Army Engineer Waterways Experiment Station, Vicksburg, MS.
. 1986 (Feb). "Asphalt Pavement Recycling Primer," Miscellaneous
Paper GL-86-4, US Army Engineer Waterways Experiment Station, Vicksburg, MS.

A3
APPENDIX B: FACT SHEET
 US Army Cops
FTAT Projects
of Engineer For Information on FIAT Proiects
Oft thecOi Contact Information Manager,
of Engseers Dr. Robert M. Dinnat or Mr Jeffry J. Walaszek
USA-CERL. P.O. Box 4005.
Champaign, Il1. 61820-1305 217-373-6700 or 217-373-7216

December 1987

PAVEMENT RECYCLING

Description of Technology. Pavement recycling has proven to

be an acceptable, cost-effective construction technique to be
considered when rehabilitating pavements. Even when recycling is
not the most cost-effective method it should always be considered
because of potential intangible benefits. These benefits include
the conservation of natural resources and energy and the
preservation of the environment. Bituminous pavement recycling
is normally divided into three categories--surface, cold-mix and
hot-mix recycling. Surface recycling should be considered
anytime a surface distress on a structurally sound pavement
requires correction such as to increase skid resistance, decrease
permeability to air and water, improve properties of the asphalt
binder, or improve rideability of the pavement.

Cold-mix recycling should be considered anytime a pavement

has deteriorated to a point where it is more economical to
recycle thaa use a conventional overlay, where an overlay is
prohibited by existing grades, and when the pavement structure
requires strengthening. Cold-mix recycling reuses part or all of
the existing stabilized base course or an intermediate course
material for the rehabilitated pavement structure. Cold-mix
recycling can be designed to blend new material with the old
materials or to use the old materials without the use of new
materials. Under certain conditions, it is used as a surface
course material on secondary roads; however, raveling should be
expected.

Hot-mix recycling is used to reconstruct the asphalt

concrete portion of the pavement structure. To hot-mix recycle,
the existing asphalt concrete is removed to the desired depth,
crushed if needed, and mixed in a hot-mix asphalt plant with new
aggregate, asphalt cement, and recycling agent if needed.
Recycling agents should be used only when required to soften the
old asphalt cement to desired penetration. Hot-mix recycled
.ixes can be designed for use as Intermediate courses or surface
courses in the pavement structure.

Portland cement concrete (PCC) recycling should be

considered when good aggregates are not available or when new
aggregates are rot cost-effective when compared to recycled PCC
aggregate. PCC pavement recycling involves removing the existing
pavement and crushing and resizing the removed PCC for use as
aggregare in new PCC, asphalt concrete, cement-treated base, or
aggreLate base course.
Status of Demonstration. Th' 1984 and 1985 field pavement
recycling demonstration projects have been completed at Fort
Gillem, Georgia. The 1986 pavement recycling demonstration
project has been completed at Fort Leavenworth, Kasas. The 1987
pavement recycling demonstration project has been completed at
Fort Benjamin Harrison, Indiana. At present, there are no plans
for additional pavement recycling projects.

Notebook articles, videotapes, and tec-inical reports will be

prepared on the recycling techniques demonstrated.

Benefits of Technology. Pavement recycling provides a

pavement rehabilitation or construction procedure which allows
the optimum use of money and materials. This often results in a
significant cost savings in the range of 10 to 30 percent. The
cost savings calculated on the FTAT demonstration projects were
approximately 16 percent for hot-mix recycling and approximately
21 percent for cold-mix recycling.

These cost savings were computed by comparing to alternate

methods of rehabilitating the pavements. By reusing parts or all
of the materials in the existing pavement structure to produce
the rehabilitated pavement, depletion of natural materials was
reduced. Also, the need of a permanent dump site for the removed
old pavement was eliminated. The reoccurrence of reflective
cracking was minimized or eliminated. The pavement structure was
strengthened. Old drainage facilities and systems which were
still functioning were saved.

Points of Contact. Mr. T. W. Vollor or Mr. Randy Ahlrich,

U.S. Army Engineer Waterways Experiment Station, P.O. Box 631,
Vicksburg, MS 39180-0631, 601-634-2206.
APPENDIX C: CONTRACT SPECIFICATION EXAMPLE
 Cold Mix Recycling

Applicable publications
47. The publications listed below form a part of this specification to
the extent referenced. The publications are referred te in the Appendix by
the basic designation only.
a. Military Standards (MIL. STD.):
MIL-STD-620A Test Methods for Bituminous Paving
Materials

b. American Society for Testing and Materials (ASTM) Publications:

D 140-70 Sampling Bituminous Materials
(R 1981)
D 977-80 Emulsified Asphalt
D 2041-78 Theoretical Maximum Specific Gravity
of Bituminous ?aving Mixtures
D 2397-79 Cationic Emulsified Asphalt
Mixing plant
48. The mixing plant (travel or fixed) shall be designed,
coordinated, and operated to produce mixture within the JMF. The plant
shall be equipped with positive means to control the amount of additional
asphalt, water, and time of mixing. Time of mixing shall be the interval
between the time the bituminous material and/or water is spread on the aggre-
gate and the time the same aggregate leaves the mixing unit.
Weather limitations
49. A recycled cold mix course shall not be constructed in rain or on a
layer which contains free water either within the layer or on its surface.
Recycled cold mix course shall not be placed when the air temperature is less
than 50*F.
Grade control
50. The finished and completed surface shall conform within 0.05 ft to
lines, grades, cross section, and dimensions shoun. Lines and grades, as
indicated, will be maintained by means of lirn- and grade stakes placed by the
contractor at site of the work.
Surface-smoothness requirements
51. The surface of the finished pavement shall be checked longitudi-
nally and transversely with a 10-ft straightedge. The straightedge shall be

placed parallel to the center line of each lane paved, at intervals over the

C3
width of the surface. The straightedge shall also be placed perpendicular to
the center line of each lane paved, at intervals over thie length of the sur-
face. The finished surface of the pavement shall not deviate more than
3/8 in. from the 10-ft straightedge. Surface irregulars exceeding this toler-
ance shall be corrected without additional cost to the Government.
Straightedge
52. The contractor shall furnish and maintain at the site, in good con-
dition, one straightedge for each bituminous paver, for use of the contracting
officer in testing finished surface. Straightedges shall be constructed of
aluminum and shall have blades of box or box-girder cross section with flat
bottom reinforced to ensure rigidity and accuracy.
Sampling pavements and mixtures
53. Type, size, number, and location of samples will be determined by
the contracting officer. The contractor shall furnish all tools, labor, and
materials for obtaining samples and refilling sample locations. All tests
necessary to determine conformance to specified requirements will be conducted
by the contracting officer.
Access to plant and equipment
54. The contracting officer shall have access at any time to all parts
of the paving plant for checking adequacy of equipment in use; inspecting
operation of plant; and verifying weights, proportions, and character of
material.
Measurement
55. Cold-mix recycling paid for will be the number of square yards of
accepted work. When bituminous material is used, the unit of measurement
shall be the gallon as specified in the schedule. Gallonage paid for shall be
the number of gallons of bituminous material used in the accepted work. Gal-
lonage shall be determined either by measuring material at a temperature of
60*F or by correcting gallonage measured at another temperature to gallons at
60*F, using a coefficient cf expansion of 0.00025 per deg Fahrenheit for emul-
sified asphalt. The yardage of approved new aggregate to be paid for shall be
the number of cubic yards used in the completed and accepted surface course.
Payment
56. The quantities of bituminous materials and paving mixtures, deter-
mined as provided above, will be paid for at respective contract unit prices

C4
per square yard for bituminous mixturp. ner gallon for bituminous materials,
and per cubic yard for new aggregate. Payment shall constitute full-compensa-
tion for preparing or reconditioning existing pavement; furnishing all materi-
als, plant equipment, and tools; improving unsatisfactory areas; and labor and
incidentals necessary to complete work required. If deficiencies in the fin-

ished product exceed requirements specified, no payment will be Cade for such
areas of pavement until the defective areas are corrected.

Products

Aggregates
57. Aggregates shall consist of a mixture of aggregates salvaged from
the roadbed and of new material as directed by the contracting officer.
Aggregate quality and gradation
58. Aggregates for bituminous mixture shall be of such size that the
material can be spread to the desired thickness and compacted to meet the
specified smoothness, grade, and density requirements. The reclaimed material
shall be handled in such a manner to prevent segregation and degradation.
Bituminous materials
59. Bituminous materials shall be asphalt Type SS-1 or type CSS-l con-
forming to AS7M D977 or ASTM D2397. Sampling and testing of bituminous mate-
rials shall be the responsibility of the contractor. Sampling shall be in
accordance with ASTM D 140 for bituminous material, unless otherwise directed.
Tests shall be performed on each batch of bituminous material to ensure that
materials meet specified requirements. Copies of test results shall be fur-
nished to the contracting officer.
Job-miy formula
60. No cold recycled mixture shall be produced until a JMF has been
given the contractor by the contracting officer. The formula will indicate a
definite percentage of water and asphalt to be added to the mixture. The JMF
will be allowed an asphalt content tolerance of 0.4 percent. The asphalt con-
tent may be adjusted by the contracting officer to improve paving mixture,
without adjustment in contract unit price. When asphalt is added, the optimum

asphalt content will be selected to provide the following properties when sam-
ples are compacted at 250*F with 50 blows of standard Marshall hammer on each
side of the specimen.

C5
 Property Requirement
Voids in total mix, percent 3-5
Voids filled with asphalt, percent 75-85
Stability, pounds 500 minimum
Flow, 0.01 inch 20 maximum

The water content will be selected to provide maximum density when samples are
prepared at the optimum asphalt content and compacted with 50 blows of Mar-
shall hammer at ambient temperature.

Execution

Preparation of bituminous mixtures

61. Aggregates, asphalt emulsion, and water shall be mixed as necessary
to thoroughly coat all particles with bituminous material.

Placing

Layer thickness and curing

62. Each layer of compacted mixture shall be no more than 3 in. in com-
pacted thickness; each layer shall be allowed to cure for at least 5 days
before placing a succeeding layer.

Spraying of contact
surfaces of structures
63. Contact surfaces of previously constructed pavement, curbs, man-
holes, and similar structures shall be sprayed with a thin coat of bituminous
material.
Use of mechanical spreader
64. The cold recycled mixture shall be spread so that the surface of
the course being laid will be smooth and continuous and of such depth that,
when compacted, the surface will conform to the grade, density, and smoothness
requirements. The contractor shall establish and place lines parallel to the
center line of the area to be paved for the spreading machine to follow.
Placing of mixture shall be as nearly continuous as possible.

C6
Shoveling, raking, and
tamping after spreading
65. A sufficient number of shovelers and rakers shall follow the
spicading machine raking and adding mixture as required to obtain a course
that, when completed, will conform to all specified requirements. Broadcast-
ing or fanning of mixture over areas being compacted will not be permitted.
When segregation occurs in the mixture during placement, the spreading opera-
tion shall be suspended until the cause is determined and corrected. After
trimming, edges of the course shall be thoroughly compacted by tamping later-
ally with a metal lute. Distortion of the course during tamping will nor be
permitted.
Hand spreading in
lieu of machine spreading
66. In areas where use of machine spreading is impractical, mixture
shall be spread by hand. Mixture will be dumped, distributed into place, and
spread with rakes in a uniformly loose layer of such thickness that, when com-
pacted, will conform to the required grade, density, and thickness. During
hand spreading, each shovelful of mixture shall be carefully placed by turning
the shovel over in a manner to prevent segregation. In no case shall mixture
be placed by throwing or broadcasting.
Compaction of mixture
67. Compaction of the mixture shall be conducted such that density,
grade, and smoothness requirements are satisfied. For bituminous mixtures
rolling shall continue until all roller marks are eliminated and a density of
at least 86 percent of the theoretical maximum density (MIL-STD-620,
Method 101 or ASTM D 2041) has been obtained. Laboratory test specimens are
to be prepared from uncompacted mix taken from the pavement immediately prior
to field compaction. Samples of mix will be heated and compacted at 250°F
with 50 blows on each side of the specimen to evaluate the satisfactoriness of
the mixture. Minimum rolling equipment required includes a 10-ton steel-wheel
roller and a 15-ton rubber-tire roller capable of tire inflation pressures of
90 psi.
a. Operation of rollers and tampers. The speed of the rollers
shall be slow enough at all times to avoid displacement of mix-
ture. Displacement of the mixture occurring as the result of
reversing the direction of the roller, or from any other cause,
shall be corrected by the use of rakes and fresh mixture
applied or removed, where necessary. Alternate trips of the

C7
 roller shall be of slightly different lengths. During rolling,
wheels of steel-wheeled and rubber-tired rollers shall be mois-
tened, if necessary, to prevent adhesion of the mixture to the
wheels, but excess water will not be permitted. The contractor
shall furnish additional rollers or improve rolling techniques
if the pavement density specified is not obtained. Rollers
shall be operated by competent and experienced operators.
Rollers will not be permitted to stand on finished courses
until courses have been cured 5 days. In all places not acces-
sible to rollers, the mixture shall be thoroughly compacted
with hand tam-,ers as specified herein.
b. Correcting deficient areas. Mixture that becomes contaminated
;ith foreign material or is defective in any way shall be removed.
Skin patching of an area that has been rolled will not be per-
mitted. Holes of the full thickness of the course shall be cut
so that the sides are perpendicular and parallel to the direc-
tion of traffic and the edges are vertical. Fresh paving mix-
ture shall be placed in holes in sufficient quantity so that
the finished surface will conform to grade and smoothness
requirements. Paving mixtures shall be aerated, if necessary,
and shall be compacted to the density specified herein. The
contractor shall provide competent workmen capable of perform-
ing all work incidental to the correction of deficiencies and
defects.
Joints
68. Joints shall present the same texture, density, and smoothness as
other sections of the course. Joints between old and new pavements or between
successive days' work shall be made carefully to ensure continuous bond between
old and new sections of the course.
a. Transverse Joints. The roller shall pass over the unprotected
end of freshly laid mixture only when laying of the course has
been discontinued. The edge of the previously laid course
shall be cut back to expose even, vertical surface for the full
thickness of the course. The fresh mixture shall be raked
against the Joints, thoroughly tamped, and then rolled.
b. Longitudinal Joints. When edges of the longitudinal joints are
irregular, honeycombed, or poorly compacted, the joint shall be
cut back to expose an even, vertical surface for the full
thickness of the course.
Edges of pavement
69. Edges of pavement shall be straight and true to required lines.
After final rolling, excess material shall be cut off square and disposed of
as directed.

C8
Waterways Experiment Station Cataloging-In-Publicatlon Data

Shoenberger, James E.
Users guide : cold-mix recycling of asphalt concrete pavements I by
James E. Shoenberger; [prepared for) Department of the Army, US
Army Corps of Engineers.
25 p. : Ill. ; 28 cm. -- (Miscellaneous paper; GL-92-30)
Includes bibliographical references.
1. Pavements, Asphalt -- Recycling. 2. Pavements, Asphalt concrete -
- Maintenance and repair. I. US Army Engineering and Housing Sup-
port Center. II.U.S. Army Engineer Waterways Experiment Station. Il1.
Facilities Engineering Applications Program. IV.Title. V. Title: Users
guide: cold-mix recycling of asphalt concrete pavements. VI. Title: Cold-
mix recycling of asphalt concrete pavements. VII. Series: Miscellaneous
paper (U.S. Army Engineer Waterways Experiment Station); GL-92-30.
TA7 W34m no.GL-92-30