jim dykes president dykes paving & construction inc. atlanta, georgia presented at: the 3 rd...

Jim DykesPresidentDykes Paving & Construction Inc.Atlanta, Georgia

Presented at:

The 3rd ASPHALT SHINGLE

RECYCLING FORUM

Why We Recycle

• Rising costs and increased restrictions Rising costs and increased restrictions for landfillsfor landfills

• 11million tons of shingle waste is 11million tons of shingle waste is produced each yearproduced each year

• Less than 5% of shingle waste is Less than 5% of shingle waste is recycledrecycled

Benefits to Recycling

• Shingles are composed of 20% to 40% Shingles are composed of 20% to 40% liquid ACliquid AC

• Fiber and polymers from shingles can add Fiber and polymers from shingles can add strength to mix designstrength to mix design

• Can be added to HMA to offset liquid AC Can be added to HMA to offset liquid AC costs or to create new mixescosts or to create new mixes

Bottom Line

• An available 11 million tons of shingle An available 11 million tons of shingle waste, containing 20% liquid ACwaste, containing 20% liquid AC

• 2.2 million tons of reclaimable liquid AC2.2 million tons of reclaimable liquid AC

• At $300.00 per ton that’s At $300.00 per ton that’s $660 million$660 million worth of liquid asphalt every yearworth of liquid asphalt every year

DO THE MATH!

The Process

DoubleDoubleDeckDeck

ScreenScreen

DoubleDoubleDeckDeck

ScreenScreen

HammerHammerMillMill

HammerHammerMillMill

PrimaryPrimaryShredderShredderPrimaryPrimary

ShredderShredder

ShingleShingle

WasteWaste

5/16” 5/16” MinusMinus

5/16” 5/16” to 3/4”to 3/4”

Closed Loop System

*Larger material is normally wasted as by product. However, we further process this material.

Sort and Prep

• Remove any unwanted trash from Remove any unwanted trash from shingles such as wood or metalshingles such as wood or metal

• Paper may stay on manufacturer Paper may stay on manufacturer rejectsrejects

Problems to Overcome

• Tear-offsTear-offs Intensive pre-processing More contamination than manufacturer rejects Smell from mold

• Environmental IssuesEnvironmental Issues Dust control E.P.A. regulations concerning stockpile locations and size.

Problems to Overcome

• Allocating spaceAllocating space Locations for equipment Covered or enclosed area to keep stockpile cool

• Crossing the economic barrierCrossing the economic barrier Most unsuccessful attempts to recycle and incorporate shingle

into mixes are due to improper sizing Best approach is to add the extra equipment necessary to

process shingle down to sufficient size

Equipment

Primary ShredderPrimary Shredder

Equipment

Double Deck ScreenDouble Deck Screen

Equipment

Hammer MillHammer Mill

Equipment

Covered StockpileCovered Stockpile

Equipment

LoaderLoader

Shingle Sources

Manufacturer Rejects

Post Consumer Waste “Tearoffs”

Products

• Hot Mix AsphaltHot Mix Asphalt

• Cold MixCold Mix

• Dust ControlDust Control

Hot Mix Asphalt

Shingles breaking down as they enter hot mix

Perma Flex®

Perma Flex®

Solves Reflective Cracking Problems

Dust Control

Cold Mix Asphalt

Cold Mix DesignsBlend Percentages

Blend 1 Blend 2 Blend 3 Blend 4 Blend 5

Oversized RAP %

(3/8” to 3/4”)

70.0 60.0 50.0 40.0 25.0

Oversize Shingle %

(5/16” to 3/4”)

30.0 30.0 30.0 30.0 30.0

Fine RAP(3/8” minus)

0.0 10.0 20.0 30.0 45.0

Combined Gradations

1” 100.0 100.0 100.0 100.0 100.0

3/4” 99.1 99.1 99.2 99.3 99.4

1/2” 72.4 75.1 77.7 80.4 84.4

3/8” 42.5 48.1 53.6 59.2 67.6

#4 15.0 20.5 25.9 31.4 39.5

#8 11.1 14.6 18.1 21.6 26.9

#16 7.6 10.0 12.4 14.8 18.4

#30 4.6 6.1 7.6 9.0 11.2

#50 2.1 2.4 2.8 3.1 3.6

#100 0.3 0.3 0.3 0.3 0.3

#200 0.1 0.1 0.1 0.1 0.1

Loaded Wheel Test

• Study Showed that Blend 1, with no fines, had the greatest strength

• Important to note that strength increases as the mix cures. It may initially be very soft, but with time and traffic, ruts will be significantly reduced.

All lab testing performed by Pavement Technology Inc.

0

1000

2000

3000

4000

5000

6000

1 2 3 4 5

Blend #

Field Test:Field Test: Proving ground for Proving ground for

new asphalt mix new asphalt mix designs at Waste designs at Waste

Management transfer Management transfer station in Norcross, station in Norcross,

Georgia.Georgia.

Dykes Paving & Construction IncDykes Paving & Construction Inc..

Resources

The most complete information The most complete information can be found at:can be found at:

www.shinglerecycling.org or or www.shinglerecycling.netwww.shinglerecycling.net