increasing the use of rap: scanning tour of japanrecycles 45+ percent in their asphalt mixtures....

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March 22-24, 2016 | Nashville, TN | www.worldofasphalt.com

Increasing the Use of RAP:Scanning Tour of Japan

BRIAN K. WOOD, P.E.EXECUTIVE DIRECTOR, PLANTMIX ASPHALT INDUSTRY OF KENTUCKY

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BackgroundReclaimed Asphalt Pavement (RAP)

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Reclaimed Asphalt Pavement (RAP) in the U.S.

Over 90 percent of the U.S. highways and roads are constructed with hot mix asphalt (HMA)

FHWA (and contractors) recognizes that “the same materials used to build the original highway system can be re-used to repair, reconstruct and maintain them.”

Reclaimed (recycled) asphalt pavement (also called “RAP”) is now commonly used in the production of hot mix asphalt

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Economic Benefits 4

RAP tonnage in 2014 was 71.9 million tons.

Assuming 5% liquid, this represents 3.6

million tons of asphalt binder

conserved!

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Sustainability with RAP 5

Societal• Natural Resource

Conservation

Economic• Reuse Aggregate

and Asphalt Binder

Environmental• Reduced Emissions• Reduced Landfill

Space• Closes Life Cycle

Circle


Contractor Incentive 6

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RAP Stabilizes AC Pricing

Many states publish and index that tracks the price of liquid asphalt

Using RAP helps to stabilize mix prices despite spikes in liquid asphalt prices

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$-

$100

$200

$300

$400

$500

$600

$700

$800

Jan-

06Ju

n-06

Nov

-06

Apr

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Sep

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Feb-

08Ju

l-08

Dec

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Ma

y-09

Oct

-09

Ma

r-10

Aug

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Jan-

11Ju

n-11

Nov

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Apr

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Sep

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Feb-

13Ju

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Dec

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Tracking the Trends 8

Courtesy: National Asphalt Pavement Association (NAPA)

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2014 Survey Results 9

National Average is 20 Percent


Increasing RAP (factors) 10

More Access to

Milling

Improved Plant

Technology

Rising Liquid Asphalt Costs

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Is your goal to use more RAP?What is keeping you from achieving those goals?

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Obstacles to increasing RAP 12

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Presentation Outline

Background Compare/contrast Japanese and American

dynamics and business practices related to asphalt paving

Research and Technology Recycling Practices related to plant equipment,

laydown operations, mix designs and testing

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Japan Scanning TourDecember 1-10, 2014

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Why Visit Japan?

The National Asphalt Pavement Association (NAPA) learned that, on average, Japan recycles 45+ percent in their asphalt mixtures.

NAPA promotes the increased use of recycled products here in the United States

NAPA therefore organized a scanning trip with Japanese counterparts to investigate further

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Average RAP Comparison

0% 10% 20% 30% 40% 50%

Japan

United States

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Let’s Go and Find Out!

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Scanning Trip Planned

The US Delegation included 19 individuals representing: NAPA contractor members Four state DOT representatives National Center for Asphalt Technology (NCAT) National Asphalt Pavement Association A representative from the State Asphalt Pavement

Associations (me) Everyone arrived in Tokyo on December 2, 2014

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U.S. Delegation in Japan 19


It’s a long way from home… 20

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Travel to Narita Airport 21


Japan 101

Island nation in East Asia with the worlds 10th

largest population (over 126 million people) Greater Tokyo area and surrounding prefectures

is the largest metropolitan area in the world with over 30 million residents

Japan consists of 6,852 islands, has108 volcanos, and experience earthquakes and tsunamis

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Climate

32° - 47° North Latitude (mainland)Roughly San Diego to Seattle

Washington Temperature averages

between 41.2° F (winter) and 77.4° F (summer)

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Size and Scale 24

Japan’s land areas is 145,925 square

miles - slightly smaller than the

state of California at 163,696 square miles

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Country Comparisons

Japan has roughly half the population but only about 4% of the land area of the U.S.

Japanese production is about 50 million tons with about 1,000 plants

Unites States production is 350 million tons with about 3,000 Plants

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50,000 tons/plant

115,000 tons/plant


General Observations

Japanese culture is an interesting blend of old traditions and new technology That contrast between old and new extends into their

asphalt paving operations as well In some specific areas – the Japanese would

appear to be more advanced than the U.S. but in other ways, they appear to be decades behind

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Comparison between Japan and America

Advanced Recycling over 45%

RAP and use of rejuvenators

Performance-based specifications

Workmanship & Safety

Lagging Behind Batch plants with low

production Small projects with

high unit costs Mix designs and

materials

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Opening Reception 28

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Technical Presentations 29


Language Barriers 30

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Seminar on Recycling 31


Recycling in Japan

Government mandate Legislation on recycling construction waste is

stringent and fully implemented Japanese concluded in 1992 that RAP

mixtures were as good as virgin mixes Japan is a small country with large urban

areas so waste disposal is an important issue

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Japanese Trends 33


Japan’s Highway Network 34

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Truck Weights 35

Maximum Axle Weight is 11,000 lbs.


Government ResearchSimilar to FHWA’s Turner Fairbank

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Public Works Research Institute

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Test Track Trucks Use GPS 38

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PWRI Meetings 39


Presentations & Discussion 40

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Private Research 41


Plant TechnologyHigh RAP Mixtures

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Classroom Element 43


Cultural Differences 44

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Plant Safety 45


Virgin Materials

Handled and processed similar to the United States

Mostly sandstone or imported aggregates from Russia

Covered cold feed bins to maintain low moisture content

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Clean and Covered 47


Processing RAP

Most of the RAP we saw was delivered in pieces (not milled)

Delivered to the asphalt plant for processing

Crushed, sized & screened

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Indoor Processing Facility 49


RAP Processing

RAP is fractionated much like it is here in the U.S.

The RAP processing facility we visited was indoors (strict dust and pollution requirements)

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Managing Materials

Covered processing and bin storageThey keep RAP

dry… reported at 1.5%-2.0% moisture

RAP is tested for penetration grade

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RAP Parameters

Liquid in RAP must have a penetration of 20 or more or it will be discarded

Minimum asphalt content of the RAP must be 3.8 percent

Cannot contain too much dust

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Mix Designs in Japan

Utilizing Marshall Methods with 75- and 50-blow compaction efforts for heavy and moderate traffic (respectively)

Most common grades for virgin asphalts are 40/60 and 60/80 pen grades. Use blending charts determine ratio of RAP to virgin binder

Testing includes the indirect tensile modulus (peak stress/deformation) and a wheel tracking test (dynamic stability)

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Typical Japanese Mixtures

Most common mix is a 13mm dense-graded surface mixture Similar to a ½-inch

nominal maximum aggregate size

Gradation does not cross the maximum density line which makes it forgiving with respect to segregation

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Japanese Experience

Mixes seemed to be “reverse-engineered”

Found a combination of materials that performed well in the field and used them again and again…

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Rejuvenators

The key to using high RAP mixtures is the introduction of a rejuvenating agent to condition the RAP

This softens the hardened binder and activates the liquid

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Plant Types in Japan 57

68.8

17.7

13.5

Plant Types

Parallel Heat In Direction Dram Mixing


Parallel Heat System

Most common plant type (68.8%) and the type we visited while on our tour

Parallel dryers… one for recycle and one for virgin materials

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Maeda Road Plant (Tokyo)

Parallel Heat System Batch plant

producing 180 tons/hour 270,000 tons/year

32 employees with dorm so that mix available 24 hours

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Inside the Plant 60

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Material Flow

RAP to the dryer… enters the pugmill and is mixed with a rejuvenator…to surge bin (3 hours)

Virgin materials dried and moved over screens (typical batch plant)

RAP mixed with virgin aggregates and AC in the larger mixer

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Air Flow

Direct heating to the RAP at 300+ degrees Fahrenheit creates smoke and fumes

Plants duct the RAP dryer exhaust through an afterburner (also referred to as a thermal oxidizer and “deodorizer”) that raises the gas temperatures to above 1,292°F to burn off any hydrocarbons

Exhaust is returned to the virgin dryer to recover some heat energy

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Rejuvenators

Proprietary! One plant we visited

indicated that their product was generally classified as a paraffinic oil

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RAP Dryer/Drum 64

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Mix Types

They keep mix types to a minimum and simple descriptions

Batched a virgin mix along with 45% and 60% RAP mixes for our inspection

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Plant Controls 66

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Loading Operations 67

Maximum Asphalt Load = 9 tons


Major Plant Differences

1. Stockpile moisture content of the RAP and virgin aggregates is minimized

2. Use of batch plants instead of continuous mixing plants3. Use of a separate drum for drying and heating RAP

(parallel heating method)4. Use of the afterburner technology to burn off any

hydrocarbons in RAP dryer exhaust5. Rejuvenators mixed directly with heated RAP in a small

pugmill

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Field Operations

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Trucking Operations 70

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Paving Operations 71


Compaction Efforts 72

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Attention to DetailWorkmanship and Quality

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Protecting the Edge 74

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Longitudinal Joints 75


Excellent Workmanship 76

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Alternative Forms of TransportationHigh Speed Train

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BicyclesVery Popular Form of Transportation

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Bicycles 79


New Vehicles

New and used cars are expensive, car ownership fees and fuel levies are used to promote energy efficiency

Parking Requirements

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Closing Dinner & Reception

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Group Photo with U.S. and Japanese Delegations

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Soaking in the Culture 83


And the Karaoke…. 84

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Takeaways

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Observations

Performance based specifications Emphasis on quality workmanship Use of rejuvenators to increase RAP percentage

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Parallel Heating

Heating and isolating the RAP with the rejuvenator makes a lot of sense Adaptations would be required in US for drum plants

and for higher production Foaming the rejuvenator may be more feasible to

minimize or eliminate conditioning times

Potential for mixtures with higher RAP that demonstrate equivalent or better quality and performance

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Back Home in America

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Recommendations

There are no barriers to the potential for asphalt mixtures with higher RAP contents

Agency specifications should allow the use of RAP Best Practices for RAP should be implemented Consider production changes in our continuous mix

plants to accommodate more RAP The asphalt industry consider the use of rejuvenators to

facilitate increased amounts of RAP in our mixtures

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Big Picture Takeaways

Commitment to SUSTAINABILITY SIMPLICITY & focus on performance in mix

designs and testing Cooperation and TRUST between government &

industry Attention to QUALITY & details Overwhelming commitment to SAFETY

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For Additional Informaiton

NAPA has recently released Information Series 139

PDF copies are now available from the NAPA website

Visit www.asphaltpavement.comto download a free copy

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Thank You!Brian K. Wood, P.E. ([email protected])

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Thanks for your Participation

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increasing the use of rap: scanning tour of japanrecycles 45+ percent in their asphalt mixtures....

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