recycling dfw metroplex pavements: why, how & how much?
TRANSCRIPT
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Matthew W. Singel, P.E.
Program Manager
Soil Cement/
Roller-Compacted Concrete
Recycling DFW Metroplex Pavements:
Why, How & How Much?
Dan Richwine
Sales Manager
Cement Treated Materials
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Cement Council of Texas
Hurst, Texas
(Fort Worth Area)
Serving Texas as:
•Technical Resource
•Catalyst for Research Initiatives
•A Conduit for Innovations
•Trainers for Design and
Construction Professionals
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Water Content
Cem
en
t C
on
ten
t
Roller-Compacted
Concrete
Conventional
Concrete
Soil-Cement
Flowable Fill
Cement-Modified
Soil
Full-Depth
Reclamation
Cement-
Treated
Base
Cement-Based Pavement
Materials
Pervious
Concrete
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Soil Cement Materials in a
Pavement Section
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Method of flexible pavement reconstruction that utilizes the existing asphalt, base, and subgrade material to produce a new stabilized base course for an asphalt, chip seal, or concrete wearing surface.
Alternative Terms:◦ Full-Depth Recycling (FDR)◦ Cement Stabilized Reclaimed Base (CSRB)◦ Full-Depth Rehabilitation (FDR)◦ Cement-Treated Existing Roadway Materials (C-TERM)◦ Cement Recycled Asphalt and Base (CRAB)◦ Cement Recycled Asphalt Pavement (CRA……)
Definition of Reclamation
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Reconstruct Pavements
◦ Fast - ½ to 1 lane-mile/day
◦ Inexpensive – Saves 25% to 40% vs remove & replace
◦ Increase Strength, Uniformity & Moisture Resistance
Reuse Materials In-Place
Drastically Reduce Impact on Natural Resources (Virgin Materials) and Material Hauling
Provides Low-Maintenance, Long-Lasting Base (25+ years)
Benefits ofAsphalt Pavement Recycling (Full-Depth Reclamation with Portland Cement)
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Design
(pre-construction evaluation)
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The procedure includes the following steps:
◦ Site Investigation.
Determine cause of failure
Take core samples/test holes
Establish layer thicknesses
Obtain material samples to use for mix design
◦ Lab Evaluation.
Develop representative samples
Use proportioned materials from site investigation
Goal: Simulate Construction Process
Pre-Construction Testing
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Construction Process
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Pulverize existing pavement
Add cement (dry or slurry form)
Mix & add moisture (if necessary)
Compact
Place surface◦ Asphalt
◦ Seal Coat
◦ Concrete
Easy Construction Process!
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Spray Bar for Water
Pulverize
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Dry Form
Slurry Form
Apply Cement
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Blend Materials & Add Moisture
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Compact & Grade
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Asphalt
Concrete
Add Surface Pavement
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The success of a recycling project depends upon the careful attention to the following specified control factors:
Sieve Analysis (ASTM C136)
Atterberg Limits (ASTM D4318)
Moisture-Density (ASTM D558)
Durability Tests
◦ Wet-Dry (ASTM D559)
◦ Freeze-Thaw (ASTM D560)
Soluble Sulfates (ASTM D516)
Compressive Strength (ASTM D1633)
Quality Control
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Introduces a network of fine fractures into the base to mitigate the formation of major cracks
10-12 ton vibratory roller applied 1–2 day after placement
Low Speed
At High Amplitude
2 – 4 passes
Microcracking
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PCA Document LT 299
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Finished Base
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• Retards Reflective Cracking
• Increased Stiffness Spreads Loads
• Eliminates Rutting Below Surface
• Reduced Moisture Susceptibility
• Reduced Fatigue Cracking
• Allows Thinner Overall Pavement
Section
Engineering Benefits
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“The need to ensure that development meets the needs of the present without compromising the ability of future generations to meet their own needs.”◦ 1987, UN Bruntdland Report
Sustainable Development
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Diesel
(gal)
Removal
(cu yd)
Material
(tons)
Trucks
(Number)
New
Recycle
180
12
4500
300
2700
0
3000
500
1 Mile of 24’-wide 2-lane road,
6” base + 2” asphalt surface
Equipment & Materials:
Recycling vs. New Base
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Systematically evaluates environmental impacts of a product or system
Considers all impacts◦ Extraction of raw materials
◦ Manufacture
◦ Service life
◦ Demolition
Helps determines systems with least impact on environment
3 Phases: Inventory, impact assessment and evaluation
Life Cycle Inventory/Analysis
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Full-Depth Reclamation
Evaluation
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Provides Structure in Subgrade Soils
Reduces Construction Time & Fuel Consumption vs Other Base Methods
Offers Long-Term Support for Overlying Pavements◦ Does Not Dissipate (Leach Out) With Time
◦ Reduces Thickness of Overlying Pavements
Cement-Stabilized Base:
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Unstabilized Granular Base
100 psi
15 psi Cement-Stabilized Base
• Soil-Cement Base
• Cement-Treated Base
• Full-Depth Reclamation
100 psi
4 psi
Increased Rigidity Spreads Loads
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High water table
Moisture infiltrates base:
• Through high water table
• Through capillary action
• Causes softening, lower strength,
and reduced modulus
Cement stabilization:
• Reduces permeability
• Helps keep moisture out
• Maintains high level of strength
and stiffness even when saturated
Unstabilized Granular Base Cement-Stabilized Base
Reduced Moisture Susceptibility
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Unstabilized Granular Base
Cement-Stabilized Base
• Soil-Cement Base
• Cement-Treated Base
• Full-Depth Reclamation
Thinner Pavement Section
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Recent Local Projects
Cities◦ Bedford◦ Dallas ◦ Grand Prairie◦ Fort Worth◦ Southlake◦ Denton◦ Arlington
Counties◦ Collin County◦ Dallas County◦ Denton County◦ Ellis County◦ Kaufman County◦ Tarrant County
& Local TxDOT Districts (and many districts statewide)
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Reconstructs Asphalt Pavements
◦ Fast - ½ to 1 Lane Mile/Day
◦ Inexpensive – Saves 25% to 40% vs Remove & Replace
Reuse Materials In-Place
Drastically Reduces Impact on Natural Resources
(Virgin Materials)
Provides Long Lasting Base (25+ years)
“Portland Cement is probably the closest thing we have to a
universal stabilizer.”
- From a U.S. Army Corps of Engineers Report dated September 2002
Benefits ofAsphalt Pavement Recycling (Full-Depth Reclamation with Portland Cement)
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What About Performance?
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Full Report
(60 pages)
PCA SR016
Summary
(4 pages)
PCA IS689
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News, Events, Developments
General FDR Information
Project Descriptions
Provides Testimonials
www.RecyclingRoads.org
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Case Study: City of Dallas
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Sustainable is Obtainable
A Success Story
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Pre - 2004
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Today The City of Dallas recycles a minimum of 80% of their streets
Three new categories were established to evaluate each street
Each street is classified either Rehabilitation, Restoration or Partial Reconstruction
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For asphalt street.
25% or less of the street needs fixing.
Repairs a localized area.
Millings are recycled to produce CTB and placed back into the patched area.
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For asphalt street.
30% or more of the street needs repair.
Requires Full Depth Reclamation (FDR).
Some milling may be required if existing grade is higher than curb lines.
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For concrete streets.
30% or less of the street is need of repair.
Concrete is hauled to crushing facility.
Rebar is removed & recycled.
Concrete is crushed into base material.
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In 6 months started benefiting economically, environmentally and socially.
Of the three categories FDR is most beneficial.
FDR saves approximately 40% per lane mile.
By using FDR, Dallas is able to restore 3 times as many lane miles in a given period.
This saving in time is also a saving in cost.
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Un-bonded
Cost Type FDR COST C.T.B. COST Flexbase COST %Reduction
N0x emissions 7.30 376.88 852.46 99%
(in pounds)
Fuel Consumed 772.50 1284.64 4324.17 86%
(in gallons)
Truck Miles 253.3313,086.2
1 29,599.14 99%
TOTAL COST $38,508.25 $70,678.47 $110,147.50 79%
*To replace 1 mile of street 20' wide, 6" depth,(6% cement except for flex base which is un-bonded)
10 miles from plant, 20 miles from landfill, 67 miles from stone quarry
Truck emission of N0x as EPA standards is =1.802 tons per 125,000 miles, average fuel 5 MPG
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Using a FDR program Dallas has
Dallas has achieved ISO 9001 (QC Standards) & ISO 14001 (Environmental Standards)
Working on ISO 18001 (Safety Standards)
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Matthew W. Singel, P.E.
Cement Council of Texas
817-540-4437 ext 13
Thank You!
Dan Richwine
Texas Industries
972-409-3240