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Hot mix recycling is economically lucrative when existing bituminous pavements get
buried while constructing vehicle under passes, public under passes, and flyovers.
This is happening on many national highways in India when six-laning of existing
four–lane highways is done. In such cases, the existing bituminous pavement usually
consisting of Dense Bituminous Macadam (DBM) and Bituminous Concrete (BC),
can be milled off and RAP transported to hot mix plant for recycling. A hypothetical
case is given here. An existing four-lane highway with a total length of 120 km is to
be made a six lane highway. Due to construction of numerous under passes and
flyovers during six-laning, about 30 km of existing four-laned highway will get buried
if not reclaimed. The total tonnage of bitumen in existing 115 mm thick DBM and 40
mm thick BC is estimated to be 7,119 tons, which has a value of Rupees 22.1 crores,
considering the cost of bitumen at Rs. 31,000 per ton. The total tonnage of aggregate
which can be reclaimed from RAP is 165,238 tons, which has a value of Rs. 6.1
crores considering its cost of Rs. 370 per ton. Therefore, the gross savings from
reusing the bitumen and aggregate from RAP amounts to Rs. 28.2 crores. It is
estimated that cold milling and transport of RAP to a hot mix plant would cost about
Rs. 8.2 crores. Therefore, a net saving of Rs. 20 crores can be realized on this six-
laning project if hot mix recycling is implemented.
Cold in-place recycling should have been implemented in India many years ago when
2-laning and 4-laning of highways was begun. Most of the existing bituminous
pavements were constructed in several stages in the past using different (sometimes
unknown) types of bituminous mixes or surface treatments. These pavements can be
converted into a uniform and stable base course through cold in-place recycling. An
existing one-lane road can also be widened into a 2-lane road simultaneously by
incorporating extra virgin aggregate and asphalt binder during the same recycling
operation. If the bituminous crust of the existing road is thin, cold in-place recycling
can include the underlying water bound macadam (WBM) or wet mix macadam
(WMM). The rejuvenated, uniform, stable base can be provided with bituminous
overlay(s). This recycling/widening process has been done successfully in the US.
This is far better than strengthening the existing singe lane road with questionable
pavement courses and widening it to two lanes with dissimilar paving materials.
You can download and print these guidelines “free” from the internet links, which are
provided below. I sincerely hope engineers involved in major highway projects would
take initiative and implement recycling techniques appropriate for their projects. I
sincerely hope that the Indian Roads Congress will develop specifications for all types
of asphalt recycling as soon as possible to facilitate the implementation of recycling
by specifying agencies.
“American roads are not good because America is rich, but America is rich because
American roads are good.” - John F. Kennedy
“Never doubt that a small group of citizens can change the world. Indeed, it is the
only thing that ever has.” -Margaret Mead
The reader can download any or all of the following chapters by clicking on
URL given under each chapter (or CTRL plus click or copy and paste in
URL). For example, if the reader is interested in cold in-place recycling only,
then Chapters 13, 14, and 15 would be appropriate. Use the main reference
above if any material is quoted from any chapter. The copyright of this
manual is held solely by the US Federal Highway Administration (FHWA).
The full manual can be downloaded and printed free at the following URL:
http://www.fhwa.dot.gov/pavement/recycling/98042
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_01.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_02.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_03.pdf
4. Economics of Recycling
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_04.pdf
Equipment)
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_05.pdf
6. Hot Mix Asphalt Recycling - Drum Plant (Construction Methods and
Equipment)
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_06.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_07.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_08.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_09.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_10.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_11.pdf
and Equipment)
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_12.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_13.pdf
14. Cold-Mix Asphalt Recycling (Materials and Mix Design)
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_14.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_15.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_16.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_17.pdf
http://www.fhwa.dot.gov/pavement/recycling/98042/CHPT_18.pdf