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Reclaimed Asphalt Pavement (RAP), Shingles (RAS) and Recycled Programs Update 2012 21 st Annual Meeting October 10 – 11, 2012 Albuquerque, NM Thomas Harman.

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Presentation on theme: "Reclaimed Asphalt Pavement (RAP), Shingles (RAS) and Recycled Programs Update 2012 21 st Annual Meeting October 10 – 11, 2012 Albuquerque, NM Thomas Harman."— Presentation transcript:

1 Reclaimed Asphalt Pavement (RAP), Shingles (RAS) and Recycled Programs Update st Annual Meeting October 10 – 11, 2012 Albuquerque, NM Thomas Harman Manager, FHWA Pavement & Materials TST Baltimore, MD

2 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

3 FHWA Stakeholder Engagement Asphalt Mixture ETG Asphalt Mixture ETG Asphalt Binder ETG Asphalt Binder ETG Warm Mix Asphalt TWG – Sunset 2012 Warm Mix Asphalt TWG – Sunset 2012 Reclaimed Asphalt Pavement – Sunset 2012 Reclaimed Asphalt Pavement – Sunset 2012 Pavement Sustainability ETG Pavement Sustainability ETG NOTE: WMA and RAP ETG’s folded under the Asphalt Mixture ETG (Sep 2012) 3

4 Stakeholder Engagement in the FHWA Pavement & Materials Program 4 Pavement Preservation ETG RPUG Surface Characteristics RPUG AASHTO JTP DGIT DGIT AASHTOSubcommitteesAASHTOSubcommitteesMaterialsMaterialsMaintenanceMaintenanceConstructionConstruction IRI ETG 4

5 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

6 RAP NCHRP Report 452 defines RAP as… “material that is milled or ripped up from existing asphalt pavements or material left over from the plant operations.” NCHRP Report 452 defines RAP as… “material that is milled or ripped up from existing asphalt pavements or material left over from the plant operations.” It is critical to account for the “old” materials; i.e., binder and aggregates in the new HMA mixture designs. It is critical to account for the “old” materials; i.e., binder and aggregates in the new HMA mixture designs. AASHTO M323 on Volumetric Designs of Superpave® Mixtures, Section 5.1 starts with the determination of the properties of the RAP and provides directions for using RAP as a percentage of the mixture. AASHTO M323 on Volumetric Designs of Superpave® Mixtures, Section 5.1 starts with the determination of the properties of the RAP and provides directions for using RAP as a percentage of the mixture. 6

7 Ex. Today’s Excess RAP 100,000 Tons 7

8 RAP M 323 just modified by AASHTO (2012) to permit the use of the RAP by % binder replacement and it does not provide a table of maximum acceptable percentages. This is to be determined by the agencies through evaluations of typical materials being used geographically across the States. M 323 just modified by AASHTO (2012) to permit the use of the RAP by % binder replacement and it does not provide a table of maximum acceptable percentages. This is to be determined by the agencies through evaluations of typical materials being used geographically across the States. –Appendix X-2 provides step by step instructions for agencies to evaluate the typical RAP materials that includes the determination of the properties of the materials to develop their own acceptable percentages to be used. 8

9 Asphalt Binder Replacement Asphalt Binder Replacement –AASHTO M323 Based on RAP %Based on RAP % –Formulating recommendations for % Binder replacement Accepted% Binder replacement Accepted Recommendations to DOTs Recommendations to DOTs –Before changing to binder replacement Quantify RAP stockpile properties…Quantify RAP stockpile properties… 9 RAP

10 Ex. Increased RAP Testing Use existing mixture design Use existing mixture design Design 5 additional mixes Design 5 additional mixes Tests on RAP, virgin, & mixture properties Tests on RAP, virgin, & mixture properties –Binder and mixture properties 10

11 Ex. Test by the Agency Summary –Dynamic Modulus, |E*| –Stiffness of Binders, G* –Low Temperature Cracking –Fatigue –Not for Single Project Analysis 11

12 Ex. IN DOT RAP Assessment, |E*| 12

13 Indiana DOT’s Outcome Revised RAP Specification to Binder Replacement: Dense Surface:40% < 3MESAL or 15% Base/Intermediate:40% max Open Graded:25% max Revised RAP Specification to Binder Replacement: Dense Surface:40% < 3MESAL or 15% Base/Intermediate:40% max Open Graded:25% max 13

14 Reclaimed Asphalt Pavement (RAP) Guidance Documents AASHTO M 323 AASHTO M 323 Volumetric Mixture Design Volumetric Mixture Design FHWA RAP in Asphalt Mixtures, State of the Practice FHWA RAP in Asphalt Mixtures, State of the Practice RAP FAQ PamphletRAP FAQ Pamphletwww.moreRAP.us 14

15 Guidance Documents for using RAP NCHRP and NAPA Materials 15

16 Guidance Documents for using RAP How to Increase RAP Usage and Ensure Pavement Performance, NAPA Publication PS 34 How to Increase RAP Usage and Ensure Pavement Performance, NAPA Publication PS 34 Designing HMA Mixtures with High RAP Content, NAPA QIP-124 Designing HMA Mixtures with High RAP Content, NAPA QIP-124 TRB Webinar: Design and Production of High RAP Pavement Mixtures. TRB Webinar: Design and Production of High RAP Pavement Mixtures. 16

17 17 HMA Asphalt Pavement Recycling Expert Task Group Advance the use of RAP in asphalt paving applications by providing highway agencies with critical information regarding the use of RAP, technical guidance on high-RAP projects, and direction on research activities. The members consist of representatives from highway agencies, industry, and academia. Website: 17

18 RAP Management Best Practices Reclaimed Asphalt Pavement Management- Best Practices (draft) by Dr. Randy West. Reclaimed Asphalt Pavement Management- Best Practices (draft) by Dr. Randy West. “From the time of collection through processing, mix design, and quality control practices during production of asphalt mixtures containing RAP” 18

19 Key Best Practice for More RAP Fractionation… Fine Fraction Course Fraction 19

20 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

21 Recycled Asphalt Shingles Manufactured Waste Manufactured Waste Post Consumer Tear Offs Post Consumer Tear Offs –Cleaning and sorting of shingles –Asbestos Testing –Removing Deleterious Materials –Homogenous Product 21

22 What Are Shingles Made of ? 35% granules 35% granules 30% asphalt 30% asphalt 15% fiberglass 15% fiberglass 20% mineral filler 20% mineral filler 22

23 Recycled Asphalt Shingles 23

24 Recycled Asphalt Shingle Use in US Source: 2011,

25 25 Asphalt Roofing Shingles 11 million tons of waste asphalt roofing shingles are generated in the US per year. 11 million tons of waste asphalt roofing shingles are generated in the US per year. –Manufacturing Waste ~ 1 million tons –Roofing tear-offs ~ 10 million tones Reclaimed Asphalt Shingles - RAS Reclaimed Asphalt Shingles - RAS –Crushed/ground and screened –Used in hot mix asphalt –High beneficial reuse 25

26 Reclaimed Asphalt Shingles (RAS) Potential benefits of RAS in HMA include: Improved resistance to pavement cracking Improved resistance to pavement cracking –Due to reinforcement from fibers Improved resistance to rutting Improved resistance to rutting –Due to fibers and increased stiffness of binder Reduced costs for the production of HMA Reduced costs for the production of HMA –Conservation of natural resources Conservation of landfill space Conservation of landfill space –Reduced costs for Shingle waste disposal 26

27 Current FHWA Involvement Pooled Fund Study for RAS Pooled Fund Study for RAS Engineering Properties of Recycled Asphalt Shingles Engineering Properties of Recycled Asphalt Shingles Asphalt Shingle Recycling Forums Asphalt Shingle Recycling Forums Support for Highway Agencies Support for Highway Agencies 27

28 RAS Standards M323 Modifications; Binder replacement revisions for RAP and/or RAS (part 1 completed) M323 Modifications; Binder replacement revisions for RAP and/or RAS (part 1 completed) PP53, MP15, Modifications regarding RAS (needs work) PP53, Standard Practice for Design Considerations when Using RAS in HMA & MP15, Use of RAS as an Additive HMA Modifications regarding RAS (needs work) Development of Technical Information on Shingles to replace the existing standards Development of Technical Information on Shingles to replace the existing standards 28

29 Reclaimed Asphalt Shingles (RAS) Industry Guidance CMRANAPA Construction Materials Recycling Association (CMRA)

30 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

31 Ongoing RAP/RAS Research… Field monitoring of the MnROAD RAP sections Field monitoring of the MnROAD RAP sections Proposed RAP/WMA Study at FHWA Accelerated Loading Facility (ALF) Experiment – (TFHRC) Proposed RAP/WMA Study at FHWA Accelerated Loading Facility (ALF) Experiment – (TFHRC) Northeast States High RAP Pooled Funded Project – (UNH) Northeast States High RAP Pooled Funded Project – (UNH) Performance of Recycled Asphalt Shingles in HMA (TPF-5(213)) – (ISU) Performance of Recycled Asphalt Shingles in HMA (TPF-5(213)) – (ISU) NCHRP 9-46: Improved Mix Design, Evaluation, and Materials Management Practices for Hot Mix Asphalt with High Reclaimed Asphalt Pavement Content – (NCAT) NCHRP 9-46: Improved Mix Design, Evaluation, and Materials Management Practices for Hot Mix Asphalt with High Reclaimed Asphalt Pavement Content – (NCAT) 31

32 Research- Continued RNS: Experimental Design for Field Validation of Tests to Predict Cracking in Asphalt Mixtures – (NCAT & AFH60) RNS: Experimental Design for Field Validation of Tests to Predict Cracking in Asphalt Mixtures – (NCAT & AFH60) RNS: Use of Soft Recycling Agents in Hot Mix Asphalt (HMA) and WMA (Warm Mix Asphalt) Containing High Asphalt Binder Replacement Ratios – (AFH60 & AFK10) RNS: Use of Soft Recycling Agents in Hot Mix Asphalt (HMA) and WMA (Warm Mix Asphalt) Containing High Asphalt Binder Replacement Ratios – (AFH60 & AFK10) RFP: NCHRP 9-55; Recycled Asphalt Shingles in Asphalt Mixtures with Warm Mix Asphalt Technologies RFP: NCHRP 9-55; Recycled Asphalt Shingles in Asphalt Mixtures with Warm Mix Asphalt Technologies 32

33 Technical RAP/RAS Information NAPA RAP/RAS/WMA survey, analysis and reporting 2012 and beyond – (NAPA) NAPA RAP/RAS/WMA survey, analysis and reporting 2012 and beyond – (NAPA) AASHTO RAP use survey, analysis and reporting 2012 and beyond – (DelDOT) AASHTO RAP use survey, analysis and reporting 2012 and beyond – (DelDOT) Shingles Best Practices Guide – (NCAT) Shingles Best Practices Guide – (NCAT) RAP in Rubber Modified mixes RAP in Rubber Modified mixes Proposed Comprehensive RAP Best Practices Report/Guide – (FHWA) Proposed Comprehensive RAP Best Practices Report/Guide – (FHWA) Proposed Technical Advisory: Best Use and Ownership of RAP – (FHWA) Proposed Technical Advisory: Best Use and Ownership of RAP – (FHWA) Proposed Technical Advisory: Shingles Best Practices Guide – (FHWA) Proposed Technical Advisory: Shingles Best Practices Guide – (FHWA) 33

34 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

35 Recycled Program Technologies (HIR,CR,FDR) Hot In-Place Recycling (HIR) is a paving technique that principally recycles the top 2 inches of asphalt pavement. Hot In-Place Recycling (HIR) is a paving technique that principally recycles the top 2 inches of asphalt pavement. Cold Recycling (CR) is a asphalt pavement rehabilitation technique that typically consists of rehabilitating 2-6 inches of the existing pavement. CR Options include: Cold Recycling (CR) is a asphalt pavement rehabilitation technique that typically consists of rehabilitating 2-6 inches of the existing pavement. CR Options include: –Cold In-Place (CIR) or –Cold Central Plant Recycling (CCPR) –w/Surface Overlay 35

36 Recycled Program Technologies (HIR,CR,FDR) Full Depth Reclamation (FDR) is a technique that extends the rehabilitation into the subbase/base typically 12 inches. Full Depth Reclamation (FDR) is a technique that extends the rehabilitation into the subbase/base typically 12 inches. –FDR is for severely deteriorated roadways –w/Surface Overlay 36

37 Recycled Program Technologies Guidance Documents Basic Asphalt Recycling Manual (BARM) dated (Currently being updated by FHWA and ARRA for release in 2012) Basic Asphalt Recycling Manual (BARM) dated (Currently being updated by FHWA and ARRA for release in 2012) FHWA-NHI Training Course # (Asphalt Pavement In-Place Recycling Technologies) FHWA-NHI Training Course # (Asphalt Pavement In-Place Recycling Technologies) –Web Based Training –Instructor Lead Training (2-days) –Released 08/29/12 nationally and training dates available 37

38 Recycling Program Benefits - Reduced costs Reduced costs Reduction in User Delays Reduction in User Delays Shorter Construction Periods Shorter Construction Periods Mitigation or elimination of existing pavement distresses Mitigation or elimination of existing pavement distresses Improved roadway performance Improved roadway performance No disturbance of subgrade (except FDR) No disturbance of subgrade (except FDR) Preservation of the environment (reduced landfilling) Preservation of the environment (reduced landfilling) 38

39 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

40 National Legislation: Moving Ahead for Progress in the 21 st Century (MAP-21) President signed into law P.L , Moving Ahead for Progress in the Twenty First Century (MAP-21), on July 6, MAP-21 extended SAFETEA-LU for the remainder of FY 2012, with new provisions for FY 2013 and FY 2014 beginning on October 1, SAFETEA-LU expired on 9/30/09

41 Moving Ahead for Progress in the 21 st Century (MAP-21) SEC INNOVATIVE PROJECT DELIVERY METHODS SEC INNOVATIVE PROJECT DELIVERY METHODS –Sub SEC. (3) INNOVATIVE PROJECT DELIVERY Permits State Agencies to use 100% Federal Funding, for various innovative project delivery methods including In-place recycling technologies. 41

42 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

43 2011 NAPA Summary Statistics RAP use growing steadily RAP use growing steadily –10% increase RAS use growing rapidly RAS use growing rapidly –57% increase RAP & RAS saving over 4 MT binder RAP & RAS saving over 4 MT binder WMA growing very rapidly WMA growing very rapidly –180% increase

44 Our Visit FHWA Technical Asphalt Program Reclaimed Asphalt Pavements (RAP) Reclaimed Asphalt Shingles (RAS) Research & Technical Information Recycled Program Technologies (HIR,CIR,FDR) MAP-21 NAPA 2011 Statistics Upcoming Recycled Materials or Program Events

45 Upcoming Events Recycled/Reclaimed Materials and Recycled Programs Industrial Resources Council Annual Conference, Indianapolis, IN., November 28-29, 2012; Go to: Industrial Resources Council Annual Conference, Indianapolis, IN., November 28-29, 2012; Go to: National Asphalt Pavement Association, 21st Century Asphalt Pavements Conference: Value, Quality, and Performance - Goes WEST, December 5-6, 2012, Salt Lake City, UT.; Go to: National Asphalt Pavement Association, 21st Century Asphalt Pavements Conference: Value, Quality, and Performance - Goes WEST, December 5-6, 2012, Salt Lake City, UT.; Go to: 45

46 Upcoming Events Recycled/Reclaimed Materials and Recycled Programs Transportation Research Board (TRB) Annual Conference, Washington DC, January 13-17, 2013, TRB 92nd Annual Meeting: Transportation Research Board (TRB) Annual Conference, Washington DC, January 13-17, 2013, TRB 92nd Annual Meeting: 6 th Asphalt Shingles Recycling (ASR) Annual Conference, Denver. CO., November 7-8, 2013; Go to: 6 th Asphalt Shingles Recycling (ASR) Annual Conference, Denver. CO., November 7-8, 2013; Go to: 6 th Rubber Modified Asphalt (RMA) Conference, Tempe, AZ., October 15-17, 2013: Go to: 6 th Rubber Modified Asphalt (RMA) Conference, Tempe, AZ., October 15-17, 2013: Go to: 46

47

48 Victor (Lee) Gallivan, PE Recycled Material Program Manager Ph: Cl:


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