Recycled Asphalt Program & Environmental Stewardship Program (Post Consumer Content) Robert C. Rea Nebraska Department of Roads WASHTO – Omaha, Nebraska April 2014

Average RAP Contents (Overall) 6.9% 27.3% 28.6% 34.4% 37.3% 39.2%

RAP Savings ($ millions) 3.6M 23.3M 19.8M 41.7M 35.3M 43.6M

How did we get to 39.2% average RAP ? Design and Specifications to optimize RAP Design and Specifications to optimize RAP RAP Incentive for binder savings

1. Binder Cost Subsidiary to Mix (36 States) Not Needed -- Incentive is already there to use less contractor purchased ‘new’ binder SPECIFICATIONS 2. Binder Paid Separately as Bid Item (14 States) Needed -- No incentive for the Contractor to underrun an established item, so we must place incentive on the net binder savings SPECIFICATIONS and INCENTIVE

15% of Binder Savings For Contractor 35% of Binder Savings For Contractor 50% of Binder Savings For Contractor DOT Millings from ‘ON’ project DOT Millings from ‘OFF’ project Contractor ‘Owned’ Millings 90% of our projects are this 8% of our projects are this 2% of our projects are this 85/15 Incentive Split 65/35 Incentive Split 50/50 Incentive Split

Example 40,000 Ton Project ( 5 M ESAL Design – Typical SPR mix ) MILLINGS FROM ON PROJECT 85/15 Incentive Split Mill 2” – Fill 3” Mill 2” – Fill 3” Hot Mix = $ 30 per ton Hot Mix = $ 30 per ton Binder PG = $650 per liquid ton Binder PG = $650 per liquid ton Design is for 5.4% Binder Content Design is for 5.4% Binder Content

Total Cost = $2,604,000 Recycle Savings to DOT = $0.00 Recycle Incentive to the Contractor = $0.00 Total final Cost Realized by DOT $2,604,000 Virgin Mix (No RAP) Hot Mix = 1,200,000 Hot Mix = 1,200,000 Virgin Binder = $1,404,000 Virgin Binder = $1,404,000 Binder from RAP = $0 Binder from RAP = $0 Total Cost = $2,604,000 Total Cost = $2,604,000 Pre-incentive 2008 (6.9% RAP) Hot Mix = 1,200,000 Hot Mix = 1,200,000 Virgin Binder = $1,307,124 Virgin Binder = $1,307,124 Binder from RAP = $96,876 Binder from RAP = $96,876 Total Cost = $2,507,124 Current w/Incentive (45% RAP) Hot Mix = 1,200,000 Hot Mix = 1,200,000 Virgin Binder = $772,200 Virgin Binder = $772,200 Binder from RAP = $631,800 Binder from RAP = $631,800 Total Cost = $1,972,200 Total Cost = $2,604,000 Recycle Savings to DOT = $96,876 Recycle Incentive to the Contractor = $0.00 Total final Cost Realized by DOT $2,507,124 Total Cost = $2,604,000 Recycle Savings to DOT = $537,030 Recycle Incentive to the Contractor = $94,770 Total final Cost Realized by DOT $2,066,970

Virgin Mix (No RAP) Total final Cost Realized by DOT $2,604,000 Pre-incentive 2008 (6.9% RAP) Current w/Incentive (45% RAP) Total final Cost Realized by DOT $2,507,124 $2,507,124 Total final Cost Realized by DOT $2,066,970 On one 40,000 ton hot mix project On one 40,000 ton hot mix project

REASONS RAP USE MAY BE LIMITED REASONS RAP USE MAY BE LIMITED 1.Agency limits use of RAP or says ‘I want the new stuff, not the used stuff ’ 2.Stigma of lesser quality, Engineered Design a must 3.Plant Superintendant says ‘The plant won’t run that much’ 4.Design must optimize mill and fill strategies or ‘Road Mining’ 5.Requires binder grade bumps/dumps when higher amounts are used 6.Restrictive in the specification, i.e. dust/asphalt maximum 7.Limits the RAP #200 amounts and therefor rejects the RAP 8.Voids and VMA and other properties restrict the amount of RAP

CAACAA o 83 Allows for RAP Variation, typically 90+ FAAFAA o Allows for RAP Variation, typically 44+ o FAA Sp. Gravity slightly lowers true FAA o Binder Grade and Volumetrics provide added Rutting Resistance o Overshoot FAA – Increased Cracking VoidsVoids o Allow more dust & binder, better field density Min. BinderMin. Binder o Used as Factor for VMA #200#200 o Typically around 4-6%, D/B around

APA Testing of SPR Mixes 8000 Cycles 8000 Cycles 100 PSI Pressure Load 100 PSI Pressure Load 64 degrees C 64 degrees C Max of 12 mm Rutting Max of 12 mm Rutting

APA Testing of SPR Mixes

44.7%

Approach to a 50% RAP Project 1.Pick a 20,000 to 40,000 Ton Project 2.Use a ‘tried and true’ mix that you know works and has been a workhorse for your state 3.Specify the quality and type of virgin aggregate that you want to use, in other words, the ones that you like and are of good quality 4.Use softest base oil you can get either -34 or -28 if you can 5.Specify a minimum Binder Content if you don’t pay ac separately 6.Specify minimum 40 % RAP 7.Have the RAP come from the road…….fresh processed millings 8.Be flexible with the #200 material 9.Lower voids and no VMA spec, effects of burnoff oven – another all day presentation to discuss this  control by voids and binder content 10.Place it in all lifts, especially surface, we want to monitor this material

Robert C. Rea office mobile

Type ‘R’ Asphalt $ 36 $ 24 $ 12 - $ 20 $ 44

RAP Savings Potential $ 12 to $20 per Ton $ 12 to $20 per Ton x ?? Million Tons x ?? Million Tons $ 10 to 40 Million $ 10 to 40 Million Annual Savings realized every year, over and over and over again. Not to mention, Better on the environment, Green Technology, Recycling, Less Raw Materials, Less Hauling, Less Transportation and consumption of fuels ……..

Post Consumer Content

On Project Plan Sets in 2014

Thank You!