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Recycling Emulsions for Pavement Preservation “Going from Good to Great to Green”

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Recycling Emulsions for Pavement Preservation “Going from Good to Great to Green” Recycling Emulsions for Pavement Preservation “Going from Good to Great to Green” Presented by: Wade Miller Western Emulsions, Inc. Western Emulsions, Inc. • Founded in Dec. 1977 • 5 Plants and Terminals in 4 States • 10 DOT’s in Western States Footprint • Most recent March 2009: Grand Opening of Emulsion Plant in Roswell, New Mexico Our Business • Emulsions Manufacturing • Liquid Asphalt Sales • Transport Asphalt Emulsions • Spread Asphalt Emulsions • Technical Consultation Pavement Preservation Defined • Integrated, cost-effective set of practices that extend pavement life, improve safety and meet motorist expectations.” • Proactive program employing a network- level strategy to enhance performance • “The right treatment for the right road, at the right time” Pavement Preservation Benefits • Cost Savings – Surface treatments save 80 – 98% of the cost per lane-mile compared to mill & overlay • Jobs – PP creates 25% more, dollar-for-dollar, compared to reconstruction • Environmentally superior to traditional R&R – GHG Emissions – Energy consumption – Solid waste/landfill impact What are Emulsions? • 60%-70% Asphalt • 30%-40% Water • Two major components will not mix (they are insoluble) • Definition of an Emulsion: A mixture of two insoluble liquids Why Emulsions v. Hot AC? • Lower working temperatures • No heat needed - energy savings • Easy to use at remote locations • Breaking process controlled by chemistry • Can be easily recycled in the future Growing Usage of Emulsions • The United Stated systems of roads and highway-valued at over $1.75 trillion is steadily deteriorating. The American Society of Civil Engineers (ASCE) 2009 Report Card for America’s Infrastructure give a grade of D- for the nation’s roads. ASCE estimates the total cost of repairs and needed upgrades is $2.2 trillion. • Pavement Preservation (Asset Management) • Recycling • Declining Budgets • Environmental Concerns Emulsions Not All Created Equally • Slow-setting (old technology) v. Rapid-setting (new technology) • Cutback-based (old-technology) v. Solvent- free (new technology) Cutback Emulsions Emulsions Used by DOT - 85% are slow-setting type emulsions - 75% contain solvents (kerosene, diesel, naptha) The Western Emulsions Difference • Technological Innovations – Solvent-Free Materials – Rapid-setting Products – More eco-efficient, cost-effective processes • Now used as alternatives to the cutback products Why rapid setting emulsions? • Weather friendly • Less motorist inconvenience • Less likely to cause environmental issues • Labor Savings Western Emulsions’ Innovations • Our Emulsions were green before green was popular • Energy efficient • Water based • Low temperature handling • Little or no emissions with most emulsions • Recycling, sustainability Pavement Preservation Using PASS® - Treatment Strategies New Solutions • Emulsions vs. Hot Mix Asphalt • Preservation rather than reconstruction • Reduced Emissions Pavement- Warm Mix • Cold-In-Place Recycling-CIR • Full Depth Recycling-FDR • Solvent Free Prime-AEP • Scrub Seals-Cape Seals • 100% Reclaimed Aggregates Three Processing Methods • There are three PASS R /RAP processing methods which are being successfully used today by both agencies and contractors: – 1. Grade processing, compaction and sealing – 2. Grade mixing, laydown and compaction – 3. Central plant mixing, stockpiling, laydown and compaction Applications Grave Emulsion Full Depth Reclamation Max 13” Base Stabilization Max Depth 13” Cold In-Situ Recycling 2” Cold Mix Wearing Coarse Where Can PASS-R Be Used “Pavement Preservation” Cold Mix 101 “Cold Mix Paving” • Slurry seal • Road Building • Microsurfacing Structural Layers • Chip seal PAVEMENT LAYERS • Tack coat WEARING COURSE TOP SOIL BASEBASE TOP SOIL SUB-BASE SOIL STABILIZED ROADBED Stockpilable 1 week – 1 month Windrows Start Grader Good Workability Compacted Immediately Compaction ETB - Emulsion Treated Bases & GEM - Granular Emulsion Mixes Recycle (RAP) Emulsion Mix – Central Plant Mixing Recycle (RAP) Emulsion Mix – Central Plant Mixing Recycle (RAP) Emulsion Mix – Central Plant Mixing Blade Laid Recycle (RAP) Emulsion Mix – Central Plant Mixing Paver Lay-down and Compaction Recycle (RAP) Emulsion Mix – Central Plant Mixing Windrow Lay-down, Paver Laid Recycle Applications – Cold In Place Recycling Cold-In-Place-Recycling Train Recycle Applications Cold In Place Recycling CIR Paving/Lay-down Equipment COLD MIX FOR RE-DIMENSIONING AND REINFORCING OLD PAVEMENT Widening Cold Mix Stabilized Shoulder Old Pavement Old Pavement Base Profile of old road and new road geometries Preservation Strategies Rejuvenating Fog Seals Rejuvenating Scrub Seal / (Quick Breaking) Cape Seal RAP Slurry Seal, Micro- Surfacing and Chip Seal CIR Train-Yellowstone National Park • Recouping investments in aging infrastructure America needs its roads, but they are aging. Vehicle miles traveled in the U.S. have increased five-fold over the past 50 years to 3 trillion vehicle miles in 2006. Roadways are becoming distressed, carrying heavier loads than originally intended. New Technologies: • Solvent-Free Cold In- Place Recycling (CIR) • Solvent-Free Full Depth Reclamation and Granular Base Stabilization (FDR/GBR) • Vapor Barriers • Soil Remediation Trackless Fog Seals New Technologies Trackless Tack and Bond Coats Full Depth Reclamation Solvent Free Cold Mix, with Virgin Aggregate or RAP Warm Mix Asphalt Global Warming and GHG Emissions EPA proposes mandatory reporting of GHG by large emitters on 3-10-09 GHG emissions per tonne of laid material 200 180 160 Laying 140 Transport 120 Manufacture 100 Aggregates 80 60 Binders GHG emissions (kg/t) emissions GHG 40 20 0 Cold mix asphalt Thermorecycling Bituminous concrete Cement-bound aggregate Emulsion in-situ recycling Road base asphaltWarm concrete mixEmulsion asphalt bound concrete aggregate Untreated granular material High modulus asphalt concrete Continuous reinforced concrete Cement-bound agreggate & "AJ" Concrete bituminous with 10% RAP Soil treated in-situ with lime + cement Aggregate withCement hydraulic concrete road slabsbinders without dowels Road baseRoad asphalt baseRoad asphalt baseconcrete asphalt concrete with concrete 20% with RAP 30% with RAP 50% RAP Aggregate with hydraulic road binders & "AJ" 17% of HMA Why Environmentally-Friendly Emulsions? • IARC • Higher Temperature • Kyoto Treaty Trends • Naphthalene & PAH • Rising Energy Costs Emissions • Odors • Particulate Emissions • Increased Activism • Regulatory & Permitting • No Premature Oxidation Ergon & Western Emulsions CIR Sealing Compacted Grade Sealing Compacted Roadway Gradation of RAP and Compactive Effort – Unbound Pavement Douglas County, NV – Carson Valley Only a very few micro cracks have appeared in over 80 miles of PASS/RAP pavements after 5 winters. Routine preventive maintenance consists of a fog coat of PASS (1:1) at 0.6-0.12 gsy at 3-5 year intervals Luna County New Mexico PASS/RAP with chip seal cap Luna County, New Mexico Table Mixed PASS/RAP RAP Mix • RAP millings from ¾” original mix, screened on 1 1/2” sieve • 2-3% pre-mix water added to mixing table Table Mix • 7% PASS R (1:1), or 3.5% PASS R emulsion concentrate, was added to pre-wet millings in mix table PMRE /RAP Stockpile • Table mix was stockpiled with bucket loader 1- 4 days after mixing Blade Laydown of Stockpiled Mix Wexford Rd Wilhoit • PMRE/RAP mix was hauled by truck (approx. 25 miles) to Wilhoit where it was paver laid on a compacted RAP base (5-6”) • Burmed RAP millings for shoulders had been fogged with PASS 1:1 Wexford Rd. • No problems with paver laying • No sticking in paver or haul trucks Wexford Rd • 2 Steel wheel rollers • 2 passes in vibratory mode, 2 passes static established as optimum rolling pattern. Rubber tire roller can iron out imperfections for several days following laydown. Wexford Rd • 1 Day after placement and compaction • Wexford Rd open to traffic during construction • New mat open to traffic 2-3 hours after rolling Wexford Rd • 30 days after placement, no surface treatment • Yavapai County fog sealed road with PASS QB after 6 weeks; chip seal was applied after 4 months Ponderosa Park Ponderosa Park Paver Lay Ponderosa Park Uncompacted, compacted mat Superstition Rd Superstition Rd Chip sealed 3 mos. After paving Yavapai County • Almost 10,000 tons of screened millings were pugmill mixed with PMRE called PASS R at 3.5% emulsion with moisture content at similar % . The processed material was stockpiled for paver laydown over several weeks. RAP Processing Yavapai County RAP Feed Conveyors from Hoppers PMRE/RAP pugmill to stockpile Twin shaft pugmill Processed Millings 7% PASS PMRE/RAP Laydown YC PMRE/RAP Uncompacted Mat PMRE/RAP Rolling and Compaction Millings for Pavements • The low temperature flexibility of PMRE rejuvenating binders, combined with the polymer network, enable PMRE emulsions to bind RAP millings (grindings) together within a mix and to all compacted surfaces. • Solvent free PMRE eliminates the ‘slickness’ of rejuvenating oils such as ERA’s PMRE/RAP Summary • Mixing: • Laydown – Mix table – Blade – Windrow – Paver – Pugmill – CIR (screed) – CIR – Stockpile up to six weeks Compaction and Maintenance • Steel wheel • Fog sealing – Immediate breakdown – Recommended during and 2nd pass in vibratory first 60 days mode • Chip sealing – May iron out slight – recommended during imperfections during first 6 months if week following pavement has very placement with coarse surface texture or pneumatic roller if raveling occurs Cost Comparisons • Bound RAP can be produced for
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