AEMA-ARRA-ISSA-PPRA Fall Meeting Recycling, Ayrton Senna Highway Brasil, & USA
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1 AEMA-ARRA-ISSA-PPRA Fall Meeting 2015 Recycling, Ayrton Senna Highway Brasil, & USA
2 CCPR (Cold Central Plant Recycling) 2012: The Ayrton Senna Highway in Brazil was rehabilitated under challenging conditions by using the Wirtgen Cold Recycling technology in plant. Sao Paulo: a city with more than 20 million citizen. 2
3 CCPR (Cold Central Plant Recycling) AYRTON SENNA HIGHWAY KMA 220 Ayrton Senna Highway in Sao Paulo / Brazil 3
4 LOCAL BAR
5 CCPR (Cold Central Plant Recycling) Ayrton Senna Highway / Brazil: 8-lane divided facility Brazil s most heavily trafficked highway 5
6 CCPR (Cold Central Plant Recycling) Ayrton Senna Highway / Brazil: Pavement condition after standard rehabilitation procedure Mill and Fill 6
7 CCPR (Cold Central Plant Recycling) ADT > 250,000vpd (15% Trucks) (OUTER RECYCLED LANE > 15,000 trucks / day in each direction) Milling & Replacing 4 ins HMA lasts < 3 months Lane closure only between 21:00 05:00 Ayrton Senna Highway / Brazil: Traditional Rehabilitation / Traffic Loading
8 CCPR (Cold Central Plant Recycling) HMA ± 4 ins CEMENTED CRUSHED STONE (G2) ± 10 ins CRUSHED STONE (G2) ± 8 ins SELECTED COARSE GRAVEL (G6) ± 8 ins EMBANKMENT (RIVER LEEVEE) (G7) Semi-infinite Results of pavement investigations 8
9 Rehabilitation options ins HMA? BSM-b 2 ins 4 ins HMA BSM-a 8 ins Nominal
10 Step 1 - mill off asphalt layers 4 ins
11 Construction sequence Ayrton Senna Highway / Brazil: Milling of the asphalt layer (4 ins) at night 11
12 Construction sequence Ayrton Senna Highway / Brazil: Crushing screened RAP 1 ins minus 12
13 Construction sequence KMA 220 Sized RAP loaded to CCPR (Cold Central Plant Recycler) BSM (Bitumen Stabilised Material) Mix Design: 2.5% Foamed Asphalt + 1.5% Cement 13
14 Step 2 - mill and remove CTB layer 10 ins
15 Construction sequence Ayrton Senna Highway / Brazil: Mill & Remove 10 ins CTB layer in one pass 15
16 Construction sequence Ayrton Senna Highway / Brazil: Paving of the first BSM layer with a thickness of 8 ins 16
17 Construction sequence Ayrton Senna Highway / Brazil: The BSM layer is levelled and pre-compacted with an asphalt paver 17
18 Construction sequence Ayrton Senna Highway / Brazil: Full depth (8ins) compaction of the BSM material with a padfoot roller 18
19 Construction sequence Ayrton Senna Highway / Brazil: Final compaction with a tandem steel drum roller 19
20 Construction sequence Ayrton Senna Highway / Brazil: Paving the second BSM layer 4 ins 20
21 Construction sequence Ayrton Senna Highway / Brazil: 4 ins BSM layer after final compaction. Ready for the asphalt overlay. 21
22 Finish Pave 2 ins HMA 2 ins HMA (gap-graded / fine mix) Rockfill where heaving was detected.
23 Construction sequence Ayrton Senna Highway / Brazil: A tack coat is applied between the BSM and the asphalt layer 23
24 Construction sequence Ayrton Senna Highway / Brazil: Pave 2 ins HMA 24
25 Construction sequence Ayrton Senna Highway / Brazil: 25
26 Monitoring Ayrton Senna Highway / Brazil: two months under heavy traffic 26
27 Monitoring Average: 0.45 mm 0.34 mm Before rehab After rehab Deflection decrease from average 0.45 mm to 0.34 mm
28 Monitoring June months after construction Est traffic > 9.0 million trucks
29 Decision to Proceed Confidence in Concept
30 Interstate I-81 30,000 VPD 8,000 trucks Continual maintenance problem due to poor base materials I-81 Virginia DoT Recycling Alternative FIRST MULTI RECYCLING/STABILISATION PROCESS IN N.AMERICA
31 10 ins Asphalt layers Poor Clay Support Native Mill & Fill Maintenance, limited success Cracks reflecting back after 6 months
32 ALTERNATE FOAMED ASPHALT STABILISED BASE PROPOSAL Re-Construction Design Material Structural Thickness S.N Coefficient SMA IM-19.0D BM DGAB 21B Proposed Recycling Alternative Material Structural Thickness S.N Coefficient SMA IM-19.0D FBSB LSSB OGB Total Total FBSB Foamed Bitumen Stabilised Base LSSB Lime Stabilised Base
33 I81 Truck Lane
34 Milling 10ins depth Lime Stabilisation 12ins depth 100% Recycle Millings Pave Recycled Millings as Base
35 I81 Fast Lane
36 Phase 2: LH Fast Lane Cold In Place Recycle Depth 5 Width % Foamed Bitumen Pave with attached AB375T screed
37 Concept Summary Right Lane Traffic 7.8 million trucks 20.2 million cars Left Lane Traffic (overtaking lane) 1.6 million trucks 3.8 million cars August 2015 (4 years)
38 Economics of Recycling Questions Can we recycle and save $ Do we lose performance YES SAVE $$ NO LOSS OF PERFORMANCE WELL ENGINEERED PRODUCT
39
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