AEMA-ARRA-ISSA-PPRA Fall Meeting 2015 Recycling, Ayrton Senna Highway Brasil, & USA
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
CCPR (Cold Central Plant Recycling) AYRTON SENNA HIGHWAY KMA 220 Ayrton Senna Highway in Sao Paulo / Brazil 3
LOCAL BAR
CCPR (Cold Central Plant Recycling) Ayrton Senna Highway / Brazil: 8-lane divided facility Brazil s most heavily trafficked highway 5
CCPR (Cold Central Plant Recycling) Ayrton Senna Highway / Brazil: Pavement condition after standard rehabilitation procedure Mill and Fill 6
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
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
Rehabilitation options 13.75 ins HMA? BSM-b 2 ins 4 ins HMA BSM-a 8 ins Nominal
Step 1 - mill off asphalt layers 4 ins
Construction sequence Ayrton Senna Highway / Brazil: Milling of the asphalt layer (4 ins) at night 11
Construction sequence Ayrton Senna Highway / Brazil: Crushing screened RAP 1 ins minus 12
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
Step 2 - mill and remove CTB layer 10 ins
Construction sequence Ayrton Senna Highway / Brazil: Mill & Remove 10 ins CTB layer in one pass 15
Construction sequence Ayrton Senna Highway / Brazil: Paving of the first BSM layer with a thickness of 8 ins 16
Construction sequence Ayrton Senna Highway / Brazil: The BSM layer is levelled and pre-compacted with an asphalt paver 17
Construction sequence Ayrton Senna Highway / Brazil: Full depth (8ins) compaction of the BSM material with a padfoot roller 18
Construction sequence Ayrton Senna Highway / Brazil: Final compaction with a tandem steel drum roller 19
Construction sequence Ayrton Senna Highway / Brazil: Paving the second BSM layer 4 ins 20
Construction sequence Ayrton Senna Highway / Brazil: 4 ins BSM layer after final compaction. Ready for the asphalt overlay. 21
Finish Pave 2 ins HMA 2 ins HMA (gap-graded / fine mix) Rockfill where heaving was detected.
Construction sequence Ayrton Senna Highway / Brazil: A tack coat is applied between the BSM and the asphalt layer 23
Construction sequence Ayrton Senna Highway / Brazil: Pave 2 ins HMA 24
Construction sequence Ayrton Senna Highway / Brazil: 25
Monitoring Ayrton Senna Highway / Brazil: two months under heavy traffic 26
Monitoring Average: 0.45 mm 0.34 mm Before rehab After rehab Deflection decrease from average 0.45 mm to 0.34 mm
Monitoring June 2015 30 months after construction Est traffic > 9.0 million trucks
Decision to Proceed Confidence in Concept
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
10 ins Asphalt layers Poor Clay Support Native Mill & Fill Maintenance, limited success Cracks reflecting back after 6 months
ALTERNATE FOAMED ASPHALT STABILISED BASE PROPOSAL Re-Construction Design Material Structural Thickness S.N Coefficient SMA 0.44 2 0.88 IM-19.0D 0.44 2 0.88 BM-25.0 0.40 10 4.00 DGAB 21B 0.12 6 0.72 Proposed Recycling Alternative Material Structural Thickness S.N Coefficient SMA 0.44 2 0.88 IM-19.0D 0.44 2 0.88 FBSB 0.30 12 3.60 LSSB 0.15 12 1.80 OGB 0.05 12 0.60 Total 32 7.08 Total 28 7.16 FBSB Foamed Bitumen Stabilised Base LSSB Lime Stabilised Base
I81 Truck Lane
Milling 10ins depth Lime Stabilisation 12ins depth 100% Recycle Millings Pave Recycled Millings as Base
I81 Fast Lane
Phase 2: LH Fast Lane Cold In Place Recycle Depth 5 Width 12 6 2.2% Foamed Bitumen Pave with attached AB375T screed
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)
Economics of Recycling Questions Can we recycle and save $ Do we lose performance YES SAVE $$ NO LOSS OF PERFORMANCE WELL ENGINEERED PRODUCT