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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). 39.2%. 37.3%. 34.4%. 28.6%. 27.3%. 6.9%. RAP Savings ($ millions). 43.6M. 41.7M.

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slide1

Recycled Asphalt Program

&

Environmental Stewardship Program

(Post Consumer Content)

Robert C. Rea

Nebraska Department of Roads

WASHTO – Omaha, Nebraska

April 2014

slide2

Average RAP Contents (Overall)

39.2%

37.3%

34.4%

28.6%

27.3%

6.9%

slide3

RAP Savings ($ millions)

43.6M

41.7M

35.3M

23.3M

19.8M

3.6M

slide4

How did we get to 39.2% average RAP ?

  • Design and Specifications to optimize RAP
  • RAP Incentive for binder savings
slide5

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
slide7

DOT Millings from ‘ON’ project

DOT Millings from ‘OFF’ project

Contractor ‘Owned’ Millings

15% of Binder Savings

For Contractor

35% of Binder Savings

For Contractor

50% of Binder Savings

For Contractor

65/35 Incentive Split

85/15 Incentive Split

50/50 Incentive Split

90% of our projects are this

8% of our projects are this

2% of our projects are this

slide8

Example 40,000 Ton Project

( 5 M ESAL Design – Typical SPR mix )

MILLINGS FROM ON PROJECT

85/15 Incentive Split

  • Mill 2” – Fill 3”
  • Hot Mix = $ 30 per ton
  • Binder PG 64-34 = $650 per liquid ton
  • Design is for 5.4% Binder Content
slide9

Virgin Mix (No RAP)

  • Hot Mix = 1,200,000
  • Virgin Binder = $1,404,000
  • Binder from RAP = $0
  • Total Cost = $2,604,000

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

  • Pre-incentive 2008 (6.9% RAP)
  • Hot Mix = 1,200,000
  • Virgin Binder = $1,307,124
  • Binder from RAP = $96,876
  • Total Cost = $2,507,124

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

  • Current w/Incentive (45% RAP)
  • Hot Mix = 1,200,000
  • Virgin Binder = $772,200
  • Binder from RAP = $631,800
  • Total Cost = $1,972,200

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

slide10

Virgin Mix (No RAP)

Total final Cost Realized by DOT $2,604,000

Pre-incentive 2008 (6.9% RAP)

Savings from optimizing RAP

$440,000 to $550,000

Total final Cost Realized by DOT

$2,507,124

Current w/Incentive (45% RAP)

Total final Cost Realized by DOT

$2,066,970

On one 40,000 ton hot mix project

slide11

REASONS RAP USE MAY BE LIMITED

  • Agency limits use of RAP or says ‘I want the new stuff, not the used stuff ’
  • Stigma of lesser quality, Engineered Design a must
  • Plant Superintendant says ‘The plant won’t run that much’
  • Design must optimize mill and fill strategies or ‘Road Mining’
  • Requires binder grade bumps/dumps when higher amounts are used
  • Restrictive in the specification, i.e. dust/asphalt maximum
  • Limits the RAP #200 amounts and therefor rejects the RAP
  • Voids and VMA and other properties restrict the amount of RAP
slide12

SPR – Mix Design

  • CAA
    • 83 Allows for RAP Variation, typically 90+
  • FAA
    • Allows for RAP Variation, typically 44+
    • FAA Sp. Gravity slightly lowers true FAA
    • Binder Grade and Volumetrics provide added Rutting Resistance
    • Overshoot FAA – Increased Cracking
  • Voids
    • Allow more dust & binder, better field density
  • Min. Binder
    • Used as Factor for VMA
  • #200
    • Typically around 4-6%, D/B around 1.0-1.2
slide13

APA Testing of SPR Mixes

                  • 8000 Cycles
                  • 100 PSI Pressure Load
                  • 64 degrees C
                  • Max of 12 mm Rutting
slide16

Approach to a 50% RAP Project

  • Pick a 20,000 to 40,000 Ton Project
  • Use a ‘tried and true’ mix that you know works and has been a workhorse for your state
  • 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
  • Use softest base oil you can get either -34 or -28 if you can
  • Specify a minimum Binder Content if you don’t pay ac separately
  • Specify minimum 40 % RAP
  • Have the RAP come from the road…….fresh processed millings
  • Be flexible with the #200 material
  • Lower voids and no VMA spec, effects of burnoff oven – another all day presentation to discuss this  control by voids and binder content
  • Place it in all lifts, especially surface, we want to monitor this material
slide17

Robert C. Rea

402 479 3839 office

402 326 9934 mobile

robert.rea@nebraska.gov

slide18

Type ‘R’ Asphalt

$ 12 - $ 20

$ 44

$ 36

$ 24

slide19

RAP Savings Potential

  • $ 12 to $20 per Ton
  • x ?? Million Tons
  • $ 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 ……..