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Recycled Asphalt Program & Environmental Stewardship Program ( Post Consumer Content)

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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Recycled Asphalt Program & Environmental Stewardship Program ( Post Consumer Content)

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

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

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

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

  5. 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

  6. 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

  7. 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

  8. 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

  9. 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

  10. 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

  11. 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

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

  13. APA Testing of SPR Mixes

  14. 44.7%

  15. 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

  16. Robert C. Rea 402 479 3839 office 402 326 9934 mobile robert.rea@nebraska.gov

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

  18. 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 ……..

  19. Post Consumer Content

  20. On Project Plan Sets in 2014

  21. Thank You!

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