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WHAT IS RAP?
Reclaimed Asphalt Pavement (RAP)
Existing pavements removed and reused
Produced by
Milling -- Upper pavement layers removed and
replaced with new pavement
Full-Depth Removal -- Pavement completely
removed and reprocessed
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TYPICAL ASPHALT MIX
95% aggregate (approx. 30% of cost)
5% asphalt binder (approx. 70% of cost)
Reusing:
Reduces need to quarry more aggregate
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HISTORY OF RAP USE
First
used in 1915 (!)
Major emphasis started in 1970’s
Oil embargo and increased oil prices
Improved milling machines
Counterflow drum plants
Became routine in many states
Necessary to be competitive (lower bid prices)
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USES OF RAP
RAP can be used for
Base
Fill
Shoulders
Alleys
But,
the highest and best use of RAP is back into
new asphalt mixtures.
Most beneficial
Most cost effective
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PERCENT RECYCLED - 1993
100
80
80
64 60
56
60
37
40 31
20
0
Asphalt Steel Cans News Plastic Glass
ALONG CAME SUPERPAVE
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CURRENT USAGE
Most
states are back to or above pre-
Superpave usage levels.
Nationwide only a few states do not allow RAP.
AASHTO specs allow easy use of up to 25%.
Contractors
in most states reported using RAP
whenever they can.
Lower bid prices.
Surface mixes
Tendency to allow lower amounts
Friction and cracking are potential concerns
Increased resistance to rutting
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AGENCY CONCERNS
(LIMITATIONS)
Durability of Mixes
Stiffness of Binder
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WHAT CONTRACTORS CAN DO TO OPTIMIZE RAP
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OBTAINING & PROCESSING
RAP
14
COMPOSITE SOURCES (GOK)
•Usually chunks and slabs from full depth pavement removal
•Plant cleanout
•Reject material or excess returned from jobs
•Excavation
•Other sources
15
In GOK Pile
After
Processing 16
Composite RAP is reprocessed (i.e.
crushed, screened, stockpiled and
QC tested)
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The reprocessed
products are very
consistent
components
18
RAP FROM MILLING
Removes
old/distressed
pavement
Improves smoothness
Eliminates costly
shoulder work
Maintains drainage
features, curbs,
clearance
Valuable rehab option
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•Millings generally require no additional processing.
• After testing they may be incorporated into HMA
mixtures
•Millings are stockpiled separately by job and size
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FRACTIONATING TO -1/4”
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COST/BENEFITS OF RAP
PG Binder ≈ $450.00
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COST SAVINGS USING RAP
FOR A TYPICAL 19.0MM INTERMEDIATE
Avoid contamination
25
Contamination-
Not Good 26
RAP IS JUST ANOTHER COMPONENT OF HMA
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SAME STANDARDS
AS VIRGIN MIXES
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CURRENT INDOT SPECS
Up to 25.0% RAP by weight of total mixture
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POTENTIAL CHANGE IN INDOT SPECS
32
HMA RECYCLING ETG
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CONCLUSIONS
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THANKS TO:
LTAP and APAI
NAPA, AASHTO, FHWA, APAI sponsored
workshop, Materials and Energy
Conservation in Hot Mix Asphalt
Available on NAPA website
Gerry Huber
And to you!
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