MILLING PROCESS

Subject: Pavement Evaluation Rehabilitation and Maintenance (CE 623)

Presented byGROUP-I
Om Prakash (144104033)
Bibhuti B. Bhardwaj (144104041)
Ridip Dutta (144104043)
Subhadipto Poddar (144104044)
Department of Civil Engineering, Indian Institute of Technology Guwahati

METHODS FOR REMOVAL OF EXISTING PAVEMENT

MILLING

Ripping/Crushing

Definition: Milling has been defined as the method of automatically controlled

removal of pavement to a desired depth with specially designed equipment, and
restoration of the surface to a specified grade and slope, free of bumps, ruts, and
other imperfections.

It is the most widely used existing pavement removal method today

It has revolutionized the recycling of asphalt pavements

The ARRA has defined five classes of milling:

Class I: Milling the existing surface to the extent necessary

Class I and II cold

to remove surface irregularities,

milling are to be

Class II: Milling the existing surface to a uniform depth as

shown in the plans,

measured by the square

meter for specified
thickness or by the

Class III: Milling the existing surface to a uniform depth and

square meter-mm for the

cross slope as shown in the plans and/or special provisions,

actual square meters

Class IV: Milling the entire depth of existing surfacing from

the underlying base or subgrade,

milled times the mm of

depth milled. All other
classes of cold milling

Class V: Milling to a variable depth of the existing surfacing

should be measured by

as shown in the plans and/or special provisions.

ton

TYPES OF MILLING MACHINE

ON THE BASIS OF CUTTER DRUM PATTERN
Each cutter pattern is determined by the number of carbide teeth
installed on the mandrel.

More teeth produce fine patterns such as Profiling and Micro-Milling,

but production rates remain low.
Excavating and Traditional patterns allow for higher production rates,
but produce a coarser surface.

Type

Excavating
Traditional

Used in

Advantages

Projects that require

Advantageous in

substantial

the reconstruction of

roadway removal

rural roads

Most applications

Versatility
Tighter tooth spacing

Profiling

Micro-milling

To achieve a deeper cut

allows contractors

than possible

to maintain more

with micro-milling

consistent leveling

Cuts not deeper than

Leaves a finely

one inch to correct

milled surface that can

irregularities without

be opened up

applying a new layer

to traffic immediately

ADVANTAGES OF MILLING
With overlays, changes in
clearances and elevations
of the road are required.

Disadvantages of overlay
Milling and inlay techniques eliminate the need to
raise shoulders and guardrails. When the road surface
is milled prior to paving, changes in bridge
clearances are also eliminated
Multiple overlay leads to drainage problem

By milling the
old surface
and replacing it
with new
pavement,
weight limits
on bridges
remain constant

As new pavement surfaces are added to a bridge, additional weight is placed on

the structure, reducing the net effective weight that can be transported across it.

Often, older streets have as many as

four overlays, resulting in poor drainage
By milling the older
pavements, drainage can be
reestablished
to improve water run-off making the
road safer for driving

Milling Ensures Proper Water Drainage

In most cities, utilities are underneath
the pavement. Overlays require raising
utility manholes. By milling and
inlaying the new pavement, the
elevations of existing utilities remain

Milling Leaves Utilities Unchanged

Unlike the dense graded mixes of the

past, todays new mixes with interlocking
stones support heavy weights
without rutting. But if these new mixes
are placed over a rutted road, cracking
and rutting will reoccur.
Rutting Often Occurs in Older
Overlay Pavements

The milling technique itself also makes inlay

pavements superior to Overlay and prevent ReRutting

Inlays offer the additional advantage of obtaining a more

uniform joint density

With milling, the new pavement is confined between the two edges of the milled surface.
The density of the pavement is therefore uniform at the both the centerline and edges.
With overlays, it is difficult to maintain uniform densities at the centerline joints and
edges of the pavement since the mix is not confined

 The milling
technique itself also
makes inlay pavements
superior to overlays.
Milling machines
create a grooved
surface. This results in
an excellent
interlocking surface to
interface with new
pavement materials.

Many states have found that the bonding between the new and old pavements is of
superior quality due to the grooved surface created by milling machines. Often, the tack
coat can be eliminated when placing new pavement on a properly milled and grooved
surface.

DISADVANTAGES

Possible foreign object damage like dirt, clay etc create

problem in milling

Milling machines can be used only on

structurally sound pavement

Reduces the depth

of embedment of
reinforcing fabrics
and grid and/or
damages them

Ravelling may become a

problem with asphalt concrete
pavements after the milling
process, so should be inlaid
ASAP

Can not be performed directly when there is

accumulation of snow or ice on the pavement
surface

High fuel consumption in the order of 60-130 Littre/hr leads to

mass emission of pollutants into the atmosphere aggravating
the problems of air pollution.

POPULAR MILLING MACHINE COMMPANIES

COMMPANY

PRODUCTION

DISTRIBUTION

GERMANY

WORLDWIDE

CHINA

WORLDWIDE

GERMANY

WORLDWIDE

UNITED STATES OF
AMERICA

WORLDWIDE

SWEDEN

WORLDWIDE

SPECIFICATIONS OF MILLING MACHINES

MACHINE

MILLING

MILLING MILLING

DIESEL

COST

WIDTH

DEPTH

SPEED

CONSUMPTION

(USED)

(mm)

(mm)

(km/hr)

(Liters/hr)

(US $)

BOMAG BM1000/35

1000

0-330

0-1.92

60

130,000

BOMAG BM1200/35

1200

0-330

0-1.92

72

150,000

BOMAG BM1300/35

1300

0-330

0-1.92

78

180,000

WIRTGEN W35

350

0-110

0-1.5

80,000

WIRTGEN W210

2200

0-330

0-5.1

131

290,000

CAT PM200

2010

0-320

0-2.28

120

CAT PM201

2010

0-305

0-2.4

120

 Maximum width of milling i.e. 2200mm is provided by Writgen

W210.
Minimum width of milling i.e. 350mm is provided by Writgen
W35.
Maximum depth of milling is 330mm provided by models from
both BOMAG and WRITGEN.

These milling machines are available for hire from companies like
AP PAVERS and THE MILLER GROUP at rates of 1000-3000 US $
per day

MILLING OPERATIONS IN INDIA

GUJARAT

Thickness of the pavement became very high as compared to the adjoining

portions in old urban areas due to repeated maintenance and resurfacing
works on the existing surface leading to the need foe milling.

Even after milling their cost of construction became very high because
milling was done without using RAP materials.

TAMIL NADU

Milling operations was used by L&T Chennai for expansion of NH 5 from

four lane to six lanes. They also used cold recycling method for cost effective
and eco-friendly purposes.

WR 2400 cold Recycler and HAMM 3520 and 311 compactor were used in

this project.

Sources:
www.machinerytraders.com
www.bomag.com
www.writgenamerica.com
www.miltoncat.com
Pavement Milling Operations,
Air Force Handbook 10-222, (Volume 24). P- 9