Recycling and Reclamation of Airfield Pavements 35 th Airports Conference FAA Eastern Region, Hershey, PA April 4, 2012 Campbell & Paris Engineers, 35 th Airports Conference

Items for Discussion Brief Introduction (Mark McGuire, P.E. C&PE) Potential Applications / Recent Project Examples Construction Specifications / FAA MOS process Mix Designs / Construction Schedules Equipment / Advancements / Videos - References Economic Impacts / Environmental Benefits / ACRP 42 Questions Campbell & Paris Engineers, 35 th Airports Conference

Brief Introduction Campbell & Paris Engineers, 35 th Airports Conference

Brief Introduction Recycling existing Bituminous Concrete, Portland Cement Concrete, and Crushed Aggregate Materials Mobile Jaw Crushers / Mobile Impact Crushers Mobile Screens / In-Place Recyclers / Mobile Secondary Crushers Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site RAP – as a base course / aggregate substitute (D-754 ditches) RAP material condition assessment (binder) – may be more valuable at mixing plant ($10 per ton) Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site RAP – as a base course / aggregate substitute (P-610 ditches) RAP material condition assessment (binder) – may be more valuable at mixing plant ($10 per ton) Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site (RAP Stockpile) RAP – stock pile location Calculating waste – depends who you ask! Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site – Mix In Place Operations Cement Treated Aggregate / Base Course (Manassas Regional Airport) Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site – Mix In Place Operations Cement Treated Aggregate / Base Course Mix In Place Cement Added Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site – Mix In Place Operations Cement Treated Aggregate / Base Course (Burlington Int. Airport) Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site – Mix In Place Operations Cement Treated Aggregate / Base Course (Burlington Int. Airport) Campbell & Paris Engineers, 35 th Airports Conference

Potential Applications / Recent Project Examples Re-Use of Materials on Site – Mix In Place Operations Cement Treated Aggregate / Base Course (Burlington Int. Airport) Campbell & Paris Engineers, 35 th Airports Conference

Project Specifications / FAA MOS Process RAP Specification FDR Specification DOT/FAA Order F Eastern Region 5300 Form Campbell & Paris Engineers, 35 th Airports Conference

Mix Designs / Construction Schedules Access to Site to Obtain Material Specification requirements for mix designs: open to interpretation or strict requirements? Does the schedule account for the laboratory time to process the mix designs? Initial paperwork Milestone: QC Plan, Construction Schedule, Submittals, & Mix Designs Campbell & Paris Engineers, 35 th Airports Conference

Equipment / Advancements / Videos (source: Wirtgen America) Campbell & Paris Engineers, 35 th Airports Conference

Equipment / Advancements / Videos (source: Wirtgen America) Campbell & Paris Engineers, 35 th Airports Conference

Ripped Asphalt Large slab feed. Often contaminated with dirt. Milled Asphalt When stockpiled it often clumps together. Equipment / Advancements / Videos (source: Wirtgen America) Campbell & Paris Engineers, 35 th Airports Conference

Road aggregate  Better compaction  Improved mechanical properties  Better layer’s stability  Better wear resistance Concrete aggregate  Better flow ability  Better compaction  Better quality  Less cement and water Flaky aggregates Elongated aggregates Cubical aggregates Benefits of shape Equipment / Advancements / Videos (source: Wirtgen America) Campbell & Paris Engineers, 35 th Airports Conference

Equipment / Advancements / Videos (source: Wirtgen America) Jaw Crusher 7:1 reduction ratio = 25” feed reduced to 3.5” final product size Horizontal Shaft Impact Crusher 15:1 reduction ratio = 25” feed reduced to 1 ½” final product size Vertical Shaft Impact Crusher 4:1 reduction ratio = 3” feed reduced to ¾” final product size Cone Crusher 5:1 reduction ratio = 4” feed reduced to 13/16” final product size Campbell & Paris Engineers, 35 th Airports Conference

Equipment / Advancements / Videos (source: Wirtgen America) Primary, Secondary and Tertiary crushing. crushing ratio max. 15:1 advantages high production cubical shaped end product large crushing ratio flexabile disadvantages high wear costs high content of fines Horizontal shaft impact crusher Campbell & Paris Engineers, 35 th Airports Conference

Economic Impacts / Environmental Benefits SOCIAL, ECONOMIC, AND SUSTAINABLE DESIGN CONSIDERATIONS Typical Recycling or Mix in Place operations have the following benefits:  Eliminate operations associated with full depth demolition and removal of pavement section  Eliminate off-site hauling operations  Reduce risk and potential delay associated with subgrade exposure  Alleviate construction efforts required for achieving compaction of problematic subgrade  Eliminate necessity for quarry to produce virgin aggregate material  Eliminate batch plant operations for new material (if applicable)  Eliminate hauling operations associated with importing new material  Simplified construction methods requiring less equipment and man-power to complete construction Campbell & Paris Engineers, 35 th Airports Conference

Economic Impacts / Environmental Benefits Campbell & Paris Engineers, 35 th Airports Conference

Economic Impacts / Environmental Benefits Campbell & Paris Engineers, 35 th Airports Conference

Economic Impacts / Environmental Benefits Campbell & Paris Engineers, 35 th Airports Conference

Economic Impacts / Environmental Benefits Campbell & Paris Engineers, 35 th Airports Conference

Questions? Campbell & Paris Engineers, 35 th Airports Conference