BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr.

Basil David Daniel

CHAPTER 5

PAVEMENT
REHABILITATION
RECONSTRUCTION & RECYCLING

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Reconstruction is the removal and rebuilding of all (including

subgrade) or part of the road pavement using fresh material and new
construction specifications.

Pavements that have failed severely are usually those where

deterioration has been allowed to occur without maintenance.

0 – 25
PCI =

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

There are two types of reconstruction:

(1) Full-depth reconstruction

Full reconstruction is needed when the subgrade layer as well as the

pavement layers have deteriorated beyond repair. The rebuilding will
include the subgrade.

(2) Partial-depth reconstruction

Partial reconstruction is needed when the road base has been

contaminated and it has lost its inherent stability. The rebuilding
does not include the subgrade.

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Identifying Full Reconstruction

Full reconstruction may be needed for the following combination of failures:

• Pavement surface which suffer from crocodile cracks with rut depths of
more than 25 mm, without shoving.
• Pavement surface which suffers cracking with rut depth of more than 15
mm and deep shoving.

Identifying Partial and Base Reconstruction

Partial reconstruction may be needed for the following failures or

combination of failures:

• Spalling and crocodile cracking with rut depth of less than 15 mm.
• Shoving with rut depth less than 15 mm.
• Crocodile cracking with block size less than 100 mm with shoving.

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Generally there are three types of recycling techniques:

• Hot Plant Mix Recycling

• Hot In-Place Recycling
• Cold In-Place Recycling

The main advantage of recycling is that it gives the opportunity to

use the materials that have been laid down.

Studies have indicated that a saving of nearly 50% of total cost is

possible when compared to structural resurfacing.

Recycling is suitable for countries

experiencing scarcity of road building
materials.

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Hot plant mix recycling is a process in which all or some portion of

the pavement structure is removed, reduced to a desired size, and
mixed hot with additional asphalt cement at a central plant.

The process normally includes the addition of new aggregates and

may include the addition of a recycling agent.

The finished product meets the requirement of the standard material

and mix specifications of a hot mix asphalt, base, and binder or
surface courses.

It can correct mix deficiencies and functional distress and improve

structural strength.

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Material Removal Reducing size of Aggregate Testing

and Stockpile aggregates

Mix Design

Hot Mix Production

at Plant

Process & Quality

Control

Placement

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Merits:

There is significant cost saving through the reuse of the

materials, lower processing cost and energy saving.

Machines that will be able to utilize the process are plenty.

Limitations:

However, if the presence of the following materials are

detected, recycling is unsuitable:
• 10% seal coat, slurry seal or cold patch
• cutback asphalts
• coal tars

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

HIPR is currently defined as recycling works to a depth of about 1 to

2 inches (25.4 mm – 50.8 mm). The process involves heating,
scarifying, reshaping the materials and compacting the surface.

Additional aggregate or an asphalt rejuvenator may be added to the

existing materials.

Recycling of the surface is to improve the top layer where rapid

aging of the asphalt takes place.

Here, the asphalt increases in viscosity, decrease in penetration and

ductility more rapidly than the underlying layers. It will only correct
surface distress.

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Heating and Spraying of Adding of new

Scarifying Rejuvenating agent aggregates
(optional) (optional)

Mixing

Compacting

Application of
Overlay or Seal
Coat

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Merits:

HIPR rectifies surface problems by reusing the material with or

without the addition of new materials and new binders or
recycling agent. Hence, the initial investment for these
materials remains useful. Furthermore, scarce material can be
conserved.

Roads can be opened to light traffic soon after construction and

the original road profile can be maintained.

No hauling and central plant processing costs.

Limitation:

However, this method does not correct structural problems, the

equipment is expensive and requires curing time for strength
gain.

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

CIPR is the process when in-place recycling of more than 2 inches (> 50.8
mm) of the pavement and with no application of heat is done.

There are 3 distinct types of CIPR:

(i) Type I : Rip/Pulverize and Compact

Pulverizing equipment is used to produce reclaimed asphalt pavement
that may be used as a base course material, with the addition of emulsion
of recycling agent.

(ii) Type II : Single Unit Recycler

A single unit mills the pavement, mixes the milled material with the
recycling agent and produces a material suitable for a stabilized base
course or wearing course.

(iii) Type III : Recycling Train

Multiple unit train with milling, crushing, screening and pugmill parts to
rework the material suitable for a base course

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure
Type I CIPR (Rip/Pulverize & Compact)

Rip existing pavement Pulverize ripped material Windrow the material

Apply rejuvenating agent Mix with existing or new base

aggregate material

Spread base to required Compact, seal and cure Apply wearing course
thickness

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Type II CIPR (Single Unit Recyler)

1 2

The unit rips and pulverizes the A grader or paver spreads and levels
pavement material, adds new the material.
aggregates, asphalt binding agent, and
thoroughly mixes all the materials

3 4

A roller compactor is used to compact Surface treatment or overlay

the material.

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Type III CIPR (Recyling Train)

Usually additive tanks are first, followed by the milling machine, crusher,
pugmill mixer, asphalt paver and rollers

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Type III CIPR (Recyling Train)

2 1

The recycling process starts at the milling unit,

which grinds off the existing pavement.

2
From the milling machine the materials move by
conveyor to a screening unit with larger material
crushed and returned to conveyor for screening

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Type III CIPR (Recyling Train)

2 1
3
4

3
Screened materials are transported to the mixing
unit or pugmill. It is weighed, mixed with
measured quantities of aggregate, water and
emulsion.

4
After mixing, the new mix is placed in a windrow.

BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Construction Sequence &

Procedure

Type III CIPR (Recyling Train)

5 A paver then picks the mix up and spreads it.

6
After the emulsion has set, the mix is compacted
with a pneumatic roller to be followed by a steel
wheeled roller.

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BFC 3042 HIGHWAY ENGINEERING Lecturer: Mr. Basil David Daniel

Merits:

• The procedure can be used to any depth of the pavement.

• It can be adopted to overcome both structural and functional problems
as well as rectifying functional problems only.
• The original road profile can be maintained.
• No hauling or central plant processing cost.
• Materials can be conserved.

Limitations:

• However, thin CIPR does not correct structural problems of poorer

quality, unlike in plant mix.
• There is no standard specification.
• It requires curing time for strength gain.

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