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ASPHALT CEMENT CONCRETEPAVEMENT RECYCLING
Cass and Montgomery Counties
Final ReportIowa DOT Project HR-1018
Federal Highway AdministrationDemonstration Project No. 39Contract No. DOT-FH-15-336
October 1986
Highway Division
-----~tA Iowa Department-----~., of Transportation
DISCLAIMER
The contents of this report reflectthe views of the authors and do notnecessarily reflect the official viewsor policy of the Iowa Department ofTransportation. This report does notconstitute a standard, specification,or regulation.
Final Reportfor
Iowa DOT Project HR-1018
Federal Highway AdministrationDemonstration Project No. 39Contract No. DOT-FH-15-336
ASPHALT CEMENT CONCRETEPAVEMENT RECYCLING
Cass and Montgomery Counties
ByDonald Jordison, P.E.
Bituminous Field EngineerOffice of Construction
Iowa Department of Transportationand
Richard D. SmithResearch Technician
Office of MaterialsIowa Department of Transportation
Phone: 515-239-1003October 1986
TABLE OF CONTENTS
Page
Abstract .•••. 1
Introduction. 2
PurposeProject
and Scope .Location and History.
34
Preliminary Investigation. 6
Traffic Volume ..Sufficiency Rating ........•.•••....Present Serviceability Index Value.Friction Numbers ..•Cracking .......•...Reclaimed Material.
667778
Mix Design •• 10
Bid Letting • .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 11
construction . .. .. 12
Base Preparation ..Plant Operation ...Pollution Control.Placement ......••.
12121316
Cost Compar i son .......... .............................................................................. 16
Energy Conservation. .. .. 18
Conservation of Natural Resources •.•.............•.•....••• 18
Performance ............................................................ 18
Environmental Considerations. ............................................................ 21
Summary and Conclusions. ...................................................................... 21
Acknowledgement . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 23
References •..• 24
&4109 ..
Bids ..
4126,& Bridge
2528
3033
364951
for
Engineering Fabric.Energy Consumption.
ofof
Appendix FAppendix G
Appendix DAppendix E
Appendix AAppendix BAppendix C
ABSTRACT
This demonstration project consisted of three adjacent highway resurfac
ing projects using asphalt cement concrete removed from an Interstate
highway which had become severely rutted.
The salvaged asphaltic concrete was later crushed and hauled to a plant
site where it was combined with virgin materials to resurface the three
projects. Only two of the projects were used for performance evaluation
as the third project was in an interchange area including ramps and was
otherwise too short.
It was concluded that recycling was cost effective and a high quality
surface can be constructed using recycled asphalt cement concrete.
PAGE 2
Recycling Asphalt PavementsUS 34 & US 71 - Cass and Montgomery Counties
FHWA Demonstration Project No. 39
INTRODUCTION
As the result of the increase in costs of paving materials, energy short-
age, and our dwindling aggregate supplies, the concept of pavement recy-
cling is being considered by the Highway community for the rehabilitation
or reconstruction of bituminous pavements. In the future, as petroleum
products become scarce and higher in price, the ability to build new as-
phalt roads will be reduced. A shortage of quality aggregates for road
construction in selected areas has become a problem in some parts of the
country. Even in Iowa we must at times haul aggregates 30 to 50 miles,
which at todays fuel prices can be a very costly item. Recycling has a
great potential, not only for preserving valuable resources, but also for
controlling escalating costs.
There are three basic types of asphalt pavement recycling; hot mix recy-
cling, cold mix recycling, and surface recycling. Hot mix recycling, the
subject of this report, is a process where the major portion of an exist-
ing pavement structure, including in some cases the underlying treated
base material, is removed and sized, then mixed hot with added asphalt
cement and aggregate in a central plant. The finished product is termed
recycled hot mix and has been used in Iowa for base, binder, and surface
courses.
Iowa was involved in some of the first successful hot mix recycling
projects in the country with work in Kossuth County, Iowa. In 1976
PAGE 3
Kossuth County constructed the largest single recycling project in the
United States using 80,000 tons of asphalt materials. To date, Kossuth
County has recycled over 300,000 tons of asphaltic concrete material.
The Kossuth County projects were designed to rip up the old asphaltic
concrete pavement, haul it to the plant site for crushing and then lower
ing and widening the road bed prior to reconstruction of the pavement.
Material was crushed to a maximum size of 2 inches. The new mix con
tained 50% salvaged and 50% new aggregate in 1976 and 1977 and then a
40-60 combination in 1978, and approximately 4% A.C. was added to the
total mix. The mix was produced in a drum dryer operation, referred to
as a drum within a drum. This material was hauled to the project and
placed and compacted in a 4 and 2 inch lift in the conventional manner.
The Iowa Dept. of Transportation completed its first major hot mix recy
cling project in 1980. This project was on Iowa 44 in Guthrie County
from Panora east, 15 miles. This 60,000 ton project used approximately
25,000 tons of salvaged material from Interstate I-80 in Adair County.
These initial efforts have prompted the State to continue with hot mix
recycling and in 1981 approximately 30 miles of recycling work in Cass
and Montgomery Counties were let and completed and are the subject of
this report.
Purpose and Scope:
The fundamental objective of this study is to evaluate the hot mix recy
cling process by collecting information pertaining to the following:
PAGE 4
1. Pavement history and design criteria
2. Construction criteria
3. Recycling equipment
4. Mixture properties
5. Cost of alternative methods
6. Energy consumption
7. Environmental considerations
8. Post construction performance
Project Location and History:
This work consists of three projects in Cass and Montgomery Counties.
Project No. FR-71-3(26)--2G-15 is on Iowa US 71 in Cass County from the
Montgomery County line, north approximately 16 miles to just south of the
City of Atlantic, project FR-71-2(17)--2G-69 in Montgomery County from
the junction of US 34 northerly 12.5 miles to the Cass County line, and
project FR-34-2(22)--2G-69 which is an interchange area.
A review of the old records and history of US 71 showed that the present
pavement was constructed in 1971. It consisted of 6 inches of soil lime
subbase and 9* inches of asphaltic concrete. The original pavement de
termination called for a future 3/4" surface course, but that lift had
not been constructed. The pavement contained numerous transverse cracks
which had dipped, areas of alligator cracking, and minor surface dis
tortion.
The US 34 eastbound lane was a portland cement concrete pavement placed
in 1965 and the westbound lane along with the interchange loops and ramps
PAGE 5
consisted of the 6 inch soil lime subbase with 9~ inches of asphaltic
concrete placed in 1971. The original full depth asphalt section had not
received an overlay since construction, although the original design con
cept called for 3/4" in the future.
Cracks developed every 40 to 60 ft and deteriorated and dipped causing
substantial loss of ride quality of the pavement. Investigation revealed
significant asphalt stripping from the aggregate and debonding of lift
courses at the cracks. For these reasons the project was implemented.
Through the years the Montgomery County section which was in another
maintenance area had received some sealing of cracks using a cut-back ma
terial. The Cass County project had not been crack sealed. Therefore,
the cracks were more deteriorated and depressed (dipped). On both US 71
projects extensive crack sealing was done in the Spring of 1980. This
work involved pumping an ag-lime emulsion slurry into the wider cracks.
These cracks were then leveled with the same ag-lime slurry. In the win
ter of 1980 the depression over each crack was leveled, using a coarser
limestone emulsion slurry in two applications. At the time of con
struction the cracks were nearly 100% filled and for the most part level
with the adjacent section. The pavement had areas of alligator or map
cracking in the outside 6 ft. These areas had structural problems and
required special treatment with reinforcing fabric.
PAGE 6
PRELIMINARY INVESTIGATION
Traffic Volume:
The Montgomery section had an average daily traffic in 1978 of 1220 vehi
cles per day and a projected 1998 ADT of 1690. The Cass County section
had 1978 ADT of 1684 vehicles per day with the 1998 ADT projection of
2331 vehicles per day. Trucks were 12% and 17% respectively.
Sufficiency Rating:
The Iowa Department of Transportation developed a sufficiency rating sys
tem based on "the tolerable standard approach". A tolerable standard is
defined as the minimum prudent condition, geometric or structural, which
can exist without being in need of upgrading.
There are three major categories which are broken down into specific rat
ing items. The three major categories and maximum points are Structural
Adequacy, 25 points; Safety, 40 points; Service, 35 points, giving a Max
imum SUfficiency Rating of 100 points.
All rating items used are assigned approximately 1/2 the maximum points
whenever a rating item equals the tolerable standard. Each rating item
is assigned a maximum number of points, thus, using 100 points as a total
for all rating items, a road section having a total rating below 50
points is considered to be in need of upgrading to eliminate the intoler
able conditions (1).
PAGE 7
The sufficiency ratings in 1980 for US 71 in Montgomery County between US
34 and the town of Grant was 89 and from Grant to the Cass County line
was 92. The ratings in Cass County were 78 from Grant to the south junc
tion of IA 92 and 82 from there to the north end of the project.
Present Serviceability Index Values:
The preliminary present serviceability index values were determined by
using the IJK roadmeter. Results of these tests indicated ratings of
3.00 and 2.73 for two sections in Montgomery County and ratings of 3.08
and 2.80 on two sections in Cass County.
Friction Numbers:
US 71 was divided into four sections for test purposes. Preliminary
friction tests were made at 40 mph in accordance with ASTM E-274. Tests
were run at ~ mile intervals in both lanes in the inside wheel path. Av
erage friction numbers at 40 mph with an ASTM E-501 ribbed tire ranged
from 42 on one section in Montgomery County to 38 on one section in Cass
County.
Cracking:
Crack surveys were made in December 1979 and February 1980. The cracks
were classified as to Class 1, 2, 3, and 4 depending on depth of de
pression across the crack and method recommended for repair (Appendix A).
PAGE 8
Table I shows the number of cracks by class from the two surveys.
TABLE ICRACK SURVEY
Class
1234
Map Cracking
Dec. 79
1896742142
303549 ft. 2
Feb. 80
2182643486198
8248 ft. 2
There was some crack maintenance performed during the winter, causing
some cracks to change in classification.
Reclaimed Material:
Approximately 40,000 tons of asphaltic concrete were removed from 1-80 in
Cass County between US 71 and the Adair County Interchange during the
1977 construction season. Some of the material had been heater planed
and some had been resurfaced with a thin layer of hot sand surface
course. No attempt was made to separate the salvaged material during the
removal and stockpiling operations.
The salvaged It" thick binder course was produced and placed in 1973 and
1974. It was Type "A" 3/4" asphaltic concrete composed of 65% crushed
limestone produced from the Argentine Geologic Formation; 35% locally
produced sand and 5;% 85-100 penetration A.C. The salvaged H" thick
surface course was also produced and placed in 1973 and 1974. It was
Type "A" t" asphaltic concrete composed of 65% crushed gravel produced
from a glacial deposit near Auburn, 35% locally produced sand, and 5.25%
85-100 penetration A.C.
PAGE 9
A combination of material characteristics, traffic volume and environ
mental conditions during the summer of 1974 resulted in severe ruts and
corrugations. Following removal of this mix, tests were run on the mate
rial in conjunction with research project HR-lOll, "Recycling of Asphalt
Concrete From I-80 in Cass County" to determine the condition of the re
claimed material and to establish a job mix formula for a small test
project to be constructed.
The original A.C. exhibited penetrations in the 85 to 100 range; the ori
ginal absolute viscosity tests were in the 650 to 700 poise range. With
the exception of one sample, the recovery tests indicated that little
hardening occurred during the two to three years of service life. The
low absolute viscosity and temperature susceptibility of the asphalt ce
ment have been considered factors in the poor performance of the original
resurfacing.
Approximately 40,000 tons of material had been removed from I-80 by mill
ing and hauled to a sand production site about 3 miles north of the junc
tion of US 71 and I-80. In January of 1979, a contract was let for
crushing, hauling and stockpiling of the salvaged asphaltic concrete ma
terial from I-80. The removed material was crushed to pass a 1" sieve
and stockpiled as a single product. No other gradation limits were spec
ified. The contractor elected to crush at the original stockpile lo
cation and haul to the new site some 12 miles away.
PAGE 10
The crushed material was to be stockpiled in such a manner as to minimize
both consolidation and segregation of the stockpiled material and waste.
Wheel and track equipment were prohibited from operating on the stockpile
to minimize conglomeration of the salvaged material.
MIX DESIGN
The design of recycled asphalt mixtures consists of blending salvaged and
crushed asphaltic concrete material with new aggregate to produce asphalt
cement concrete. In this case it was a Type B recycled !" mix
(Appendix B).
Gradation tests were made on the salvaged asphaltic concrete as it was
processed. Information on the average gradation of the reclaimed aggre
gate was given to the contractor. This gradation was to be used as a ba
sis for determining the combined gradation of the aggregates for the new
mix. Based on this gradation information and on previous experience, a
blending ratio of equal parts of crushed, salvaged asphaltic concrete and
new aggregate was selected. Since stripping was evident in the material
salvaged from the I-80 project, hydrated lime was to be added to the sal
vaged material prior to heating. The hydrated lime content of the com
bined material was intended to be 1% by weight. The new aggregate was to
be a combination of coarse and fine aggregates with the applicable qual
ity requirements of Iowa DOT Specification 4126 (2), Aggregate for Type
B, A.C.C.(Appendix C). The crushed particle needs of the mixture were
satisfied by the use of the recycled asphaltic concrete. The gradation
of the virgin aggregate was such that when combined with the recycled ag-
PAGE 11
gregate the composite aggregate mixture met requirements of Iowa DOT
Specification 4109 (1), Aggregate Gradations (Appendix D).
Asphalt cement selected for this project was the grade AC 2.5 - ASHTO
M-226 Table 2. Basic additional A.C. content of the prescribed 50-50
mixture expressed by percent in the total mixture was 2.75%.
BID LETTING
The projects were let January 20, 1981. The bid range for
FR-71-3(26)--2G-15 was $767,261.00 to $933,255.98; for FR-71-2(17)--2G-69
was $562,216.44 to $696,631.00; for FR-34-2(22)--2G-69 was $219,343.26 to
$261,335.05. The bid sheets for each project are in Appendix E. The
three projects were tied for bid letting.
Western Engineering Co., Inc. of Harlan, Iowa, was the low bidder and was
awarded the contracts.
PAGE 12
CONSTRUCTION
Base Preparation
The thermal cracks in the base had been filled by injection of a lime
slurry the winter prior to resurfacing. The crack depressions had been
leveled with a slurry.
There was some alligator cracking in the outside six feet of the pave
ment. These areas were covered with an engineering fabric before resur
facing. Areas reported as base failures were leveled with hot mix before
the fabric was placed.
Project FR-71-2(17)--2G-69 had 386.6 square yards of fabric placed and
tack coated with 0.26 gallon of A.C. per square yard and project
FR-71-3(26)--2G-15 had 5,542.64 square yards of fabric placed with 0.24
gallon of tack coat per square yard (Appendix F) .
Surface preparation generally consisted of cleaning with a rotary broom
and cleaning any open cracks with compressed air.
Plant Operation
The asphalt plant was a CMI Drum Mix Plant modified to mix recycled
asphaltic concrete. The virgin aggregates were fed into the burner end
of the drum and the recycled asphaltic concrete was fed into the drum
through a collar at the center of the drum.
PAGE 13
The virgin material was super heated and then combined with the recycled
material at the center of the drum preventing the burning of the asphalt
cement from the recycled asphalt cement concrete. Hydrated lime used as
an anti-stripping agent (1% by weight) was pneumatically fed into the
outlet end of the drum when the asphalt cement was added.
After some production, an auxiliary dryer was installed to pre-dry the
recycled asphaltic concrete. The moisture content of the recycled mate
rial was reduced from 5.6% to 1.5%. Production could be increased by 60
tons per hour to about 275 tons per hour by pre-drying 50% of the recy
cled material going into the mix and combining it with the other 50% as
taken from the stockpile before being fed into the drum mixer-drier.
Pollution Control
A baghouse was used initially for dust collection, but after two baghouse
fires it was replaced with a wet scrubber.
Pollution testing for the auxiliary dryer and the baghouse system was
conducted by a private testing firm. The summaries of the test results
are in Tables II and III.
PAGE 14
TABLE IISUMMARY OF RESULTSWESTERN ENGINEERING
PARTICULATE EMISSIONS - CMI PILOT(Auxiliary Dryer)
Test Number 5 6 7Test Date 9-16-81 9-17-81 9-17-81
Production TPH 100 75 83
Gas Data
TempoF 777 676 709
CO 2 Vol % 5.0 5.8 7.0
°2 Vol % 15.0 15.0 12.5
Excess Air 245 254 143
H2
0 Vol % 22.6 19.7 22.1
ACFM 28,142 21,456 28,903
DSCFM 9,061 7,845 9,997
Particulate Emissions
gr/ACF 0.14 0.12 0.15
gr/DSCF 0.43 0.33 0.43
lb/hr 33.4 22.0 37.0
Isokinetic 114.0 99.4 99.2
PAGE 15
TABLE IIIWESTERN ENGINEERING
ATLANTIC, IOWASUMMARY OF PARTICULATE EMISSIONS
(Baghouse)68°F STANDARD TEMPERATURE
Test II 1 2 3Test Date 8-3-81 8-3-81 8-3-81
Stack Gas
Temperature of 362 339 346
ACFM 50,752 46,907 47,156
DSCFM 21,752 20,723 20,158
CO2 Vol % 6.0 6.3 6.5
°2 Vol % 13.5 13.0 12.7
H2O
Vol % 30.0 30.4 32.3
Excess Air 157.5 156.5 147.1
Emissions
gr/DSCF 0.027 0.015 0.018
gr/ACF 0.012 0.006 0.008
Ib/hr 5.1 2.6 3.1
Isokinetics 99.0 100.0 102.3
PAGE 16
Placement
The asphaltic concrete was placed 2 inches thick by a B1aw Knox paver.
Initial compaction was with a Hyster C615 single drum vibratory roller
weighing 23,500 lbs including 2,500 lbs of water. Finish rolling was
with a Cedar Rapids CR2-88 vibratory roller in the static mode weighing
32,500 lbs including 2,500 lbs of water. A Bros pneumatic roller weigh
ing 31,000 lbs with 22 ply tires at 125 psi was on the project site but
was not always used. Sprinkle treatment aggregate was applied with a
Bristowes spreader.
During rolling operations, bumps appeared at crack locations in the
underlying pavement. The bumps were from slippage over cracks which had
been sealed and leveled with an asphalt emulsion slurry. The problem was
remedied by placing loose mix over the area ahead of the paver and by
modifying the rolling pattern.
COST COMPARISON
The average cost of in Type B surface course asphalt cement concrete in
Iowa in 1981 was $13.10 per ton plus the asphalt cement which averaged
$212 per ton. A in Type B surface course with 5.25% a.c. would cost
$24.23 per ton.
This demonstration project included three construction projects. The
asphaltic concrete tonnage and cost per ton for each project are listed
in Table IV. The cost is based on the bid prices and pay quantities for
asphalt cement concrete, new aggregate, asphalt cement, and crushing and
stockpiling of the recycled asphaltic concrete.
PAGE 17
TABLE IVRECYCLED ASPHALTIC CONCRETE
Project1/2" Type "B" SurfaceTons A.C.C. $ Ton
Leveling CourseTons A.C.C. $ Ton
FR-7l-3(26)--2G-15
FR-71-2(17)--2G-69
FR-34-2(22)--2G-69
28,848.42
22,181.32
6,105.00
20.30
22.00
24.22
2,406.32
301.93
61.83
22.95
26.01
33.30
The cost does not include the cost of removal of the recycled asphaltic
concrete, as it would have been wasted if not recycled, or any savings
which may be realized from not having to dispose of the material in a
landfill.
It is impossible to determine cost benefits for the leveling course be-
cause of the small quantities involved. The savings based on the surface
course for FR-71-3(26)--2G-15 were $113,374.29 ($3.93/ton), for
FR-7l-2(17)--2G-69 were $49,464.34 ($2.23/ton), and $61.05 ($O.Ol/ton)
for FR-34-2(22)--2G-69 for a total savings of $162,899.68 for the three
projects.
The plant site was located on the first project listed above and the last
project listed was the farthest from the plant site. The first project
also had the greatest tonnage with the last project being only 1.9 miles
long and having the least tonnage of asphalt cement concrete.
PAGE 18
ENERGY CONSERVATION
The three projects used 43,299.17 tons of recycled asphalt cement con
crete. Assuming that the useable a.c. content was 2%, there would be
865.98 tons less of a.c., at 587,500 BTU/Ton, (3) manufactured conserving
an equivalent 6.00 gal. of gas per ton. The total gasoline equivalent
required to manufacture 865.98 tons of asphalt cement would be 5,195.35
gallons.
The recycled mix would contain 42,433.19 tons of aggregate. The crushed
stone would require 56,000 BTU/Ton (2) to manufacture. This would be an
equivalent 19,010.07 gallons of gasoline or 0.45 gallons of gasoline per
ton of aggregate. A summary of energy consumption is in Appendix G.
CONSERVATION OF NATURAL RESOURCES
Iowa has no crude oil from which to obtain asphalt cement and sources of
aggregate are becoming limited, therefore, natural resource conservation
as well as energy conservation is very important. The conservation of
865 tons of asphalt cement and 42,433 tons of aggregate is especially im
portant in southwest Iowa where aggregate is very scarce.
PERFORMANCE EVALUATION
The present serviceability index (PSI) has been determined biennially.
Table V shows the crack and patch surveys, rut depth, friction numbers,
and the PSI for half-mile test sections of US 71 in Montgomery and Cass
Counties. Each half-mile test section is representative of the area
listed by milepost for each section.
PAGE 19
TABLE VUS 71 MONTGOMERY - CASS - RECYCLED A.C.
1/2 Mile Test SectionNo. of cracks
Patch Mean Average FrictionDate Transverse Longitudinal (Sq.ft.) Rut Depth Fault No. PSI
Milepost 29.56 to 37.13
1980 42 3.00
81-82 3.75 0 0 0.065 0.145 46 3.67
83-84 6 1 0 0.09 0.20 3.52
85-86 7 0 0 0.14 0.30 40 3.33
Milepost 37.13 to 42.13
1980 43 2.73
81-82 4.25 0 0 0.075 0.195 45 3.67
83-84 7 0 6 0.08 0.17 3.52
85-86 6 0 0 0.13 0.22 40 3.27
Milepost 42.13 to 46.13
1980 41 3.08
81-82 4.75 0 0 0.08 0.10 47 3.69
83-84 8 1 0 0.12 0.17 3.41
Milepost 46.13 to 58.48
79-80 38 2.80
81-82 4. 08 0 0 0.10 0.13 45 3.69
83-84 3 0 0 0.12 0.12 3.41
85-86 5 0 0 0.15 0.12 49 3.37
PAGE 20
Cores were drilled from three locations in March 1986. Some cores were
tested for density and voids and others from the same locations were ex-
tracted for aggregate gradation and asphalt cement properties. The re-
suIts of the tests are in Table VI.
TABLE VIUS 71 CASS - MONTGOMERY COUNTIES
RECYCLED ASPHALT CONCRETE MIX
Sieve Analysis - % Passing1/2 3/8 4 8 16 30 50 100 200
Montgomery Co. - Sta. 80
Plant Report 96 86 71 59 48 32 13 6.1 4.2
ExtractedMarch 1986 97 87 71 59 48 35 19 12 9.3
A.C. 5.69%; Pen. 58; Abs. Vise. 1480; Density 2.36; Voids 2.3%
Cass Co. - Sta. 840
Plant Report Lt 95 86 71 57 46 30 13 6.5 4.8
ExtractedMarch 1986 98 90 73 60 48 35 20 13 11
A.C. 5.52%; Pen. 63; Abs. Vise. 1210; Density 2.36; Voids 2.7%
Cass Co. - Sta. 519
Plant Report 95 84 67 54 43 28 14 6.6 4.8
ExtractedMarch 1986 96 90 77 62 49 35 20 12 9.8
A.C. 5.39%; Pen. 43; ABs. Vise. 2190; Density 2.36; Voids 2.2%
PAGE 21
The highway has been visually inspected periodically. As indicated in
Table V, there is slight rutting, which is no worse than if the asphaltic
concrete were made using all new materials. The surface is in excellent
condition, as there is no raveling or excessive asphalt cement.
The cracks that have reflected through the surface began to dip and have
been sealed and any loss of ride quality has been restored. Any dipping
of cracks was not related to the recycled asphalt cement concrete.
ENVIRONMENTAL CONSIDERATIONS
The recycling of the asphaltic concrete caused no environmental problems.
On the other hand, environmental damage may have been prevented as the
asphaltic concrete was placed back into a highway rather than in a land
fill where water could possibly strip the asphalt cement from the aggre
gate polluting the ground water in the immediate area.
SUMMARY and CONCLUSIONS
This demonstration project consisted of three highway resurfacing
projects using asphalt cement concrete removed from an Interstate highway
which was resurfaced because of severe rutting. The removed asphaltic
concrete was hauled and stored at a sand production site for later use.
The stockpiled material was later crushed to a one inch maximum size and
hauled about 12 miles to a plant site where it was combined with virgin
aggregate and asphalt cement for resurfacing the three projects.
PAGE 22
The three projects were adjacent to each other, but the project on US 34
was a short project, including an interchange, so all of the post con
struction evaluation was conducted on the two adjacent projects on US 71.
From this demonstration project, it can be concluded that recycling as
phalt cement concrete into another highway is a cost effective nonpollut
ing method of disposal.
A high quality highway surface can be constructed using recycled asphalt
cement concrete.
Savings may be realized from the need for less asphalt cement and aggre
gate.
There is significant energy and natural resources conserved, especially
in an area lacking aggregate and where all asphalt cement has to be im
ported.
Cost effectiveness is dependent upon the distance involved in processing
and hauling the recycled asphaltic concrete.
PAGE 23
ACKNOWLEDGEMENT
The Red Oak Construction Residency personnel are gratefully acknowledged
for the complete diaries and records kept during the project. It would
have been impossible to prepare the report without them.
The inspection personnel included John Tebrinke, Richard Blackburn, Larry
Bruce, Robert Foster, Duane Heeren, Dennis Jones, Stephen Kling, and
Perry Smith.
The assistance of O. J. Lane, Jr., District Materials Engineer, and the
late Charles Huisman, DOT Materials Engineer, for their assistance during
the development and construction of the project is also acknowledged.
PAGE 24
REFERENCES
1. Iowa Department of Transportation, "Iowa Primary Road SufficiencyLog" .
2. Iowa Department of Transportation, "Standard Specifications for Highway and Bridge Construction", Series 1977.
3. The Asphalt Institute, "Energy Requirements for Roadway Pavements",IS-173, November 1979
Appendix A
PAGE 25
A.C
.PAVEMENT
SURFACECRACKS
CLASSI
VISUALCO
ND
ITION
S:
1.0.0"
to0.25"
averaged
epressio
n.
CLASSII
VISUALCO
ND
ITION
S:
~
METHOD
OFREPA
IR:
1.B
loww
ithcom
pressedair
torem
oveloose
material
2.Seal
crackw
ithem
ulsified
asph
alt(C
RS-2)
METHOD
OFREPA
IR:
-c'>'" enN0'>
1.0.25"
to0.50"
averaged
epressio
n.
1.B
lowcom
pressedair
torem
oveloose
material
2.Seal
crackw
ithem
ulsified
asph
alt(C
RS-2)
3.8"
wide
stripseal
with
3/8"cover
aggregate
A.C.PAVEMENT
SURFACECRACKS
CLASSIII
VISU
AL
CO
ND
ITION
S:
1.0
.50
"to
1.0
"av
erage
dep
ression
2.N
earstra
igh
tlin
ecrack
3.O
ccasion
alseco
nd
arycrack
CLASSIV
VISU
AL
CO
ND
ITION
S:
1.0
.75
"p
lus
dep
ression
2.V
lide(3
/4"+
)crack
3.S
econ
dary
cracko
rb
reaku
p
METHOD
OFR
EPAIR
:
1.Saw
4"w
idere
tracin
gcrack
line
2.F
ull
dep
thp
atch-
(tack
,p
re-mix
or
ho
t-mix
&sp
ecia
lco
mp
action
)
METHOD
OFR
EPAIR
:
1.12"
wide
removal
2.F
ull
dep
thp
atch(p
er
std.
specs.)
"0
»'" ,..,.,N-J
Appendix B
PAGE 28
PAGE 29
IOWA DEPnR"rl1EN"!' I)F l'RA1~SPOR'I'A'I'ION
OFFICE OF MATERIALS!"'ISPllt,l.T Ctmcr::ETE nrx l)ESIG1~
LAB LOCA"rION AMES
I1HEf4DED USE:
110. :;~00
(.,. ?--:S. ~)
+0.3
,\. ?7. :·:5~;o
~ 91.,5202. :.)6:~ . () II 'I\ .0\ 8:t.~5 II\ • '12. ;:)8'\ .00.9:',\\7.2? \ .0
\1.9
THIS
,50:~.'3 1 ~~
\ 6,2.3132.611 ,1I .0)18:.~ • 'I::S::.~ . 0 ::.~ . ,) \L ~,!
(-).I?:·S1::;.6,1]'/ . I0.3
::':.3U.. :'~67 ]>Ul,~\ES
:.\.8
\ ,3
])j;l'E REPOR"fEJ) 6/22/8\FR-71··3(~!6)"·-2G··\5
Fl~~311-2(22)'--2l3-69FR·-71··~(\7)··"·2(3-69
TO S'I'f\I\:T THe: ,JO[I,
,)'INCI..(,IFi::~ . "(
::;03:::\:13\ 0:2. :~n
2 • \~l ,1 /1
1.01 a::~. '163.9.::.~ .•) it:L:50.lf3\ :5 . \"1'1 . :5
fJ • (J
l:'l?'lSF"-·3J6,,[",,:c:. ;W.
D.•JtJr,Dl.SlJtlc ..JOltl'S
A CONTENT UF s . ::3"01. fiSHlt;l... T .IS r;'CCDliMEIWCDIS AN A()IIIl'IllN 1)1~ 3.0% A$Pl~AL'l'.COP.!ES,
ASPH. MIX Dr::SIG1~
PROJECTS LISTED AD()VEI). I~. SI~YDEF~
w. (3: !)Ur"Grd-l
~~>~~~~~~~STWESTCRt~
SIZE 1/2"CI~SS
COUN'l'Y MON1'GOMERYriOl~rGDMEnY
CON1'RAC'rOI~ WES'J'EI~N
FF<CH'\ MU1HC;UliEr~Y l...IHE lH.n~lH 16.3 lHI...LS.: Fl~(Hi 0 . .5' til. WEST Or:'F'RO,). I..()CI~lIUI~ U.S. 7'\ Ii'~TEr~CH(:,14GE: FAST j .» i1J:LESi Ffi'OI'\ CASS CO, l.IfiE SOUTH
AGG. soul\:b:~s ·{;V:l::!·;~;I:/.Hli~~i::~::._ ;1TU~NTIC nF~ ...· Ct,SS en ; Std41, '" I.Yl1tdi F'Il _ cr.ss cu.;5;f'1I...\~f:';G\:::I." "",SPHP,LT CUNChETE CONTf.\Jl11t·!(:; • '\:-; (\SPHf;LT
JIJD MIX FORMIJ1.A AGGI~EGA'rE PROPOR'1'10r~s: "20X'AA'I'l-17S, ~0X A~'1"-'17~: 50% ABC:I-52;.•.- - - •..- - .",.-"_••.••..- '"',- "-.- "-""", " , , , - _.I:>LUS ..,.1 % 1--1 YDr((','!'E]) 1...1 rlE _ DF' 'j'O T III.. .•.M I X _ .• _
.108 MIX r~OI~riIJl.,A _. (:(lI18Il~El) 15RAl)A'I'[IJN~'''\/2' \' :3/,\' 112' 3/t]" rW.'1 IW.13 uu. \6 1-10.30 lW.~jO IW.100
\00 97 DB 7::,~ 50 II', ::H \7 '9.11
TOl.ERA1-lI:E: 95/10075 [lLOIJ i·It~R.},H;:\LL liENSITYnSPHAl']' SOURCE A'~l) APPI~(JXltiA'J'E VISCClSI"ryxxxxxxxxxxx::c\xxxx ~: I:'1SF'I·I",t1.,T j~d)DCD% ';r'·tl. U~ ;11;.:NlJrlf.1EF( OF l"lr,r::SHI:;1..1.. Ol...OWSMARS],tALl.. S']'ABILI1'Y - ]_BS.Fl.OW .. 0.0\ ULSF'. Gf\. llY I)lshJ\CI~r"lEHT (U\J:1 1)1::'NS _ )BULI< SP. GR. I:OMB. I)RY AGO.sr. (iR. nSP~l, 0 77 F.Cf':tLC _ SOL.J.1) SF'. Gl~.
/. VOIDS ,- C",LC.r,ICE SP. c;f(.Yo VOIDS .- 1:::.!CFx WA1'E]~ A8S0Rl~"IDI~ - AGGI~EGA'rl~
x VOlns IN 'rti£ l"lII-iERAt. ~GGREGA'l'EX \).1'1.1). FILl.ED urru fiSPH{,L.TCALCULATED ASP1'~.FJ.l_M "~IICI(NESS(MrCRI)r~S)FILLER/DX'rIJMEN Rn']'X()
l'HIS IS A 8()R!)ERL.INE MIX DESI(~I-I - VAI~IA'rIONS !>UE '1'0 '1'~1E snL,V~13EUr-IATERIAI... IJILL EIE THE r\Esr:-l)I~SJ.r.lll.. J.TY OF THE COr4Tf~I:-"CTI1~(j 11Ul'HOf,Il'y _V1'I~lr~ITIONS DUE 1'0 TI'lE I)InGll~ (\GC1~J:·:GATE WILL, Dr: 1'1-11:'~ GU1-l']'f<{,\CTor::sR€SF·OHS1ElJ.LITY. SlGNr::D: (lEG:N,:':-,f-<l) G. r~f\'!'lI.!H
lEST (lll-: r I' • I ;-!' :
Appendix C
PAGE 30
JII
coursesshall
meet
theF
ollowing
requ
iremen
tsfor
them
aterialspecified
inthe
con
tractdocum
ents.
4122.03A
GG
RE
GA
TE
FO
RST
AIJIL
JZE
DSH
OU
LD
ER
S.A
ggregatefor
stabilizedshoulders
shallm
eetrequirem
entsof
41
20
.04
or,w
henspecifically
designated,4
12
0.0
5.
Sincecom
paction
isa
specificationreq
uirem
ent,
the
percen
tpassing
theN
o.2
00
sieveshall
beco
ntro
lledas
specified.
4122.02M
AC
AD
AM
STO
NE
BA
SE
MA
TE
RIA
L.
This
aggregate
shallbe
thep
rod
uct
ofcrushing
limesto
ne,
do
lom
ite,or
qu
artzitean
dshall
meet
the
following
requ
iremen
ts:A
.A
brasionL
oss.T
he
percentageo
fw
ear,determ
inedin
accord
ance
with
AA
SH
TO
T9
6,
Grading
Aor
B,
shalln
ot
exceed4
5,
B.
Soundness.W
hensu
bjected
toth
efreezing-and-thaw
ingtest,
Lab
orato
ryT
estM
ethod211,
Meth
od
C,
thepercentage
lossshall
no
texceed
10.C.
Gradation.
The
aggregatefor
bo
thbase
courseand
chokesto
ne
courseshall
bep
rod
uced
fromth
esam
esource
byan
imp
actb
reaker
prim
arycrusher,
bo
tha
pro
du
ctof
that
op
eration
.T
hegrates
orb
reaker
barsshall
beadjusted
toproduce
anom
inalm
axim
um
sizeof
4inches,
andthe
pro
du
ctof
theprim
arycrusher
shallbe
screened
overa
Lin
chscreen.
The
aggregateretain
edon
theI-1J1ch
Screenshall
befurnished
asthe
Macadarn
basecourse
material.
The
aggregatepassing
the
Lin
chscreen
shallbe
furnishedas
thech
ok
esto
ne
coursem
aterial;h
ow
ever,
additionalrestric
tionsm
aybe
placedon
thism
aterial.
4125.05G
RA
DA
TIO
N.
Cover
aggregateshall
meet
requirem
ents
of
Sectio
n4109
forthe
gradationn
um
ber
app
rop
riatefor
the
sizedesignated
orreq
uired
andthe
aggregatefurnished.
.,;1 ,I:1I·1'!
41
25
.01
Grad
ation
Nu
mb
er
CO
VE
RA
GG
RE
GA
TE
Size
53
84125.02A
BR
AS
ION
LO
SS.T
hepercentage
of
wear
asd
etermin
edby
AA
SH
TO
T9
6,
Method
C,shall
no
texceed
40
.
4125.03SO
UN
DN
ESS.
When
theparticles
retainedon
theN
o.
4sieve
inall
sizes,ex
cept
sand
,are
subjectedto
theIreeeing-and-thaw
tngtest,
Lab
orato
ryT
estM
ethod211,
Meth
od
C,
theloss
shalln
ot
exceed
10percent.
4125.04SH
AL
E.
Fo
r112·
and318-inch
sizes,shale
particlesIn
thep
ortio
nretain
edon
theN
o.4
sieveshall
no
texceed
5.0p
ercent
of
the
particlesretained
onth
atsieve.
Sand
cov
er'aggregate
shalln
ot
con
tainm
oreth
an2.0
percentshale
particles.retain
edon
theN
o.16
sieve.
Sectio
n4
12
5.
Cover
Aggregate
4125.01D
ESC
RIP
TIO
N.
Aggregate
forb
itum
ino
us
sealco
at,S
ection
23
07
,shall
beco
mp
osed
of.hard
,durable
rock
,sand,
orcom
binationsthereof,
washed
andfree
fromobjectionable
claycoatings,
and
shallm
eetth
efollow
ingrequirem
entsfor
the
sizedesignated
inth
eco
ntract
do
cum
ents.
Unless
oth
erwise
specified,the
1/2-inchsize
shallbe
used.T
he1{2-
and3
/8-in
chsizes
may
be'cru
shed
ston
e,or
gravel,or
am
ixtureof
thesem
aterialsw
ithsand.
537G
RA
NU
LA
RM
AT
ER
IAL
FO
RS
AS
41
24
.01
"Th
eliZ
-inch
sizem
aybe
used
wh
enth
e3
/8+
inch
sizeis
specified
ifth
ep
ercent
passin
gth
eN
o.
20
0siev
ed
oes
no
tex
ceed1
.5p
ercent.
tFin
eag
greg
atefor
con
cretem
eeting
the
req
uire
men
tso
fS
ection
41
10
may
beu
sedfo
rsan
dco
ver.
Section
41
26
.A
ggregatefor
Cold-L
aidB
ituminous
Concrete
and
Ty
pe
BA
sphaltC
ement
Concrete
4126.01D
ESC
RIP
TIO
N.
The
aggregateshall
consistof
gravelor
crush
edsto
ne,
orb
oth
,co
mb
ined
with
sandand
filler,an
dshall
meet
the
following
requ
iremen
ts.
4126.02A
GG
RE
GA
TE
.A
ggregateshall
consistof
hard
,durable
rock
or
gravelan
dsand
particlesm
eetingthe
following
add
ition
alreq
uirem
ents:
Section
41
24
.G
ranularM
aterialfor
Soil-A
ggregateS
ubbase
4124.01G
EN
ER
AL
.G
ranularm
aterialto
beadded
tothe
road
bed
for
con
structio
no
fsoil-aggregate
subbasem
aybe
anym
ineralaggregate
meeting
thesereq
uirem
ents.
The
aggregateshall
meet
requ
iremen
tso
fS
ection4109
forgradation
nu
mb
er13.
The
plasticityin
dex
shalln
ot
exceed
4fo
rgravels
and6
forcrushed
ston
e.W
henth
egranular
material
iscru
shed
limesto
ne
Or
do
lom
ite,the
po
rtion
of
particlesretain
edon
theN
o.4
sieveshall
no
thave
apercentage
lossexceeding
15w
hen
sub
jectedto
thefreezing-and-thaw
ingtest,
Lab
orato
ryT
estM
etho
d211,
Method
C.W
henth
eco
ntract
includesw
ork
describedin
Sections
22
02
,2203,
22
04
,or
22
05
,aggregate
mix
tures
perm
ittedfor
theseiterns
will
beconsidere
daccep
table.
1/2
inch
Cru
shed
ston
eG
ravel
3/8
inch
Cru
shed
ston
eor
gravelS
and
141516""1
7t
-0
»G>
rrt
w~
4126.04A
GG
RE
GA
TE
FO
RT
YP
EB
Ace
5395
40
AG
GR
EG
AT
EF
OR
TY
PE
AA
ce
4127.01
C.C
rushedP
articles.A
llm
ixturesrequired
byS
ection2
30
4,
andall
Class
1m
ixtures,shall
have30
percentcrushed
particlesin
theaggregate.
The
percentageo
fcrushed
particlesshall
beadjusted
orcontrolled
tom
eetrequirem
entsof
them
ixdesign.
A.
Abrasion
Loss.
Aggregate
retainedon
theN
o.4
sieveand
crushedaggregate
passingthe
No.
4sieve
shallbe
producedfrom
sourcesw
hichnorm
allyshow
anabrasion
lossn
ot
exceeding45,
asdeterm
inedin
accordancew
ithA
AS
HT
OT
.96.B
.F
reezing-and-Thaw
ingT
est.A
ggregateretained
onthe
No
.4sieve
andcrushed
aggregatepassing
theN
o.4
sieveshall
bep
rod
uced
from
So
urces
wh
ichnorm
allyshow
afreezing-and-thaw
ingloss
no
texceeding
10for
Method
Cand
45for
Method
A,
when
testedin
accordancew
ithL
aboratoryT
estM
ethod211
usingaggregate
crush
edor
screenedto
3/4~jnch
maxim
umsize.
The
engineerm
ayw
aivethese
requ
iremen
tsfor
sandand
gravelw
henthe
amo
un
tretained
onthe
No.
4sieve
isJess
than5
percentof
them
aterial.
41
26
.03
FIL
LE
R.
Finem
aterialad
ded
tothe
mixture
with
ou
theating
shallm
eetrequirem
entsfor
mineral
fillerin
AA
SHT
OM
17except
thegradation
shallbe
determ
ined
inaccordance
with
AA
SH
TO
T11.
41
26
.04
CO
MP
OSIT
EA
GG
RE
GA
TE
.T
hecom
positeaggre
gateshall
befree
fromvegetable
matter
andfrom
adh
erent
films
of
clayor
oth
erm
atterw
hichw
illp
reven
tcoating
of
particlesw
ithbitum
en.Silt
andclay
naturallyoccurring
inaggregate
no
tbe
consideredobjectionable
providedthey
remain
finelydivided
anduniform
lydistributed.
All
mixtures
shallhave
atleast
20percent
naturalsand
inthe
po
rtion
passingthe
NO
.4sieve.
Natural
sandrequired
forw
earingcourse
mixtures
shallbe
gradedsuch
thatw
hensieved
throughthe
following
numbered
sieves-i-S,16,
30,50,
and1
00
-no
tm
oreth
an50
percen
tshall
passo
ne
sieveand
beretained
onthe
nex
thigher
nu
mb
eredsieve.
The
composite
aggregateshall
meet
thefollow
ingrequirem
entsfor
theclass
andm
ixturesize
specified.A
.P
lasticityIndex.
The
composite
aggregateshall
havea
plasticityindex
no
texceeding
4.B
.G
radationT
hecom
positeaggregate
mixture
forthe
job-mix
formula
aggregateshall
meet
requirements
ofS
ection4109
forthe
gradationn
um
ber
app
rop
riatefor
theclass
andm
ixturesize
specified.C
lassan
dM
ixtu
reS
ize
Class
1,1
inch
Class
1an
d2,
3{4in
chC
lass1,
1{
2in
chC
lass1,
3{8in
ch
Grad
ation
Nu
mb
er18192021
Crushed
particlesm
aybe
ob
tained
fromcrushed
ston
e,m
ineralfiller,
or
crushedsand
or
gravel.W
hencrushed
sandor
gravelis
furnished,it
shallbe
pro
du
cedas
aseparate
operationby
crushingsand
or
gravelparticles
tothe
exten
tth
at90
percen
tor
more
will
passthe
sieveon
which
90percent
orm
orew
asretain
edbefore
crushing.D
.P
roductionL
imits.
Pro
du
ction
gradationlim
its[or
thevarious
aggregatesw
illbe
furnishedas
aguide
tothe
con
tractor
soth
atthe
com
bin
ation
of
theseaggregates
indesignated
pro
po
rtion
sshould
resultin
agradation
within
thejob-m
ixtolerances.
Section
41
27
.A
ggregatefo
rT
ypeA
Asphalt
Cem
ent
Concrete
41
27
.01
DE
SC
RIP
TIO
N.
Aggregate
forT
ypeA
asphaltcem
ent
con
creteshall
consisto
fa
mix
ture
of
crushedstone,
orgravel,
combined
with
sandand
filler.Par-ticles
retainedon
theN
o.4
sieveshall
beconsidered
coarseaggregate,
andparticles
passingthe
No
.4sieve
shallbe
consideredfine
aggregate.A
ggregatesshall
com
ply
with
thefollow
ing.
41
27
.02
MIN
ER
AL
FIL
LE
R.
Finem
aterialadded
tothe
mix
ture
with
ou
theating
tosecure
thedesired
percentagepassing
theN
o.200
sieveshall
meet
requirements
ofA
ASH
TO
M17
excep
tthe
gradationshall
bed
etermin
edin
accordancew
ithA
AS
HT
OT
11.
41
27
.03
FIN
EA
GG
RE
GA
TE
.Fine
aggregateshall
consistof
hard,durable
grainso
fnatural
sand
,crushed
ston
e,or
crushedgravel,
freefrom
injurioussubstances,
includingshale
particles,in
the
po
rtion
retainedon
theN
o.16
sieve,in
excessof
2.0percent.
Material
fromeach
separatesource
tobe
usedas
fineaggregate,
beforebeing
deliveredto
the.stockpile
from.
which
them
ixingp
lant
will
besupplied,
shallbe
screenedand
processedto
theex
tent
that
itw
illco
ntain
nolum
ps,balls
ofclay,
foreignm
aterial,or
pebblesw
hichw
illbe
retainedon
a1
1/2
·inch
sieve.
41
27
.04
CO
AR
SE
AG
GR
EG
AT
E.
Coarse
aggregateshall
consist
of
crushedsto
ne,
gravel,or
mixtures
ofcrushed
stoneand
gravel.W
hencrushed
gravelis
used,it
shallbe
producedas
aseparate
operationby
crushinggravel
particlesto
theex
tent
that
90p
ercent
orm
orew
illpass
thesieve
onw
hich90
percentor
more
was
retainedbefore
crushing.T
hescreen
sizeused
toseparate
material
priorto
crushingshall
beincreased
asnecessary
tocom
pensatefor
screeningefficiency
andm
aterialvariability.
Coarse
aggregateshall
bep
rod
uced
fromsources
which
normally
showan
abrasionJoss
no
texceeding
40,determ
inedin
accordancew
ithA
ASH
TO
T9
6,
and
afreezing-and-thaw
ingloss
no
tgreater
than10
orw
henspecifically
required,not
greater
-0
»G:l
en
wN
Appendix D
PAGE 33
4106.01P
AP
ER
AN
DP
LA
ST
ICF
ILM
527528
P,\P
ER
AN
DP
LA
ST
ICF1L
lvf4106.02
of
no
tm
ore
than75
secondsand
shallbe
ofsu
chconsistency
that
theycan
bereadily
sprayedto
auniform
coatingat
temperatures
above40
degreesF.
4105.03M
OIST
UR
ER
ET
EN
TIO
N.
When
testedin
accordancew
ithL
abo
ratory
Test
Method
90
1,
theefficiency
ind
exof
them
aterialshall
notbe
lessthan
95.0percent,
exceptthat
material
showing
moisture
Josso
fless
than1
.0p
ercent
of
the
qu
antity
of
water
remaining
inthe
testspecim
enat
thetim
ethe
curingm
aterialis
appliedw
illbe
acceptab
le.
4105.04SE
TT
ING
.L
iquidcuring
com
po
un
ds
shallset
within
2hours
afterapplication,
toform
afirm
,w
ater-imperm
eablefilm
,adhering
stronglyto
theconcrete.
41
05
.05
WH
1TE
-PIG
ME
N"rE
DC
OM
PO
UN
DS
White
pigmented
compounds
shallconsist
offinely
ground,w
hitepigm
entand
vehicle,ready-m
ixedfor
usew
itho
ut
alteration.T
hepigm
entshall
notsettle
badlyor
cakein
thecontainer,
andthe
compound
shalln
ot
thickenin
storageso
asto
causechange
inconsistency
which
may
resultin
anonuniform
spray.A
fterthe
compound
sprayedon
asm
oothsurface
hasdried,
itshall
havean
apparentdaylight
reflectancenot
lessthan
70.0percent-relative
tom
agnesiumoxide.
The
rateof
applicationshall
ben
ot
lessthan
0.067gallon
persquare
yard(15
squareyards
pergallon).
The
compound
shallbe
stirred-continuouslyduring
thetim
eit
isbeing
applied.
4105.06D
AR
K-C
OL
OR
ED
CO
MP
OU
ND
S.D
ark-coloredcorn
poundsshall
consistof
asphaltem
ulsifiedor
cut-backw
itha
volatilesolvent
andshall
containn
ot
lessthan
50.0percent
asphalt.T
heyshall
setsufficiently
2hours
afterapplication
sothat
aw
hitewash
coatingw
illn
ot
bediscolored.
The
rateof
applicationshall
ben
ot
lessthan
0.08gallon
persquare
yard(12.5
squareyards
pergailon).
4105.07L
INSE
ED
OIL
EM
UL
SION
.W
henlinseed
oilem
ulsioncuring
compound
isspecified,
thefollow
ingshall
applyin
lieuof
oth
errequirem
entsof
thissection.
Linseed
oilem
ulsioncuring
com
po
un
dshall
bea
nonplgm
entedm
aterialth
athas
beenhom
ogenizedto
producea
uniformm
ixtureas
setforth
inU
nitedS
tatesD
epartment
ofA
gricuiturepatent
applicationserial
nu
mb
er365,900,
filedJune
1,1973.
The
material
shailm
eetrequirem
entso
fA
STM
C309
andC
156.
Section
4106.P
aperand
Plastic
Filmfor
Curing
Concrete
4106.01C
UR
ING
PA
PE
R.
Paper
tobe
usedfor
curing
con
creteshall
meet
requ
iremen
tso
fAST~1"1
C1
71
,ex
cept
that,
inlieu
ofthe
moisture
Josslim
itationprescribed,
thefollow
ingshall
apply:T
hem
oistureloss
shallnot
begreater
than5.0
percentof
theoriginal
mixing
water
usedw
henthe
paperis
testedin
accordancew
ithL
aboratoryT
estM
ethod901,
with
thepaper
remaining
inplace
for24
hours.T
hepaper
shallbe
preparedin
sheetsof
sufficientw
idthto
coverthe
fullw
idthof
concretesurface
beingplaced
with
ou
tstretching
andw
ithnorm
alallow
ancefor
shrinkage.
4106.02P
LA
STIC
FIL
M.
Plasticfilm
usedfor
curingconcrete
shallbe
tough,pliable,
moisture-proof,
andsufficiently
durableto
retainits
moisture-proof
propertiesduring
thetim
e'itis
inplace
onthe
surfaceof
theconcrete.
Itshall
meet
requirements
of4106.01
forretention
ofm
oisturein
concreteand
forsize
ofsheets.
The
plasticfilm
shallbe
white-pigm
entedm
aterial.T
hefilm
shallbe
notless
than0.00085
inchthick,shall
haven
ot
lessthan
70percent
daylightreflectance
relativeto
them
agnesiumoxide
when
testedin
accordw
ithAsrrvI
E97,
andshall
beopaque.
Ifthe
thicknessof
plasticfilm
isless
than0.0034
inch,it
shallnot
beused
more
thanonce
forcuring
concrete.
Section
4107.P
lasticFilm
forS
ubgradeT
reatmen
t
4107.01G
EN
ER
AL
.Plastic
filmto
beused
fortreating
subgradeof
concretepavem
entshall
bepolyethylene
filmnot
lessthan
0.00085inch
thick,'either
clearor
white-pigm
entedtype.
The
width
ofstrips
usedshall
providea
iapnot
lessthan
12inches
between
adjacentstrips.
Plasticfilm
which
hasbeen
usedno
more
thanonce
forcuring
concretepavem
entand
hasbeen
salvagedin
usablecondition
may
beused
fortreatm
ent
ofsubgrade.
Section
4109.A
ggregateG
radations
4109.01G
EN
ER
AL
.G
radationsfor
variousaggregates
areshow
nin
thegradation
tableon
thefollow
ing.page,.and
eachgradation
isidentified
bynum
ber.W
henthe
aggregateis
testedby
means
oflaboratory
sieves,the
·sieveanalysis
shallshow
agradation
within
therange
permitted
forthe
gradationnum
berspecified
forth
ataggregate,
Section
41
10
.Fine
Aggregate
forC
oncrete
4JJO.01
DE
SCR
IPT
ION
.Fine
aggregatefor
concreteshall
consistof
clean,hard,
durable,m
ineralaggregate
particlesfree
frominjurious
amo
un
tof
silt,shale,
coal,organic
matter,
orother
-0
)0
GO
en
co.",
41
09
.01
AG
GR
EG
AT
EG
RA
DA
TIO
NS
529530
FIN
EA
GG
RE
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TE
FO
RC
ON
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'"
deleteriousm
aterialand
shallco
mp
lyw
iththe
following
requirem
ents.Fine
aggregatefor
concretefloors,
overlays,and
pavem
entsshall
benatural
sands.N
aturalsand
isdefined
asfine
aggregateresulting
fromdisintegration
ofrock
throughglacial
action.M
anufacturedsand
pro
du
cedfrom
igneousor
meta
morphic
rock
may
beused
with
approvalof
theengineer.
4110.02SH
AL
E.
S'iale
andcoal
particlesretained
ona
No.
16sieve
shalln
ot
exceed2.0
percent.
4110.03
GR
AD
AT
ION
.Fine
aggregate[or
concreteshall
meet
requirements
of
Section
41
09
forgradation
nu
mb
er1.
Inaddition,
when
thefine
aggregateis
sievedthrough
thefollow
ingnum
beredsiev
es-4,
8,16,
30
,50,
and1
00
-no
tm
orethan
40percent
shallpass
onesieve
andbe
retainedon
thesieve
with
then
ext
highern
um
ber.
4110.04M
OR
TA
RST
RE
NG
TH
,T
hem
ortarstrength
offine
aggregateshall
bedeterm
inedaccording
toL
aboratoryT
estM
ethod212.
The
streng
thof
them
ortar,tested
at7
days,shall
no
tbe
lessth
an1
.5tim
esthe
strengthof
mo
rtarin
which
standardsand
isused.
More
restrictivelim
itsfor
deleterioussubstances
orsize
of
particlesm
aybe
set,if
necessary,to
insurea
continuouslysatisfactory
mo
rtarstrength.
Section
4112,Fine
Aggregate
forM
ortar
4112.01D
ESC
RIP
TIO
N.
Fine
aggregate[or
mo
rtarshall
consistof
naturalsand
asdefined
in4
11
0.0
1,
unlessotherw
iseperm
ittedO
rspecified.
Itshall
comply
with
thefollow
ingprovisions.
4112.02D
EL
ET
ER
IOU
SSU
BST
AN
CE
S.D
eleterioussub-
stancesshall
no
texceed
thefollow
ing:~
A.
Shale
and
coalparticles
retainedon
aN
o.16
sieve,n
ot
G)
more
than
2.0p
ercent.
rrt
B.
Organic
matter,
oth
erth
ancoal,
no
tm
orethan
indicated{
.oj
bythe
stand
ardreference
colorw
hentested
accordingto
(J1
AST
MC
40.
4112.03G
RA
DA
TIO
N.
Fineaggregate
form
ortar
shallm
eetrequirem
entsof
Section
4109for
gradationn
um
ber
2.W
henm
ortar
jointsare
1/4
inchor
lessin
thickness,1
00
percentof
theparticles
shallpass
theN
o.8
sieve.
4112.04M
OR
TA
RST
RE
NG
TH
.W
hentested
asprescribed
in4
11
0.0
4,
them
ortar
strengtho
fth
eaggregate
shalln
ot
beless
than0.9
times
thestren
gth
ofm
ortar
made
fromgraded
standardsand.
Appendix E
PAGE 36
LOC
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ON
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TABULATION
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Appendix F
PAGE 49
PAGE 50
APPENDIX
Engineering Fabric
Project FR-71-2(17)--2G-69
station to Station Station to Station
488+65 to 488+95 532+37 to 532+70490+78 to 490+98 543+85 to 544+25517+50 to 518+22 544+71 to 545+00518+00 to 518+36 544+46 to 545+06227+7 to 528+20 553+69 to 554+19
Project FR-71-3(26)--2G-15Left Lane
Station to Station Station to Station
739+52 to 740+09 805+45 to 805+88741+00 to 748+10 812+73 to 812+97750+20 to 750+62 829+58 to 830+36759+18 to' 760+80 832+73 to 833+00762+00 to 765+85 834+35 to 836+77767+22 to 768+00 840+39 to 841+34768+55 to 768+75 860+,,1)7 to 860+97770+85 to 781+80 866+65 to 867+25783+00 to 783+25 869+90 to 870+11785+15 to 785+60 871+23 to 871+68803+07 to 803+57 874+20 to 877+37804+64 to 805+00 879+08 to 880+05
Right Lane885+98 to 886+17 829+61 to 830+33885+27 to 885+51 826+22 to 826+39882+20 to 882+02 825+35 to 825+50877+13 to 877+31 802+00 to 802+20874+38 to 876+32 785+15 to 785+60872+50 to 872+77 784+00 to 784+25871+65 to 871+80 783+35 to 783+60866+03 to 866+20 778+74 to 782+42855+63 to 860+29 759+18 to 765+50850+54 to 854+44 753+74 to 753+94846+80 to 847+76 752+60 to 752+84840+48 to 841+76 749+06 to 749+34834+55 to 835+33 750+23 to 750+53831+50 to 831+11
Appendix G
PAGE 51
Form 0000202·75 H·15078
PAGE 52IOWA DEPARTMENT OF TRANSPORTATION
To Office Construction Department Date December 14, 1981
Ref. No.
FR-71-3(26)--2G-15Cass CO.FR-71-2(17)--2G-69FR-34-2(22)--2G-69Montgomery CountyASph. Cone. Resurfacing
Don Jordison
Asphalt Concrete Pavement RecyclingFuel Consumption.
Find listed below the summaries of energy consumption for projectsFR-71-3(26)--2G-15, FR-71-2(17)--2G-69 and FR-34-2(22)--2G-69.
John Tebrinkefor W. G. BurganRed Oak Construction
From
Attention
Office
'Subject
Gallons of fuel used is shown in equivalent gallons of gasolineat 125,000 BTU./ga110n.
No. 2 diesel was used in the plant generator, secondary dryer andtrucks that hauled the hot mix, new aggregate and hydrated lime.No. 5 fuel oil was used in the primary dryer.
The secondary dryer was used on eleven days and production was increasedapproximately 45 tons per hour when it was in operation.
Moisture content of the salvaged asphaltic concrete prior to inductioninto the secondary dryer was 4.6% to 6.2% as determined from samplesrun by the District Materials lab. Moisture content of the salvagedmaterial sampled at the outlet end of the secondary dryer was approximately 2.5%.
For comparison, the moisture content was 2.1% in the asphaltic concretethat was milled on 1-80 from Stuart to Greenfield this past season.
Moisture content of the new aggregate was approximately 2.5% in thecoarse aggregate and 7.0% in the fine aggregate.
SUMMARY OF ENERGY CONSUMPTION - Project FR-71-3(26)--2G-15:Tons mix used on road:Surface course = 28,848.42 tonsStrengthening course = 2,406.32 tonsFull depth patches = 219.54 tonsSurface patch = 8.13 tonsTotal tons used = 31,482.41
Equivalent gallonsPlant generatorPrimary dryerSecondary dryerHot mis haulNew aggregate haulHydrated lime haul
of gasoline used:= 2,582.1 gals.= 72,323.9 gals.= 982.8 gals.= 7,276.5 gals.= 3,699.0 gals= 2,018.0 gals
page 1(continued next page)
PAGE 53December 14, 1981Don Jordison
Page 2
Equivalent gallons of gasoline per ton of mix used:
Plant generator
Primary dryer
Secondary dryer
Hot mix haul
New aggregate haul
Hydrated lime haul
= 2582.131482.41
= 72323.931482.41
= 982.831482.41
= 7276.531482.41
= 3699.031482.41
= 2018.031482.41
= 0.082
= 2.297
= 0.031
= 0.231
= 0.117
= 0.064
Total gals/ton = 2.822
SUMMARY OF ENERGY CONSUMPTION - Project Fr-34-2(22)--2G-69Tons of mix used on road:Surface course = 6105.00leveling course = 61.83Full depth patch = 223.09Surface patch = 1.00Total tons used = 6390.92
Equivalent gallonsPlant generatorPrimary dryerSecondary dryerHot mix haulNew aggregate haulHydrated lime haul
of gasoline used:= 655.1 gals= 14790.3 gals= 827.9 gals= 3732.7 gals= 751.0 gals= 404.0 gals
Equivalent gallons of gasoline used per ton of mix:
Pl ant genera tor = 655.16390. 92 = 0.102
Primary dryer = 14790.3 2.314=6390.92Secondary dryer = 827.9
6390.92 = 0.130
Hot mix haul = 3732.7 0.584=6390.92
New aggregate haul = 751. 0 0.1186390.92 =
Hydrated lime haul = 404.0 0.0636390.92=
Total gals per ton = 3.311
(continued next page)
December 14, 1981
PAGE 54
Don Jordisonpage 3 of 3
SUMMARY OF ENERGY CONSUMPTION - Project FR-71-2(17)--2G-69
Ton of mix usedSurface courseLeveling courseSurface patchTotal tons used
on road:= 22181. 32= 301.93= 4.00= 22487.25
tonstonstons
Equivalent gallonsPlant generatorPrimary dryerSecondary dryerHot mix haulNew aggregate haulHydrated. lime haul
of gasoline used:= 1523.6 gals.= 45487.3 gals.= 12923.2 gals.= 7176.5 gals.= 2642.0 gals.= 1346.0 gals.
Equivalent gallons of gasoline per ton of mix used:
= 3.162
Plant generator
Primary dryer
Secondary dryer
Hot mix haul
New aggregate haul
Hydrated lime haul
Total gals. per ton
=
=
=
=
=
=
1523.622487.2545487.322487.2512923.222487.257176.5
22487.252642.0
22487.251346.0
22487.25
=
=
=
=
=
0.068
2.023
0.575
0.319
0.117
0.060
~JGB :JDT: jgcc: J. Lane, Dist. Materials Engr., D.O.T., Atlantic
RC fil e