macrebur products - mr6 - the plastic road company · macrebur® provide waste plastic additives...

MACREBUR®

MacRebur® provide waste plastic additives into the asphalt manufacturing industry. MacRebur® produce engineered fl akes and pellets, made from 100% waste plastics, designed to replace bitumen in an asphalt mix to greatly enhance asphalt performance.

MacRebur® are the only supplier of waste plastic bitumen replacing additives into the asphalt industry in the world.

MACREBUR® PRODUCTS - MR6

MACREBUR® EXPERIENCE

MacRebur’s® products are being used in asphalt for highways, airfi elds and other construction and transportation projects, as well as the utility sector and domestic markets. Our customers and clients include the asphalt manufacturers, local authorities, asphalt laying contractors, Highways England, Transport Scotland and major developers. We also work with consulting engineers to help design better road networks for the future.

MACREBUR® MR6

MacRebur’s® MR6 is an award winning mixed waste plastic pellet. It replaces part of the bitumen and can be used in any asphalt mix. MR6 introduces polymers into the mix which modify asphalt resulting in increased tensile strength, increased resistance to permanent deformation and increased fuel resistance. Due to its unique chemical make-up MR6 raises the softening point making it ideal for use in hot weather. MR6 is mainly used where a strong surface is required; roads used by heavy vehicles, truck parks, airport runways, etc.

MR6 additive makes any asphalt an exceptionally durable material and also provides excellent fatigue properties and superb deformation resistance.

BENEFITS

• Increased tensile strength

• Increased fuel resistance

• Increased resistance to deformation

• Highly resistant to scuffi ng and tearing from tight turning vehicles

• Raises softening point of asphalt

• Reduction in air voids

• Increased resistance to water sensitivity

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BS EN STANDARDS

Test conducted by Celtest and Mat Testing.The following European Standards were used for product compliance purpose:

BS EN 13108-1:2006 Asphalt Concrete in conjunction with PD6691:2012.

Guidance on the use of BS EN 13108 Bituminous mixtures - Material Specification.

The Bulk density was determined in accordance with BS EN12697-6: 2012 Procedure A.

To determine the resistance to permanent deformation of bituminous materials using the small device in accordance with BS EN 12697: 22:2003 Procedure B in air.

MATTest: Wheel-tracking rate and rut depth in accordance with BS EN 12697-22:2003+A1:2007 Small-size device, Procedure B, with samples conditioned in air.

Stiffness Modulus - BS EN 12697-26:2004

Plant produced bituminous mixtures, sampled in accordance with BS EN 12697-27.

MR6 TECHNICAL DATA:

TESTCONTROL RESULT MR6

AC 20 HDM Stiffness ITSM 7827 11,600

AC 20 HDM Water Sensitivity ITSR 93.6% 99.7%

AC 20 HDM Wheel Tracking 3.6mm 1.5mm

SMA 10 65psv Stiffness ITSM 1823 MPa 5438 MPa

SMA 10 65psv Water Sensitivity ITSR 94.8% 99.5%

SMA 10 65psv Wheel Tracking 3.1mm 1.3mm

SMA 10 65psv 4 Point Bending 100 143

35 40 HRA Stiffness ITSM 3568 MPa 4313 MPa

35 14 HRA Wheel Tracking 2.8mm 1.2mm

35 14 HRA Marshall Flow 1.7 2.1

35 14 HRA Marshall Stabilitiy 8.2 7.0

CASE STUDIES:

A7, SCOTLAND ROAD, CARLISLEThe A7, Scotland Road, is the main route into Carlisle from Scotland and Northern England. The road sees heavy traffic volumes and large goods vehicles using the road to get to and from the city.

Cumbria County Council replaced 1000 tonnes of base and binder course on A7 into Carlisle. The client asked for an environmentally

friendly PMB equivalent and MacRebur® proposed MR6 as the perfect material. The job was watched by The Department of Transport and filmed by CNN.

The asphalt used contains MR6, designed to increase the surfacing’s strength and resist deformation under heavy loads. This product was installed by Hansons UK.

The Existing Asphalt was removed and replaced with 60mm of AC 20 HDM + MR6 additive, and 40 mm of HRA + MR6 Additive to replace 6% of the bitumen content.

The result is a more environmentally friendly, longer lasting, flexible road with a high fatigue resistance that has cost the asphalt manufacturer less to produce, the council less to maintain and has used up the equivalent of 150,000 plastic bottles and 300,000 one time use plastic bags, and has also saved approximately 3 to 5 tonnes of carbon emissions.

INNSWORTH ROAD, GLOUCESTERThe Innsworth Road was identified by Amey PLC and Gloucestershire County Council as needing resurfacing. The project involved installing 400 tonnes of Tarmac’s 14mm Ultipave D, combined with 6% of the

bitumen content replaced with MacRebur’s® additive MR6.

Cores were taken from the Innsworth road in May 2017 and

compared to a control that didn’t contain MacRebur’s® MR6 additive. In all tests, including; stiffness (ITSM), Water Sensitivity (ITSR), Wheel Tracking, Soaking in diesel and a workability test, when MR6 was added into the mix, it out performs the control providing a more durable road surface, with a greater rutting resistance whilst using up the waste plastics Gloucester City Council were about to send to landfill.

‘This is a busy Urban road, utilising the MR6 additive has enabled the local authority to deliver a longer lasting more durable road whilst contributing to a more sustainable environment by utilising local waste plastic which would have otherwise ended up in landfill.’ Highway Engineer – Gloucester City Council.

MACREBUR®

MacRebur® provide waste plastic additives into the asphalt manufacturing industry. MacRebur® produce engineered fl akes and pellets, made from 100% waste plastics, designed to replace bitumen in an asphalt mix to enhance asphalt performance.


MACREBUR® MR8

MacRebur’s® MR8 comes in fl ake form and is more cost effective than standard grade bitumen. It reduces part of the bitumen and can be used in any asphalt mix. MR8 improves the rheology of asphalt resulting in smoother installation, good workability and compaction.

MR8 additive can be added to any asphalt mix and replace up to 10% of the bitumen content, whilst maintaining resistance to deformation, resistance to water sensitivity and resistance to fatigue.

BENEFITS

• Cost effective, eco-friendly alternative to bitumen

• Reduction in air voids

• Increased indirect tensile strength modulus

• Improved workability




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CASE STUDIES:

KIRKLINTON HALL, CUMBRIAKirklington Hall is a 17th Century, Grade 2 Listed, manor house. The garden, grounds and restaurant are open to the public, and a new drive was required up to and around the grounds. A cheaper alternative and an environmental solution was required by the owner who was keen to see what could be achieved with recycling. The client also required a new surface which could withstand heavy traffic from visitors, deliveries and neighbouring farm traffic, but was also in keeping with its surroundings.

The design mix was a 10mm asphalt concrete design, the aggregate had a 55 PSV, 4.4% bitumen with 40/60 Pen was used along with the addition of 0.26% MR8 flakes. All asphalt ingredients were mixed in a Benninghoven plant for 35 seconds at a temperature of 170C. The resulting batches were transported to site and laid in accordance to BS594987. The maximum possible volume of bitumen was replaced using MR8 flakes, these flakes had been produced using recycled plastic waste sourced locally to create a circular economy.

With the addition of MR8 flakes into this AC mix evidence proves that the asphalt has good structural properties even though the bitumen content had been reduced considerably, thus proving that local waste plastics can be selected, recycled and used as a binder in asphalt mixes to create suitable pavements.

BS EN STANDARDS

Test conducted by Celtest and Mat Testing.

The following European Standards were used for product compliance purpose.

BS EN 13108-1:2006 Asphalt Concrete in conjunction with PD6691:2012


The Bulk density was determined in accordance with BS EN12697-6: 2012 Procedure A

To determine the resistance to permanent deformation of bituminous materials using the small device in accordance with BS EN 12697-22:2003 Procedure B in Air.



Plant produced bituminous mixtures, sampled in accordance with BS EN 12697-27

MR8 TECHNICAL DATA:


AC 20 HDM Stiffness ITSM 7827 9133



SMA 10 65psv Water Sensitivity ITSR 94.8% 96%



MACREBUR® MR10

MacRebur’s® MR10 is an award winning additive for asphalt used in urban and rural areas that combines the properties of high fatigue resistance with excellent deformation resistance. MR10 is suitable for most locations, from rural roads to heavily traffi cked motorways but particularly where there is a potential for cracking.

MR10 comes in pellet form. It replaces part of the bitumen and can be used in any asphalt mix. MR10 introduces polymers into the mix which modify asphalt resulting in increased fl exibility and cohesion whilst reducing refl ective cracking and fatigue failures.

BENEFITS

• Increased resistance to low temperature cracking

• High elastic recovery

• Increased resistance to deformation

• Increased fatigue resistance

• Increased indirect tensile strength modulus


MACREBUR®

MacRebur® provide waste plastic additives into the asphalt manufacturing industry. MacRebur® produce engineered fl akes and pellets, made from 100% waste plastics, designed to replace bitumen in an asphalt mix to enhance asphalt performance.




®

CASE STUDIES:

ASHYARDS FARM ROAD, DUMFRIESSHIRE, SCOTLANDAshyards Farm Road, Dumfriesshire, ScotlandAn AC mix which included MR10 to replace 6% of the bitumen content was installed on the Ashyards Farm Road at the beginning of 2016. The client wanted to replace the 200 metre dirt track with asphalt concrete, but because of the constant heavy traffic on the road and the freezing winter conditions, the client had concerns that a traditional asphalt may crack and form potholes. MR10 was chosen in an AC mix because of its good low temperature cracking resistance and high elasticity recovery. The road, despite it’s muddy appearance, is performing well against the winter conditions and looks set to last for many years to come.

BS EN STANDARDS

Test conducted by Celtest and Mat Testing.

The following European Standards were used for product compliance purpose.

BS EN 13108-1:2006 Asphalt Concrete in conjunction with PD6691:2012


The Bulk density was determined in accordance with BS EN12697-6: 2012 Procedure A.

To determine the resistance to permanent deformation of bituminous materials using the small device in accordance with BS EN 12697-22:2003 Procedure B in Air.



Plant produced bituminous mixtures, sampled in accordance with BS EN 12697-27

MR10 TECHNICAL DATA:


AC 20 HDM Stiffness ITSM 7827 10,387



SMA 10 65psv Water Sensitivity ITSR 94.8% 97.9%



Today’s increased waste challenges, manufacturing pollution and growing pressures on resources have alerted MacRebur® directors to the necessity of rethinking materials and energy use in the construction industry - MacRebur® believe the time is right to take advantage of the benefi ts of a more sustainable, environmentally friendly innovation in road design, adding to the circular economy and helping end what they call “The plastic epidemic”.

MacRebur® produce road enhancing additives from 100% waste plastics classed as ‘active waste’ and were previously destined for landfi ll. Their unique and innovative manufacturing process takes the waste plastic that had no way of being recycled before it reaches landfi ll - it’s separated, cleaned, re-processes and then blended to use to enhance any type of road design from private drives to motorways. MacRebur® have created a new and revolutionary form of recycling that can be replicated worldwide, helping to clean up the huge volume of waste plastics dumped into landfi ll and our oceans every year.

Typically, the plastics MacRebur® recycle into road additives would have taken hundreds, and some thousands, of years to decompose in landfi ll sites where most of it was destined for. MacRebur® interrupt the landfi ll supply, reducing CO2 emissions, landfi ll space and money by local authorities and commercial companies who produce volumes of plastic waste.

MACREBUR’S® ENVIRONMENTAL GOALS ARE TO:

• Reduce plastic waste

• Drive greater resource productivity

• Deliver a more competitive UK economy

• Help reduce the environmental impacts of asphalt production and use in both the UK and abroad

• Add to a circular economy where waste does not exist

MACREBUR® ENVIRONMENTAL REPORT

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There are clear environmental benefits to producing plastic products from recovered plastics, compared with using virgin polymers and disposing of the product post-use via incineration or landfill. The main environmental benefit lies in the energy saved by avoiding the processes of oil refining and polymerisation of monomers. These are estimated to account for over 95% of the total energy consumed in plastics production. The estimated average net CO2 saving from recycling one tonne of plastic compared with landfill and incineration is lowest for PTTs, equivalent to 0.62 tonnes CO2. Film separately collected saves the equivalent of 0.83 tonnes CO2. Meanwhile, the environmental gains from recycling are higher for HDPE bottles (1 tonne CO2) than PET bottles (0.89 tonne CO2).

If all of the 456,000 tonnes of plastic packaging collected kerbside from UK households in 2013/14 (including 351,000 tonnes of bottles, 87,000 tonnes of PTTs and 18,000 tonnes of film) was recycled, it would save almost 400,000 tonnes of CO2 equivalent emissions compared with landfill, which equates to taking around 125,000 cars off the road.

The estimated average net CO2 saving from replacing bitumen with MacRebur® pellets or flakes is 1 tonne CO2 saved per tonne of replaced bitumen with MR6, MR8 or MR10. To add to this saving, over time MacRebur® will be able to work out the savings due to less maintenance required on highways that last longer because they contain MacRebur® additives.

macrebur products - mr6 - the plastic road company · macrebur® provide waste plastic additives...

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