This digest is one of a series produced by the Aggregates Advisory Service to provide information on aggregates efficiency issues.

The aim of this service, funded by the Department of the Environment, Transport and the Regions, is to assist the Government to achieve its objective of reducing the construction industrys dependence on landwon primary aggregates and increasing the contribution from secondary and recycled materials. Further information on aggregates efficiency issues, whether relating to primary, secondary or recycled materials, can be obtained from the Aggregates Advisory Service on Freephone no. 0800 374 279 or visit the website at http://www.planning.detr.gov.uk/aas/index.htm.

ROAD RECYCLING Ex-situ Road Recycling Why Recycle a Road?

This digest briefly describes one of the methods of road recycling. This digest covers ex-situ recycling. Digest 056 covers in-situ recycling. Two example projects are included. Road reconstruction conventionally consists of the excavation of existing material and its replacement by new. This process results in the requirement for significant quantities of new materials usually from primary sources. dispose Contact Details Walsall Example Address: Roadstone Recycling Ltd Gatherley Road Industrial Estate Brompton on Swale Richmond North Yorkshire DL10 7JQ Telephone: Fax: Contact: A52 Example Address: Staffordshire County Council Development Services Department Highways Northern Area Office Ladder Edge Leek Staffordshire ST13 7AB Telephone: Contact: 01538 483012 Mr P Pytlik Ex-situ recycling consists of the excavation and removal of existing road construction material to a stockpile. From here it is processed by grading and mixing with appropriate binders prior to being recompacted to form a road. 01748 811232 01748 812005 Mr G Cook The recycling of existing materials can result in both cost savings and reduced environmental impacts. of the It is coupled with the need to existing material the and the

environmental

impacts

from

associated

transport operation.

Ex-situ Road Recycling

Recycling can be undertaken either in-situ or exsitu. This digest relates to ex-situ recycling.

In-situ recycling is covered in Digest 056.

Department of the Environment, Transport and the Regions Research Contract MP0623 Symonds

Digest no. 060 (2:1/99)

Ex-situ recycling has the following characteristics: The recycling plant is easily transported and can be established on site in a few hours The plant is smokeless, odourless and is quiet in operation Recycling plant can be located in surroundings appropriate to the nature of the operation where environmental impacts can be mitigated Environmental impacts at the reconstruction site are reduced A wide range of materials can be processed including road planings, crushed concrete and masonry The materials can be crushed and screened to fit a predetermined grading envelope, before being mixed with a binder All materials are processed in a controllable environment resulting in the production of a quality controlled product The graded material can be stockpiled for the later incorporation of a binder Bound material, if correctly stored, can be used for up to four weeks after production The excavation of the road and its replacement can be undertaken using conventional plant and equipment

The roads consisted typically of 60-80mm of asphalt covering an unbound stone base consisting of well graded granular slag. Locally concrete was also present within the base materials.

Planing operation to remove existing road surface

Example Project: Estate Roads in Walsall

In a recent operation, Roadstone Recycling Ltd (a joint venture company formed by a partnership between Tarmac and Bruce Cook Road Planing) reconstructed sections of estate roads in central Walsall.

Excavation of existing material in preparation for resurfacing

Department of the Environment, Transport and the Regions Research Contract MP0623 Symonds

Digest no. 060 (2:1/99)

The recycling process incorporated a Foamix binder. Foamix has been widely used for a number of years in Canada and has been particularly successful in areas where indigenous aggregates are of poor quality. The binder was added at approximately 2.2% by weight and the moisture content was adjusted to achieve adequate in-situ density figures. The in-situ density was determined using a nuclear density meter.

Example Project: A52, Staffordshire

In the summer of 1997, a 0.9km stretch of the A52, which is a heavily trafficked trunk road, was reconstructed using ex-situ recycling techniques.

In this instance, the existing road was planed out to full depth and stockpiled. The resulting material was then graded and, where necessary, crushed to provide material of suitable particle sizes. This was then mixed with 3% lime and 12% pulverised fly ash (PFA). The mixture was recompacted in two 150mm layers as subbase and base course. was topped with new wearing course. It

Where

necessary, small quantities of primary aggregates were brought in to make up volumes. It is believed that this is the first project where a lime/PFA binder has been used in conjunction with recycling of existing road materials. Paving using Foamix macadam

Further Potential
These examples illustrate how recycling techniques can compete successfully with conventional road construction methods.

The grading of the feedstock material was checked on a daily basis. This was undertaken by

thoroughly mixing the stock material prior to wash grading it through a series of sieves. Density checks were undertaken each day and cores were cured and subsequently tested in a laboratory.

The

ex-situ

approach

provides

consistent

construction material and eliminates some of the variables which could occur with direct in-situ

In isolated areas of the site, soft clay was found to exist below the road base level. As this method of repaving is equally as liable to settlement as any other, a number of soft spots were excavated and backfilled with granular material reinforced with a geotextile.

recycling and allows more engineering control during the construction operation. It is anticipated that the performance monitoring can thus be more objective.

An increased use of recycling techniques such as these would reduce demand for primary aggregate,

A wearing course consisting of Masterpave (a Tarmac product) was used as a surfacing layer.

assisting the Government to achieve its aim of sustainable development.

Department of the Environment, Transport and the Regions Research Contract MP0623 Symonds

Digest no. 060 (2:1/99)