Break it up

Demolition and recycling asphalt and concrete has its benefits

Asphalt Paving Article May 10, 2005
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Feel sorry for landfill owners if pavement contractors get a hold of a new report from the Federal Highway Administration (FHWA). Landfill business might go into a substantial decline if more people find out about how pavement can be recycled and used in new roads. The report, Transportation Applications of Recycled Concrete Aggregate, gives information about the many uses of recycled concrete aggregate (RCA) in building durable new roads.

“The review team found that RCA, under specific conditions, has the potential to produce strong, durable materials suitable for use in the highway infrastructure,” said Jason Harrington of the FHWA Recycling Team, the sponsor of the report.

The report also was supported by the American Association of State Highway & Transportation Officials’ (AASHTO) Task Force on Recycling. It is the result of a year-long review of RCA use and practices in five states: California, Michigan, Minnesota, Texas and Virginia. The review was conducted by a team that included representatives from FHWA, the U.S. Environmental Protection Agency, AASHTO, the American Concrete Institute and the Recycled Materials Resource Center at the University of New Hampshire.

Recycling portland cement concrete pavements, bridge structures and decks, sidewalks, curbs and gutters has the potential to reduce waste, cut costs and provide durable new roads.
Minnesota already takes almost all of the concrete from its old pavements, crushes it and uses it as dense-graded aggregate base material.

In Michigan, RCA is used as coarse aggregate in both portland cement concrete and hot-mix asphalt.

Some individuals in Texas initially thought RCA would be a substandard material, but the Texas DOT learned that, with improved process control, RCA can be used in new concrete. The Texas DOT’s experience with production, construction and cost of RCA is related in the FHWA report.

The report also details the Virginia DOT’s experience writing standard specifications for the use of RCA in highway construction and the California DOT’s specifications for aggregate base. The specs allow contractors the flexibility to use any mixture of RCA and recycled asphalt pavement.

The FHWA Pavement Recycling Team plans to start a similar review this year of cold in-place recycling of asphalt pavement. FHWA, AASHTO and the University of New Hampshire’s Recycled Materials Resource Center have already collaborated on several workshops on the beneficial uses of recycled materials in transportation applications and are planning more such workshops. For more information, contact Jason Harrington at FHWA, 202/366-1576; e-mail: [email protected].

Products

What follows are brief descriptions of a few of the latest products for doing demolition work and recycling and reclaiming roads.

Roadtec prescription

Roadtec of Chattanooga, Tenn., now offers four different recycling products, including the RX-500, RX-700, the RX-900 and the CIR-900.

The RX-500 (Circle 901) is a 500- or 600-hp cold planer available with four track assemblies or optional three track assemblies. This lighter weight versatile machine allows contractors to cut up to 13 in. deep with a width of 6 ft 3 in., 6 ft 7 in. or 7 ft 2 in. The RX-500 is light and maneuverable for urban situations. A two-stage front load-out conveyor, with 60° swing to either side, provides ample loading capacity.

The RX-700 (Circle 902) is a 700-hp cold planer available with either three or four track assemblies. This versatile machine allows contractors to cut up to 14 in. deep with widths of 6 ft 7 in. and 7 ft 2 in. The RX-700 offers contractors more versatility and productivity. A 36-in. front load-out conveyor, with 60° swing to either side, provides ample loading capacity.
The RX-900 (Circle 903) is an 860- or optional 950-hp cold planer available with three or four track assemblies. This versatile machine allows contractors to cut up to 14 in. deep with widths of 7 ft 2 in., 8 ft 2 in., 10 ft or 12 ft 6 in. The RX 900 offers contractors more versatility and productivity. A 42-in. front load-out conveyor, with 60° swing to either side, provides ample loading capacity.

The CIR-900 (Circle 904) is a cold in-place recycle (CIR) machine capable of processing asphalt pavement and emulsion oil insitu. A computerized blending system meters the emulsion additive. Material sizing is controlled by down cutting and forward travel speed. The polyurethane track pads, D-5 track assemblies and traction control system give unmatched tractive effort.
A large-capacity rear discharge conveyor system allows for windrowing processed material off to the side or into a conventional paver. This unit can convert to a standard front-loading cold planer for traditional highway milling.

Dynamite demolition

Purpose-designed and built for demolition, the new 330C MH Demolition Machine (Circle 905) from Caterpillar Inc., Peoria, Ill., features a robust front linkage and upper frame, specially designed guarding to protect the machine and operator and a cooling system configured to reduce plugging and allow easy cleaning. The 330C MH weighs 80,265 lb and has a maximum reach at ground level of about 31 ft and a maximum reach height of 29 ft. The machine is powered by the Cat C9 engine, which is turbo-charged and produces 247 net hp.

Super crusher

The Supertrack 1310 i (Circle 906), one of eight crushers from Crushtek, Norcross, Ga., has crushing capacity up to 385 tph. This machine is suitable for most any small or large project. A larger inlet opening (50 x 28 in.) and a higher discharge height (9 ft 10 in.) allow for sizeable feed material and minimal onsite relocation caused by material pile-up. Compact working and transport dimensions (38 ft 1 in. x 8 ft 3 in. x 10 ft 7 in.) ensure easy mobility. An easy-to-use control panel and a 12-channel remote control simplify operations. Weight is 75,000 lb.

Go for a trim

The 9500 Trimmer from GOMACO, Ida Grove, Iowa, has been given more power and trimmerhead speed to increase production. The 9500 (Circle 907) is the world’s most versatile material handling machine and provides many applications as a trimmer, concrete and asphalt placer and a shoulder trimmer. The two-track 9500 with front-mounted trimmerhead allows trimming to the end of each pass or within inches of front obstacles. The new single-drive, hydrostatic motor increases trimmerhead power and speed and saves contractors time and labor with fewer connections and parts. The 9500 was designed to be user friendly and operator safe, with an efficient operator’s station that allows visibility over the entire operation.

A half in one

Marini America Inc., Downingtown, Pa., introduces their new Marini MP 2100 cold planer (Circle 908), a high-production milling machine designed to remove a half-lane of road surface in one pass. Primarily used for removing damaged or deteriorated road surfaces from highways and city streets, the MP 2100 features a maximum working speed of 98 ft per minute. A fuel-efficient, 590-hp Deutz water-cooled diesel engine powers a milling drum with 168 cutting teeth for a high horsepower-per-cutting-tooth ratio of 3.52. The cutting drum is controlled by four leveling struts and an independent microprocessor, resulting in unsurpassed cutting precision, and the unit is capable of milling depths between 0 and 12.5 in.

High scores

Case Construction Equipment, Racine, Wis., introduces a new line of cold planers, the Case/Bradco HP Series (Circle 909), with five models that range from 16 to 40 in. wide and provide cutting depths to 5 in. These high-powered planers can take on high-density concrete and asphalt for milling of potholes and leveling of frost heaves. Other applications include cutting butt joints and T-caps or removing pavement next to curbs and gutters prior to overlay. The HP Series Cold Planers are constructed of hardened, solid steel and feature greasable manifold pins and secluded zerks.

Going places

The UltraMax (UM) 1600-69 (Circle 910) is the latest addition to the UltraMax Series from Eagle Crusher Co., Galion, Ohio. This high-volume plant is highly versatile, self-contained and features a sculptured three-bar rotor made of solid steel. The portable UM 1600-69 high-volume primary/secondary impact crushing and recycling plant produces cubical product at a lower cost per ton in the toughest aggregate and recycling applications. The UM 1600-69 is powered by a standard 500-hp electric, optional 800-hp electric or 521-hp diesel engine.

Concrete buster

Quickly break up deteriorated concrete without removing sound concrete or damaging rebar with the NLB Concrete Buster (Circle 911) from NLB Corp. of Wixom, Mich. The robotic, self-propelled unit uses the power of high-pressure water (up to 20,000 psi), without the dust and noise of jackhammers or breakers. It cleans the rebar, washes away entrained chlorides and leaves a superior bonding surface for new concrete. The Concrete Buster is ideal for bridges, roads and even parking decks.

Fast track

The FT 300 track-mounted cone crusher from Johnson Crusher International, Eugene, Ohio, is the latest addition to the line of Fast Trax track-mounted plants. The FT300 plant (Circle 912) and its fully self-contained design can be transported on a standard low-boy trailer and can be fully set up and operational in a matter of minutes. The FT300 features the roller-bearing JCI Kodiak 300 cone crusher, rated at 300 hp, and can accept up to 11-in. feed materials. Based upon discharge settings from 1?4 in. up to 2 in., the FT300 can provide maximum production rates up to 460 tph.

Making an impact

The KR1515H road-portable concrete recycling plant from Grasan, Mansfield, Ohio, features the Hazemag APPH impact crusher with fully automatic, hydraulic cylinder system that provides 15-20% increased crusher capacity, smoother operation and more uniform products. The feeder pan under the crusher discharges out of the side for improved handling of tramp steel. The HR1515H (Circle 913) is diesel or electric powered and features a Grizzly bypass chute, skid-on hopper and six independent hydraulic support legs allow for easy setup without a crane.

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