Pavement Recycling Technology for Highways in Japan

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1 Pavement Recycling Technology for Highways in Japan Presented at 1st ICTI 2008 April 24, 2008 Beijing, China Hisashi Hosokawa CEO, Green ARM Co.,Ltd Tokyo, Japan 1

2 Contents 1. History of Pavement Recycling in Japan 2. From Construction to Maintenance 3. Pavement Distress and Rehabilitation Method 4. Hot In-place Rehabilitation 5. Need for Porous Asphalt Pavement Recycling 6. Conclusion 2

3 1. History of Pavement Recycling in Japan 1.1 Pavement Recycling Technologies Pavement Recycling Technologies Hot Mix Asphalt Recycling (Batch Plant) (1977) Hot In-place Rcycling(1978) Hot In-place Transforming(2005) Hot In-place Strengthening (2007) Steel Deck Asphalt Recycling(2007) 3

4 1.2 Volume of Asphalt Mixture 100,000 90,000 80,000 Recycled Mixture New Mixture Volume of Asphalt Mixture thousand ton 70,000 60,000 50,000 40,000 30,000 20,000 10, Year Source : MLIT Japan 4

5 2. From Construction to Maintenance 2.1 Pavement Ratio Present State of National Highway and Provincial Highway Pavement Ratio % Pavement Ratio Service Distance Service Distance Km Year Note: Target Length of Arterial High-standard Highway is 14000km Source : MLIT Japan 5

6 2.2 Maintenance Expenditure Ratio % Increase Per Year Year Ratio = Maintenance / (Maintenance + New Construction) 6 Maintenance Expenditure Over Over Total Road Budget Expenditure % Source : MLIT Japan

7 3. Pavement Distress and Rehabilitation Method Unevenness Alligator Crack Rutting Source : US Federal Highway Administration 7

8 3.1 Pavement Preservation Guidelines Pavement Preservation Pavement Preservation Guidelines Type of Activity Increase Increase Reduce Capacity Strength Aging Restore Serviceability New Construction Reconstruction Major (Heavy) Rehabilitation Structural Overlay Minor (Light) Rehabilitation Preventive Maintenance Routine Maintenance Corrective (Reactive) Maintenance Catastrophic Maintenance Source : FHWA 8

9 3.2 Rehabilitation Methods of Frequent Use Re-habilitation Method Mill & Fill HIR CIR Micro Surfacing (Slurry Seals) Rutting Type of Pavement Distress Unevenness(Corrugation) - Alligator Cracking Longitudinal Transverse Raveling - Bleeding - Slipperiness - Characteristics Existing Asphalt Mixture Aggregate in Use Mixture Gradation Pre-Treatment Under Layer Transport Reclaimed Materials to Plant Hard Milling or Excavation Loosening Hard Milling - Crushed and Disposed Not Crushed Crushed - Replace 100% Onsite Reuse 100% Onsite Reuse - - Unchanged Changed - Tack Coat Not Required Cleaning and Tack Coat Cleaning and Tack Coat By Truck Not Required Not Required Not Required - Usually not used Suitable Probable Unsuitable 9

10 3.3 Comparison of Rehabilitation Methods in Terms of Energy Consumption Energy Consumption, Million kcal/m Hot In-place Recycling Hot Mix Asphalt Recycling (Mill & Fill) Material Production Machine Operation Delivery of Materials Use for Other Purpous New Construction Source : Katawaki.S, The Expansion of New Civil Engineering Materials 10

11 4. Hot In-place Rehabilitation 4.1 Address Surface Distress (Hot In-place Recycling) Re-Mix Heating Rejuvenator Milling New Asphalt Mixture Compaction Mixing Spreading Re-Pave Milling & Mixing (Rejuvenator) New Asphalt Mixture Compaction Heating Spreading 11

12 Re-Pave Hokuriku Expressway(1980s) Re-Mix National Highway Route 41(1980s) Source : Association for Advancement of Surface Recycle Technology 12

13 4.2 Applicable Area (Hot In-place Recycling) Pavement Preservation Pavement Preservation Guidelines Type of Activity Increase Increase Reduce Capacity Strength Aging Restore Serviceability New Construction Reconstruction Major (Heavy) Rehabilitation Structural Overlay Minor (Light) Rehabilitation Preventive Maintenance Routine Maintenance Corrective (Reactive) Maintenance Catastrophic Maintenance Source : FHWA 13

14 4.3 Address Structural Distress (Hot In-place Strengthening) New Technology Binder Rejuvenator New Aggregates New Asphalt Mixture Compaction Heating Surface Course Binder Course Milling Beyond Surface Layer Mixing for Lower Layer 14

15 4.4 Applicable Area (Hot In-place Strengthening) New Technology Pavement Preservation Pavement Preservation Guidelines Type of Activity Increase Increase Reduce Capacity Strength Aging Restore Serviceability New Construction Reconstruction Major (Heavy) Rehabilitation Structural Overlay Minor (Light) Rehabilitation Preventive Maintenance Routine Maintenance Corrective (Reactive) Maintenance Catastrophic Maintenance Source : FHWA 15

16 5. Need for Porous Asphalt Pavement Recycling 5.1 Construction Volume 2 Porous Pavement Construction Vomume million m Porous Pavement Year Source : MLIT Japan 16

17 5.2 Advantage of Porous Asphalt Pavement Number of traffic accidents Number of Traffic Accidents for One Year for one year Dense Dense asphalt Asphalt 84%down 466sites =312km Porous asphalt Asphalt Decrease of Traffic Accidents Traffic Noise Level (db) Traffic Noise noise level Level (db) (db) Dense Porous Porous Porous Air Air Void=4% void=4% Air Air Void=10% void=10% Air Void=15% void=15% Air Air void=20% Void=20% Noise Absorption of Porous Asphalt Concrete Source : MLIT Japan 17

18 5.3 Hot In-place Transforming (Dense to Porous) New Technology New Porous Asphalt Mixture Binder Rejuvenator Sieve Compaction 13-5mm Heating Dense Surface Course Binder Course Milling of Surface Mixing for Lower Layer More than 13mm Less than 5mm Mixing for Porous Layer Porous Layer Mastic Layer 18

19 Hot In-place Transforming Project (Dense to Porous) Date September, 2006 Site National Highway Route 126 in Chiba Prefecture Construction Volume 3,000m2 (Length:400m 2Lane) Construction Speed 2.0m/min 19

20 Date September, 2005 Site National Highway Route 77 in Okinawa 20

21 Core and Marshall Test Results (National Highway Route 77 in Okinawa) Porous Asphalt 30mm 35mm Core Sample taken after Construction Hot joint Mastic Gap Asphalt 35mm 35mm Marshall Test Results of Porous Asphalt Concrete Marshall Stability Specifications Measured Value (kn) > Flow Value (mm) Air Void (%) > Coefficient of Permeability (cm/s) > Dynamic Stability by Wheel Tracking Test (Pass/mm) >

22 Reduction of CO 2 Emission Kg-CO 2 kg-co %down 11,688 Producing & deliveries of new aggregate 16,756 Compaction 8000 Compaction Separator Manufacturing & delivering of new asphalt mixture Mixer-Paver Heater-Miller Pre-Heater Hot in Place Transforming HI-T 工法 Tack coating Cleaning + Removing Milling Conventional Method 従来工法 22

23 5.4 Need for Hot In-place Recycling of Porous Asphalt Porous Pavement Construction Volume Million m Porous Asphalt Pavement Hot In-place Recycling of Dense Grade Asphalt Hot In-place Recycling Construction Volume Thousand m Year Hot In-place Recycling (Porous Asphalt Porous Asphalt) 23

24 5.5 Hot In-place recycling of Clogged Porous Asphalt New Technology New Asphalt Mixture Binder Rejuvenator Sieve Compaction Heating Porous Surface Course Binder Course Milling of Surface Asphalt Coated Sand and Filler and Extra Substance Having Caused Clogging Mixing for Porous Layer Thin Layer 24

25 6. Conclusion New Technologies Now Available to Cope with Increasing Needs for Safety, Energy Saving, Resource Saving, Green House Gas Reduction, Asset Management 25

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