Features & Benefits

Enviro-Paver® R1015 Hot In-place Recycler

PATTERSON Industries (Canada) Limited "The Process Equipment People" are
licensed manufacturers of the Enviro-Paver® Hot-In-Place Asphalt Recycling machine.

The Enviro-Paver® R1015 is the ideal machine for all 100% Hot In-place Recycling
(H.I.R.) single stage processing of highway, municipal, airport and commercial asphalt
pavements. The Enviro-Paver® R1015 not only offers superior thermal bonding
between layers and joints but also cost savings of up to 50%, compared to conventional
paving methods.

The Enviro-Paver® R1015 uses a single stage process of scarifying, milling, mixing/
rejuvenating, storing/metering and finally, screed levelling of heated, recycled
asphalt, without lifting or removing asphalt from the heated surface. All major
processing elements are closely spaced to reduce material heat loss and segregation.

Other processes using a separate windrow conveyor and standard paving machine
suffer reduced asphalt temperatures, higher emission (smoke) levels and increased
aggregate segregation.

Processes that remove heated asphalt from the surface for processing result in complex
conveying systems, reduced asphalt temperatures, higher emission levels and increased
aggregate segregation.

Enviro-Paver® R1015 shown operating at a depth of 50mm (2") at 6.7m (22ft.) per min. at a width of 4.26m (14ft.)

Enviro-Paver^® R1015 is available to the contractor in three
configurations for the following methods:

A. 100% H.I.R. method (recommended)
This is the recommended method for recycling asphalt pavements with a structurally
sound base, if:

Enviro-Paver® R1015 Extension Rake leading Extension Mill Processing depth of 50mm (2")

• The surface is rutted up to 50mm (2"),
cracked or has deteriorated.

• The surface requires levelling and minor
grade corrections.

• Modifications to asphalt mix design using
pre-engineered specifications are required.

• A finished long-term wear surface is
desired.

• Asphalt material is 100% recycled to depths of 50mm (2") without the addition of
new asphalt, using the following equipment:

• Three self-propelled, propane-fired Pre-Heaters (Heat Master HM-16 or equivalent) with
  variable width heating and heating output. The Pre-Heater ahead of the Enviro-Paver®
R1015 deposits aggregate on to the heated asphalt surface.  The on-board
computer controls and monitors the application of washed aggregate (sand, stone,
etc.) to reconstitute recycled asphalt to pre-engineered specifications.   Kiln dried
sand (required by other processes) is not required, thereby reducing recycling costs.

• One Enviro-Paver® R1015 recycling machine with an on-board computer, which
controls and monitors the application of rejuvenator fluid and machine processing
systems to reconstitute the recycled asphalt.

B. Remix method
Recommended applications are as outlined in 100% H.I.R. method. The remix method
is used when:

• New asphalt is to be mixed with recycled asphalt (pre-engineered into the
specifications). The addition of rejuvenator fluid and/or aggregate into the recycled
asphalt and the ratio of new to recycled asphalt are also determined by
pre-engineering.

• Additional material is required to correct minor grade and/or material deficiencies.

The remix method requires:
• A detachable, pin-on, front-mounted asphalt hopper/slat conveyor, equipped with a
truck pusher bar.
The on-board computer controls and monitors the discharge of new asphalt
proportionally to the volume of asphalt being recycled.
Existing asphalt is generally recycled to a depth of 40 – 50mm (1 1/2 – 2").

C. Integral overlay with 100% H.I.R. method
The integral overlay method is recommended for highway, secondary and county roads
with a structurally sound base, if:

• High-grade wear surfaces are required with thermal bonding to (pre-engineered)
recycled asphalt.

• Major grade changes are required or existing pavement needs to be strengthened with
additional material.

• Shoulder widening (up to 1m or 3.3 ft.) using recycled or new asphalt is required. For
shoulder widening, an adjustable strike-off blade is attached to the side of the R.H.
extension rake frame.
Note: Gravel shoulder must be graded and compacted before processing.

The integral overlay method requires:
• A detachable, front-mounted asphalt hopper/slat conveyer equipped with a truck
pusher bar, central conveyor, secondary auger, secondary screed and additional
control systems. Removal of the asphalt surge bin/elevator makes way for the central
conveyor. Existing asphalt is generally recycled to a depth of 40mm (1 1/2”) using
rejuvenator fluid and/or washed aggregate. A simultaneous overlay of new asphalt
(thermally bonded to recycled asphalt) is generally applied to a depth of 13 – 25mm
(1/2 – 1”).

Enviro-Paver® R1015 Pug Mill Main Mill Ext. Mill Rakes Heater Box Processing depth of 50mm (2")

How the unique Enviro-Paver® works
Asphalt pavement, previously heated by
three or more Pre-Heaters is reworked
(recycled) by the following computer-
controlled and monitored systems:

Enviro-Paver® R1015 Extension Rake leading Extension Mill Processing depth of 50mm (2”)

1. Rake Scarification system
• The Enviro-Paver® R1015
rake system dislodges the top
50 – 75mm (2 – 3") of heated
asphalt, without damaging the
aggregate (other systems
such as multistage heating
and milling increase damage
to the aggregate).

• All rakes provide full
scarification around utility
structures without being
monitored or raised.

2. Milling system (extension mills, main mill and pug mill)
• Left and right extension mills are hydraulically variable (on-the-fly) in widths from 3m –
4.5m (9.8 – 14.6 ft.).

• Left and right extension mills are hydraulically variable (on-the-fly) in widths from 3m –
4.5m (9.8 – 14.6 ft.).

• Left and right side grade controls automatically maintain the main mill grade.

• Rejuvenator fluid, sprayed on to the main mill rotor provides complete mixing with the
recycled asphalt.

• Twin-shaft pug mill collects and mixes the milled asphalt, forming a windrow.

• Extension mills, main mill and pug mill rotors are hydraulically and directly driven;
they are fitted with replaceable carbide teeth. Mills provide base material grade and
premixing of additives in front of the pug mill.

• Main mill, extension mill and pug mill rotors are all quickly replaceable for servicing.

Enviro-Paver^® R1015 Surge Bin/Elevator, Auger/Divider and Screed. Processing depth of 50mm (2")

3. Material control system
• Carson screed. Hydraulically operated
  and equipped with ultrasonic grade and
slope controls.

• Auger/divider. Hydraulically raised and
   lowered for better control of the asphalt
   head (recycled material), in front of the
   screed.

• Surge bin/vertical elevator. Allows
collection and storage of excess recycled
asphalt to be used as supplementation
(e.g. when milling to grade).

4. Quality control system
Computer control and monitoring of all Enviro-Paver® R1015 on-board machine
systems reduce operator input and the possibility of error.

This covers: Proprietary speed control, air/propane heading system, rejuvenator
dispensing system, heat management and system, material volume measuring system.

Enviro-Paver® R1015 (shown in 100% H.I.R. configuration)
Covered under Patent No. 6,769,836 as well as other Patents applied for

The Enviro-Paver® R1015 (shown above) uses a single stage process of scarifying,
milling, mixing/rejuvenating, storing/metering and finally, screed levelling of heated,
recycled asphalt, without lifting or removing asphalt from the heated surface. All major
processing elements are closely spaced to reduce material heat loss and segregation.
Other processes using a separate windrow conveyor and standard paving machine suffer
reduced asphalt temperatures, higher emission (smoke) levels and increased aggregate
segregation. Processes that remove heated asphalt from the surface for processing result
in complex conveying systems, reduced asphalt temperatures, higher emission levels
and increased aggregate segregation.

5. Major Technical Advantages of the Enviro-Paver® R1015
• Single stage process

• Quality control of recycled asphalt. The on-board computer controls and monitors
the addition of rejuvenator fluid and other additives.

• Quality control of finished mat (surface behind the screed). Automated grade
control of extension main mills and grade/slope control of the screed, combined with
the machine’s long wheel base, produce excellent riding asphalt pavement.

• Low emission process. Enviro-Paver® R1015 single stage processing allows
Pre-Heaters to operate at high temperatures without degrading asphalt surface.
Fracturing of aggregate is practically eliminated.

• Rake scarification. Rakes loosen the heated asphalt (releasing moisture) before the
mills profile the surface, reducing mill rotor teeth wear and fracturing of the aggregate.
They also provide complete scarification around iron utility structures.

• Mill and pug mill rotors. Quick-change rotors allow the removal and installation of
exchange units, reducing maintenance and down time.

• Pug mill. Twin-shaft pug mill provides complete mixing and measures the volume of
asphalt being recycled. Moisture (steam) trapped in the tumbling asphalt is removed
by an air extraction system and safely vented to the top of the machine.

• Material control system. The surge bin/asphalt elevator and auger/divider provide the
screed with a constant supply (head) of recycled asphalt. The ability to store excess
material and release material when a deficiency exists results in greater screed
accuracy, especially when automatic grade/slope controls are used. Other systems
that do not have surge storage capacity have to manually adjust the screed to release
or collect material, resulting in unwanted changes to grade and/or slope.

• Major components. From leading world class manufacturers. Parts and service are
readily available through-out the world.

• Transportation. The Enviro-Paver® R1015 is easily transported to the job site by
attaching a rear clip-on, three axles, air ride attachment. The front of the machine is
attached to a standard heavy duty highway tractor by a hydraulically extendible 5th
wheel pin stinger or front asphalt hopper/5th wheel pin. Hook-up only requires minutes,
using the machine’s hydraulic system. No trailer is needed.

• Modular design. Pin-on and/or clip-on attachments are available for various
processing applications.

• On-board computer. The computer is programmed to monitor and control all system
operations.
Parameters outside programmed limits result in four levels of machine operator
warnings:
Level 1 warnings are for advisory service schedules based upon operating hours.
Level 2 warnings require corrective action by the machine operator.
Level 3 warnings reduce or shut down the systems operation.
Level 4 warnings result in engine and computer shutdown.

• Industrial colour graphics terminals. Used by machine and screed operators,
allowing graphical monitoring of all major control and monitoring systems. Numerical
keypads and touch screens allow entry of operating parameters. Processing at
depth of 50mm (2").

Please note: For pictures on the latest Enviro-Paver® R-1015 Model 2004,
please click on Section Image Gallery.

Covered under Patent No. 6,769,836 as well as other Patents applied for

Preheating of Pavement to be recycled

The most important equipment in the equipment train apart from the Enviro-Paver® are 2 to 3 Preheaters with sufficient heating capacity to heat - penetrate the top layer of the pavement to a depth of approx. 2" without breaking the asphalt surface. This will allow the Enviro-Paver® 100% Hot-in-Place Recycler to reprocess the top layer of the pavement properly and efficiently.


Before and after using the *Enviro-Paver*^® 100% H.I.R. at a processing depth of 50mm (rejuvenator fluid and washed sand added). Note: utility structure required no adjustment and is flush to compacted recycled asphalt.

For further information, please visit

Website: http://www.pattersonindustries.com

Saving our environment, minimizing traffic disruptions!