Multiple Stage/Infrared Hot-In-Place Processes

Conventional Roto-Milling/
Repaving

OPERATIONAL

Traffic disruption

Minimal:

Traffic can pass close and around

processing equipment

Multiple stage process involves a long equipment train, operating at slow speeds.

Conventional mills and pavers require a large fleet of dump trucks to maintain constant material flow.

Machine noise

Low level: less engine horse power is required to rework the asphalt surface compared to Roto-milling

Higher level:

due to longer equipment train and multiple milling units

Noise levels are very high when Roto-milling. This creates a problem, especially in residential areas.

Mobilization of Equipment

Towable units do not require float. Fast hook up/set up.

Multiple towable units require additional tractors.

Heavy units require specialty transportation equipment.

Minimum Equipment Requirements

1 Recycling Unit

3 Pre-Heaters

2 asphalt rollers

Generally, 2 to 4 Pre-Heater/milling units; one paving machine;

2 asphalt rollers

One milling machine; one paving machine; fleet of dump trucks. Off site asphalt

2 asphalt rollers

PRODUCT

Degradation of aggregate and wear on cutter teeth

The mill's carbide teeth are working with soft pre-heated asphalt. Mill teeth generally last for weeks. The larger aggregate in the asphalt is dislodged (by rakes) but not destroyed. Rake cutters generally last for months.

Multiple stage milling increases risk of aggregate degradation. Higher rate of wear on milling teeth due to lower heat penetration levels.

The carbide teeth used to mill the pavement under ambient conditions break down the larger aggregate. High rate of wear. Water is added to cool the teeth and help the cutting action. Carbide cutting teeth only last a few hours.

Loose aggregate

There is no loose aggregate. This is a major advantage when working on airport runways. One loose stone on the runway could cause catastrophic results in today’s jet engines.

There is no loose aggregate.

Large quantities of loose aggregates and dust at airports. Clean up is required immediately but not always done properly.

Transition joint

The joint between recycled material and existing pavement is fused together due to thermal bonding. This is especially important for highway pavement and airport runways. There is no unfinished surface. After rolling, traffic can drive on the surface immediately.

Lay-down asphalt temperatures are lower therefore less thermal bonding at joints.

Poor bonding. Tack coat used to bond hot asphalt (transported from off site asphalt plant) to the cold old pavement. Cracks appear at cold joints in the pavement at an early age.

Excessive emissions

Emissions are minimal. Asphalt is not recycled in a plant.

Fleet of dump trucks not required

Higher emissions due to longer equipment train and repeated heating/milling of asphalt pavement. Fleet of dump trucks not required

Excessive emissions. Asphalt recycling plants produce large volumes of blue smoke while heating recyclable material. Large fleet of dump trucks required

Manhole covers and iron castings

Milling and scarification systems must be mechanically raised for obstructions, pavements either side of obstruction not recycled.

The milling drum must be raised otherwise serious damage will occur. Further milling is required by a small, manoeuvrable mill. Raised utility structures are left standing above grade.

Leaching into water table

There is no stockpiled material (RAP) therefore there are no chemicals to leach into the water table.

There is no stockpiled material (RAP) therefore there are no chemicals to leach into the water table.

Chemicals from reclaimed (milled RAP) leach into the water table as rain falls on the stockpile.

Productivity (50 mm/2 in depth)

Complete single-stage-single-pass process at speeds up to 9.0 m (30 ft) per minute.

Road Profile (Crown/slope control)

Milled to uniform grade, provides uniform asphalt thickness and compaction.

Variable cutting depths result in possible irregular asphalt uniformity and compaction.

Milled to uniform grade, provides uniform asphalt thickness and compaction

1.

Pre-Heating Units HM-16

3 Required

2.

ENVIRO PAVER®  R1015 Hot-In-Place Recycler

1 Required

3.

Dual Steel Drum Vibratory Roller, 8 – 12 tons

1 Required

1 Required

5.

Rejuvenator Agent (Fluid) Supply Truck

1 Required

6.

Diesel Fuel, Hydraulic and Engine Oil Supply Truck

1 Required

7.

Mechanics Service Truck with Torches, Welder, Tools and more frequently required spare parts like bolts, filters, seals, etc.

1 Required

8.

2.5 – 4.0 m³ Front End Loader for Sand

1 Required

1.

1 – Foreman

2.

1 – Mechanic (also operates the Front End Loader)

3.

2 – Traffic control officers (Flag persons)

1.

3 – Operators

ENVIRO PAVER®  R1015 Hot-In-Place Recycler

1.

1 – Operator

2.

1 – Screed operator

3.

3 – General labour
1 Ground person
2 Rake men

4.

1 – Dual Steel Drum Vibratory Roller Operator

5.

1 – Pneumatic Rubber Tired Roller Operator

1.

Faster operating speed than competing equipment under identical conditions. - ENVIRO-PAVE 100% HIR equipment has by far the most efficient pavement heating system; it combines proprietary radiant/hot air heating as opposed to infrared heating only used by others. No scorching of pavement surface by ENVIRO-PAVE 100% HIR equipment.

2.

Single-stage, single-pass (SSSP)  process as opposed to multi-stage processes. Saves time, increases productivity and reduces traffic disruptions.

3.

Single switch control – All equipment features an on-board computer. Equipment can be stopped or started with one switch without having to reset operating parameters. Saves time, increases productivity and improves quality control.

4.

Variable width scarification, milling and paving – The Pre-Heater and Recycling Unit are capable of on-the-go variable width scarification milling and paving. Permits more complex operations.

5.

Rides over and around obstructions – others equipment's mills have to be raised mechanically to clear obstructions, leaving old asphalt. The resulting untreated areas must be recycled using manual methods.

6.

Milling to uniform grade – provides uniform thickness and compaction of asphalt pavement, extends useful life and improves ride quality of pavement.

7.

Uniform pavement surface – The geometric layout of the heater recycling unit results in averaging out all imperfections in the pavement surface.

8.

High degree of quality control – The on-board computer control/monitoring system permits control and monitoring of all variables to a very high degree.

9.

Low maintenance cost – The efficient heating of the pavement reduces wear to mill teeth and rake carbide cutters.

10.

Low operating cost – The efficient heating of the pavement increases operating speeds and reduces operating costs.

11.

Minimal emissions – The efficient heating of pavement prevents overheating of pavement surface and keeps emissions at a minimum. No scorching of pavement surface by ENVIRO-PAVE 100% HIR equipment.

12.

Allows modification of existing pavement mix – The equipment design permits use of light and heavy rejuvenator fluid and Polymer liquids. The heating system permits the addition of moist or dry aggregates to change aggregate and air voids content.