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PROPOSED PAVEMENT REHABILITATION USING
CIPR – COLD IN PLACE RECYCLING
BINAMASYHURBINAMASYHUR
BINA MASYHUR SDN.BHD.
NO. 166, JALAN TU2,
TAMAN TASIK UTAMA,
75450 AYER KEROH, MELAKA.
No. Tel : 06-2311142
No. Fax : 06-2316402
Application of CIPR as pavement rehabilitation and stabilization with cement
INTRODUCTION
Road plays an important role in the communication system of mankind. From the
early form of the road structures to modern design approaches, road provide a mean
of safe and economical for transportation for good and people.
Pavement deteriorates in
time because of sun and weather.
The experience shows that the
cost of maintenance is in
correlation with the volume of
repair needed. Traditionally, the
curative maintenance is only
carried out when the pavement
showed visible defect and
curative patching will then be
carried out.
By the time the curative
maintenance is carried out, a
higher budget will be needed. For
the road to perform functionally
and structurally with significant
cost saving, conservation of
natural resources and minimizes
traffic disruption using Cold in
place recycle is a best choice in
order to:
Crocodile crack, Depression and Patching.
• Focus on rehabilitation rather than expansion of road network
• Focus on cost-effectiveness of approaches
• Minimize the use of non-renewable materials & energy
Application of CIPR as pavement rehabilitation and stabilization with cement
COLD IN PLACE RECYCLING AND STABILIZATION WITH CEMENT
1. DEFINATION
Cold-In-Place Recycling: In-situ breaking up of existing pavement using specialist
plant by means of crusher, pulverizing or blended into gradation and re-compact to
become a new pavement layer
Cement Stabilization: Addition of cement as stabilizer to the mechanically blended
material to obtain improved strength and material properties
� Recycling to 200mm depth
� 4% (2% - 6% allowed) Ordinary Portland Cement to MS522, by weight
� Minimum 28-days strength: 2.8N/m2
� Open to traffic after compaction to up to 3-days before sealing with ACB28 or
Chip seal
CIPR CONTEXT DIAGRAM
M illing and m ixing
Com paction / F inishing
Cold recycled layer after
com paction
Rehabilitated Pavem ent
New 40 m m ACW
20
Existing pavem ent
Addition of w ater
4 % Cem ent = 16 kg / m 2
Application of CIPR as pavement rehabilitation and stabilization with cement
2. ADVANTAGES
Cold in-place recycling Conventional (with reconstruction)
� Conservation of natural resources
� Energy savings (20-60%)
� Minimizes traffic disruption and
time delays
� Wide range of distresses can be
rectified
� Significant cost savings
� Less Manpower
� Minimum material stockpile
� Bigger Number of Manpower
� Longer Time to complete
Pavement thickness design
Original pavement Recycled pavement
Application of CIPR as pavement rehabilitation and stabilization with cem
Original surfacing
Original roadbase
New surfacing
Recycled structural course
Original subbase
Sub-grade Sub-grade
Remaining subbase as foundation platform
Application of CIPR as pavement rehabilitation and stabilization with cement
3. MATERIAL AND PRODUCTION
Specification parameter for cold in place recycling with cement.
No. Parameter Requirements
1. Compressive strength > 2.8 N/mm2
2. Cement Content Optimum Value 2 – 6 %
3. Gradation As specified below
B.S. Sieve Size Type 1 Type 2
37.5 mm 100 100
20.0 mm 52 -100 60 – 100
10.0 mm 32 – 70 40 – 65
5.0 mm 20 – 58 30 – 55
2.0 mm 12 – 42 20 – 40
425.0 micro meter 4 – 26 10 – 25
75.0 micro meter 2 - 10 4 - 10
Materials
Using ordinary Portland cement for stabilizing agent.
Additional material (for widening and topping up): shall be crushed rock, which is
hard, durable, clean, and essentially free from clay and other deleterious material.
Compaction requirements
Either as a percentage of maximum dry density or bulk relative density
� Usually between 97 and 100 % of mod AASHTO for natural gravels
� Usually between 100-102 % of mod AASHTO for crushed stone or
recycled cement-treated layers, particularly when supported by a treated
layer
Application of CIPR as pavement rehabilitation and stabilization with cement
Construction tolerances
• Surface levels
– A lot size shall be 50 levels taken in random pattern
– The lot will comply with the requirements if the following tolerances
are met:
• H90 15mm – i.e. at least 90% of all surface levels measured are
within 15 mm, plus or minus, of the specified levels, and
• Hmax 20 mm – i.e. individual spots shall not deviate by more
than 20 mm from the specified levels
• Layer thickness
– A lot size shall be 20 layer thickness measurements
– The lot will comply with the requirements specified of the following
tolerances are met:
• D90 20mm – i.e. at least 90% of all thickness measurements
are equal to or thicker than the specified thickness, minus 20
mm
• Dmean ≥ Dspec – 5 mm
• Dmax < 27 mm – i.e. no individual layer thickness
measurement shall be less than the specified thickness minus
27 mm
• Width
– Nowhere shall the outer edge of the recycled layer deviate by more
than 50 mm from the edge lines shown on the drawings
• Cross-section
– When tested with a 3m straightedge laid at right angles to the road
centre-line, the surface shall not deviate from the bottom of the
straightedge by more than 6 mm
• Surface regularity
– When testing the finished layer with a standard rolling straightedge,
the number of surface irregularities shall not exceed:
• 4, for the average number of irregularities per 100 m equal to or
exceeding 6 mm when taken over 300 m to 600 m lengths
• 6, for the number of irregularities per 100 m equal to or
exceeding 6 mm when taken over a single 100 m section
Application of CIPR as pavement rehabilitation and stabilization with cement
Requirements before recycling commences
• Determination of in-situ moisture contents
– 1 week in advance
• Daily production plans
– Sketch of overall length, width, showing parallel cuts and overlaps
– Sequence and length of each cut
– Estimated time required for cutting, mixing & compaction
– Location of samples taken for moisture determination
– Proposed water addition for each cut & transition line
– Amount & type of stabilizing agent(s)
– Proposed control testing program
• Referencing of horizontal alignment by means of pegs (or poles)
• Preparation of the surface
– Clean of all vegetation and other foreign matter
– Removal of standing water
– Remarking proposed longitudinal cut lines
Pre-milling, where required
Loose Sampling:
Grading - Type 1 or 2
Determination of Maximum Dry Density
(MDD) Mg/m3
Determination of Optimum Moisture
Contents (OMC) %
Application of CIPR as pavement rehabilitation and stabilization with cement
Trial sections
• 300 m in length
• Demonstrate capability of equipment & processes
• Determine effect on the grading by varying forward speed & rate of rotation of
the milling drum
• Establish the application rates of the stabilizing agent(s)
• Verify the optimum compaction moisture content and determine the sequence
and manner of rolling necessary to achieve minimum compaction
requirements
4. MIX DESIGN OF COLD IN PLACE RECYCLE
MIX DESIGN FLOW CHART
Design Constraints Aggregate Selection
Mix Type
Selection
Exclude as an
option
No
Moisture Considerations
Stabilization Agent Selection
Yes
Lab Trial Mixes
Conditioning of Specimens
Properties of Mix
Material Classification & Compliance
Application of CIPR as pavement rehabilitation and stabilization with cement
Aspects addressed
Characteristics of material
Engineering properties (UCS, ITS, strain-at-break, etc.)
Mechanical properties (stiffness, shear strength)
Durability
Behavior under loading
Change in above properties with loading
Mix design
Linkages with field behavior and performance
Structural design
� Construction
Determination of Application Rate and Amount of Cement to be used.
4% cement is to be used with water to give initial strength to recycled layer thus to
exhilarate the setting time of stabilization. Cement application rate is calculated as
below :
Volume of CIPR / m2 - 0.2 m
3 (1m x 1m x 0.2m)
Weight / m2 - 400 kg (Density 2000 kg / m
3)
4% cement by weight - 16 kg / m2
Area per 50 kilo / bag of cement - 3.12 m2
(50kg / bag / 16kg / m2)
Length and Width / area - 1.30 m length x 2.4 m width
Proposed length, width for - (1.30m length x 2.4m width)
50 kilo (1 bag of OPC) = 3.12 m2
Application of CIPR as pavement rehabilitation and stabilization with cement
5. PLANT AND EQUIPMENT
Equipment and Machineries
The machineries and equipment to be used in the Cold in Place Recycling are
complying with the Standard Specification for CIPR.
The minimum requirement of plant and machineries for the performance of a
particular Cold in Place Recycle operation is listed in the following table.
Plant Item
Minimum requirement
Recycler Wirtgen WR 2500
o Cold in place recycling.
o 2.4 m max cutting and recycling width.
o 500 mm max cut and recycling depth.
o Built in micro processor to regulate
application of water with respect to travel
speed and mass of recycle material.
o Built in metering system for pumping water
at 200 lit/minutes.
o Direct attachment to water tanker.
o Self cleaning spray nozzles across width
recycling.
Vibratory Roller
o Compaction.
o 15 – 20 static mass.
o Vibration frequency: 29 – 35 Hz.
o Vibration amplitude: 0.91 – 1.66 m (large
amplitude / low frequency for initial
compaction, deep penetration of energy;
Small amplitude / high frequency for the final
compaction, shallow penetration of energy.
Application of CIPR as pavement rehabilitation and stabilization with cement
Plant Item
Minimum requirement
Motor Grader
o Surface grading.
o Hydraulic control, constant-speed.
o 100 kW engine power.
o 3.66 m blade length, 610mm blade height.
Water Tanker
o Watering.
o Min. 15,000 liter capacity tankers shall be
used to as mobile water supply during
recycling.
o Spare water tanker of similar capacity shall
be provided at site to ensure continuous
daily watering supply.
Backhoe / Fork-lift
o Placement of cement bags.
o Excavation work for widening.
Application of CIPR as pavement rehabilitation and stabilization with cement
Plant Item
Minimum requirement
Hand Tools
o Hard raker.
o Hand shovel.
o Wheel barrow
o Site Assistant
Application of CIPR as pavement rehabilitation and stabilization with cement
6. METHOD OF CONSTRUCTION COLD IN PLACE RECYLING (CIPR).
ILLUSTRATING THE CONSTRUCTION PROCESS OF CIPR
PROCESS RECYCLING & STABILISATION
DIRECTION OF WORK
a. Imported Material
Topping up need to be done to avoid lack material after recycling in order to get
uniform level of finish surface, thus avoid irregularities in finish surface. Area that
having depression or need to be topping up with important material (crusher run) due
to thin existing road layer of Bituminous and road base shall be identify.
Application of CIPR as pavement rehabilitation and stabilization with cement
b. Cement Spreading
Area of cement shall be measure in order to get 4% by weight per square meter.
Spreading of cement shall using hard raker (manually) by general workers in order to
control cement content during recycling.
Unloading of cement Manual Cement Spreading Cement uniformly spread
c. Recycling Using WR2500 Recycler
Recycling process shall be carried using WR2500 Recycler and pushing the water
tanker. The machine shall be inspect to ensure the proper recycling is carried out and
set up the recycling train as been agreed in method statement. Hose that connect water
tanker and recycler for water supply shall not have a bad leaking.
Application of CIPR as pavement rehabilitation and stabilization with cement
Data provide:
Result of calibration of water flow from
recycler through nozzles. (This is to
ensure water spray rate is as been in
design).
Speed of recycler during recycling is as
been in method statement. (Acceptance
criteria shall be as low 1m/minute and up
to 10m/minute).
Pulverisation
Depth of recycling
(Depth checking with interval of 20m
(LHS & RHS) shall be carried out to
ensure the depth is +/- 10mm of design
depth 200mm). Records shall be kept in
Joint Dipping Form.
In case of area that determined to be out of design (e.g. exceed water content,
improper level after curing) after recycling, the area have to be excavate, spread
cement and recycle it again.
Application of CIPR as pavement rehabilitation and stabilization with cement
d. Compaction of Recycled Asphalt Pavement
Compaction must be carried out in accordance as below:
Initial Compaction
Initial compaction shall be carried out immediately after recycling. This used a static
compaction by roller. Roller moves at the back or recycler.
Final Compaction
Final compaction shall be carried out after grading works with proposed passes
2 passes static
2 passes vibrate with high amplitude
2 passes vibrate with low amplitude
2 passes static
e. Surface Grading (Surface level and Shape Control)
Grading works shall be commended after
initial compaction and before final
compaction using 6 tyre grader. Grading
works shall comply with agreed
percentage of camber of roads.
After grading works and compaction had
finished, the finished level shall have
uniform and well distributed of recycling
material with no segregation.
Application of CIPR as pavement rehabilitation and stabilization with cement
f. Curing of Recycled Asphalt Pavement
Curing shall be carried out by spreading
a low quantity of water onto final
recycled layer. It can only be opened to
traffic minimum 3 hours after final
compaction. (Please refer to photos
below)
g. Opening to Traffic of Recycled Asphalt Pavement
Recycled asphalt layer can only be open
to traffic minimum 3 hours after final
compaction.
h. Overlaying with ACB 28 Binder Course
ACB 28 binder course can only be open
to traffic not less than 4 hours after
commencement of rolling or restricted to
minimum speed of 30 km/hr or less and
sharp turning when opening in less than
4 hours
Application of CIPR as pavement rehabilitation and stabilization with cement
i. Road Marking
Road marking will be carried out after
the completion of the pavement work.
With end surface of pavement is high in
texture value, road marking will be
carried out twice. The first layer will
apply after the completion of work; the
second layer is carried out 3 months
after that.
j. Dust Control
In order to control dust after excavating for widening, cement spreading, recycling
and other works involved during this process, a low quantity of water is spread onto
surfaces to control dust. Workers need to be supplied with proper mask during works
commenced.
7.0 TRAFFIC MANAGEMENT DURING CONSTRUCTION
Traffic Management and Safety
Ensure that traffic safely accommodated on the remaining width of road while work is
underway, to provide enough and proper signage, cones and other safety equipment
(safety vest and safety boot) to road users and workers during construction and
signboard to inform road users that the road is under construction process with
estimated time taken mentioned on it. It is also recommended to inform road users to
take other alternative road for comfort riding.
Traffic Management Scheme
Refer to the Traffic Management Scheme as per Arahan Teknik (Jalan) 2C/85. Extra
flagman is needed at the middle of closure length to accommodate traffic while using
half lane road.
Personal Protective Equipment
Workers shall be supply with proper attire to carry out site works (e.g: safety
footwear, mask, hand glove, and safety vest)
Application of CIPR as pavement rehabilitation and stabilization with cement
Machineries Parking During Working Time and At Night
Ensure that all machineries parked during working time and at night are in 1 place and
in proper arrangement without disturbance to road users and the road itself. This is to
ensure safety for road users during both times.
8.0 PERFORMANCE CONTROL
Quality Control
The Quality Control and Assurance shall follow the Project Quality Plan (PQP). All
test and inspection shall be in accordance to the Project Specification and summarized
in accordance to Inspection and Test Plan (ITP) of the PQP.
Material delivery inspection shall include;
a. Aggregate delivery – supplier source, time, date and quantity delivered.
b. Aggregate gradation as specified in the ITP.
c. Water – check source of water.
Quality checks on machine, equipment and plant shall be:
a. Use machineries inspection forms for approval from JKR / Client.
b. Check that all machineries, equipment and plant are clean and all parts are
working.
c. Check for adequate machineries used from the List of Equipment/
machineries.
Application of CIPR as pavement rehabilitation and stabilization with cement
Daily inspection shall include:
a. Weather checks based on area weather changes.
b. Check additional crusher run requirements (kg/m2) and compare with
required design specification.
c. Check cement spreading rate (kg/m2)
e. Check on homogeneity of the recycled material and uniform placement of
the CIPR mix at the back or the recycler.
f. Check on rolling speed, rolling overlap, number of passes.
g. Check on finished surface level tolerances and cross slope chambering.
9.0 CONCLUSION
Cold In Place Recycle method is practicable alternative to re strengthen the sub base
of pavement using existing pavement material by in-situ breaking up using specialist
plant by means of crusher, pulverizing or blended into gradation and re-compact to
become a new pavement layer with stabilizer agent to obtain improved strength and
material properties
We are also capable of achieving:
� Energy savings (20-60%)
� Wide range of distresses can be rectified
� Significant cost savings
� Less Manpower
� Minimum material stockpile
Getting In-situ Moisture
Content using Speedy Moisture
Tester
Application of CIPR as pavement rehabilitation and stabilization with cement
10.0 COMPLETED PROJECT
BINA MASYHUR has completed various road rehabilitation projects using CIPR
method and stabilization with cement over the past year including:
i. Felda Route FT 1279, Negeri Sembilan in 2005, - 1.0 km
ii. Felda Route FT 1419, Negeri Johor in 2005, - 1.0 km
iii. Felda Route FT 009, Negeri Sembilan in 2005, - 22.0 km
iv. Federal Route FT 091, Negeri Johor in 2006, - 7.0 km
v. Felda Route FT 1283, FT 1271 & FT 1270, Negeri Sembilan in
2006, - 16.6 km
vi. Jalan Pekeliling, Pasir Gudang in 2007 – 10.0 km
vii. Lebuhraya Pasir Gudang FT 017 in 2007 – 6.0 km
viii. Federal Route FT 005, Rengit Johor in 2007 – 1.0 km
ix. Federal Route FT 092, Desaru in 2008 – 4.0 km
x. Felda Jelai, Negeri sembilan in 2008 – 1.0 km