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ROADCARE (M) SDN BHD
COLD IN-PLACE RECYCLINGTECHNOLOGY
By:
Muhamad Radzif
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Cold In-place Recycling (CIPR)
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COLD IN-PLACE RECYCLING
(CIPR)
In this technique, the recycling machine scarifies
the existing pavement layers, to maximum depth of
350mm, then adds either cement or bituminousmaterials or both as stabilizing additives before
relaying it back on the same pavement area in a
single process. CIPR provides a more cost-effective alternative to pavement rehabilitation that
requires partial or total reconstruction .
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BACKGROUND OF CIPR
Pavement Recycling has been used in Malaysia since 28
years ago
1985 - Rehabilitation of FT02 between Kuala Lumpur and
Kuantan (Temerloh) 1988 - FT 08 between Pagar Sasak and Merapoh, Pahang
using cement as a stabilising agent
2002Jalan Felda Bukit Sagu in Pahang (Foamed bitumen)
Until now more than 300 km length of CIPR projects weresuccessfully completed by HCM and Roadcare in Malaysia
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COLD IN-PLACE RECYCLING
(CIPR)
RESEARCH PROGRAM
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RESEARCH PROGRAM
The research program on Full Depth Reclamation (FDR) was
initiated in 2004 and completed in 2012.
Collaboration between the Public Works Department andKumpulan IKRAM Sdn. Bhd.
The research activities involved site construction, field test,laboratory test and simulation test.
Four stabilizing agents namely cement, lime, emulsion andfoamed asphalt are employed in this research.
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RESEARCH PROGRAM
This research aims to find out the fundamental properties of
stabilized reclaimed pavement obtained through the FullDepth Reclamation (FDR) technique and the most cost
effective stabilization technique for reclaimed pavement.
The results from this research are used to predict theperformance of FDR pavements in Malaysia.
A guideline on the design and construction of FDR pavement
will be produced based on the results of this research.
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CIPR WHERE TO USE?
Severe Crocodile Cracks
Rutting or Deformation
Pumping
MAJOR DISTRESSStructural failure
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CIPR WHERE TO USE?
BLOCK CRACKING
INSUFFICIENT PAVEMENT STRUCTURE
DEEP RUTTING or DEFORMATION
SEVERE CRACKS AND POTHOLE
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MATERIALS
Materials used in CIPR
Existing pavement material
Imported pavement material(where required)
Stabilising agents
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MATERIALS
Stabilising agents used in CIPR
Cement
Emulsion (QS3E)
Foamed Bitumen
Other additives
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COLD IN-PLACE RECYCLING
(CIPR)
PAVEMENT EVALUATION,DESIGN AND COST ANALYSIS
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PAVEMENT EVALUATION
Data Collection / Testing
Analysis
Design
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PROCESS OF
PAVEMENT
EVALUATION
Comprehensive
Analysis
D or ND Test S.C.S. Laboratory test
Analysis of Data
Identify Primary
Modes of Distress
Implementation
Economy?
Suitability?
Treatment Method
PENDOSOutput
NO
OK
PAVEMENTEVALUATION
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PAVEMENT EVALUATION
-FWD
-Testpit
-Coring/DCP
-Axle load study
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PAVEMENT DESIGN
Empirical Componen Analysis using
Arahan Teknik Jalan 5/85 as a guideline
Mechanistic analysis method using software
Rubicon
Mix design using samples taken from test
pit at site
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COLD IN-PLACE RECYCLING
(Cement)
Proposed Design Conventional Design
40 mm ACWC(overlay)
160 mmACBC
CIPR- Cement
Partial
Reconstruction(Remove Asphalt layer)
340 mm
200mmCIPR
(cement)
300 mm
50mm ACWC
+ 60mm ACBC
(overlay)
Sub-gradelayer
Design Comparison
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COLD IN PLACE RECYCLING
(CIPR - with Cement)
Cost Analysis* Unit Rate used in cost analysis
Asphaltic Concrete Wearing Course (ACWC20)
Asphaltic Concrete Binder Course (ACBC28)
Prime Coat
Tack Coat
Milling existing asphalt layers not exceeding 150mm
depth
Cold In-Place Recycling (CIPR) not exceeding 200mm
depth using 4% cement (CTB)
Description of Works UnitRate
(RM)
cu.m
cu.m
sq.m
sq.m
sq.m
sq.m
657.14
636.57
17.40
20.90
1.76
1.65
* Based on schedule of rates for road maintenance in Peninsular Malaysia
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COLD IN PLACE RECYCLING
(CIPR - with Cement)
Cost AnalysisConventional Design(Mill and Pave)
Cost/m(RM)40mm ACWC (overlay)
Milling 150mm Deep
=
17.4080mm ACBC
Prime Coat = 1.7680mm ACBC
ACBC 160mm = 101.85
Tack Coat (2layers) = 3.30
ACWC 40mm (overlay)
=
26.27
Cost per sq.m = RM 150.58
Existing Road Base
Sub base
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COLD IN PLACE RECYCLING
(CIPR - with Cement)
Cost/m(RM)
50mm ACWC (overlay)
Recycle 200mm with4 % Cement
= 20.9060mm ACBC
Prime Coat = 1.76
ACBC 60mm = 38.19
Tack Coat (1 layers)
=
1.65
200mm Recycle
ACWC 50mm (overlay) = 32.85
Cost per sq.m = RM 95.35
Existing Road Base
Sub base
Proposed Design(Cement Treated base)
(overlay)
Cost Analysis
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Existing Pavement
Structure
Conventional Design
(Partial Reconstruction-Remove Asphalt Layer)
50 mm ACWC(overlay)
Sub-gradelayer
150 mmACBC
150 mmAsphalt
RoadBase
350 mm
Cost per m2= RM 95.35
350 mm
200mmCIPR
(cement)
300 mm
Proposed Design
(CIPR-Cement)
50mm ACWC
+ 60mm ACBC
(overlay)
Required overlay 135mm
Mill and replace150 mm
COST COMPARISON
(Structural Component Analysis)
Cost per m2= RM 150.58
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COLD IN-PLACE RECYCLING
(CIPR)
CONSTRUCTION
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COLD IN-PLACE RECYCLING
(Cement)
OR
TRAIN ARRANGEMENT
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COLD IN-PLACE RECYCLING
(Cement)
TYPICAL TYPE OF RECYCLER
RECYCLER WITH
TAMPING SCREED
RECYCLER WITHOUT
TAMPING SCREED
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COLD IN-PLACE RECYCLING
(Cement)
TYPICAL TYPE OF RECYCLERDirect Injection of Cement
Using WM1000 (Slurry)
At Pasir Puteh Kelantan
Manually Spread
Mechanical Spreader
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COLD IN-PLACE RECYCLING
(Cement)PLACING THE RECYCLED MATERIAL &
COMPACTION
PLACING THE RECYCLED MATERIAL
INITIAL COMPACTION
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COLD IN-PLACE RECYCLING
(Cement)
TRIMMING & COMPACTION
TRIMMING (if necessary)
FINAL COMPACTION
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COLD IN-PLACE RECYCLING (Lime)
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COLD IN-PLACE RECYCLING
(Foamed Bitumen)
OR
TRAIN ARRANGEMENT
COLD IN PLACE RECYCLING
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COLD IN-PLACE RECYCLING
(Foamed Bitumen)
COLD IN PLACE RECYCLING
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COLD IN-PLACE RECYCLING
(Foamed Bitumen)
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COLD IN-PLACE RECYCLING
(Emulsion)
TRAIN ARRANGEMENT
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COLD IN-PLACE RECYCLING
(Emulsion)
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COLD IN-PLACE RECYCLING
(CIPR)
QUALITY CONTROL
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To ensure final product conforms to
specification
Test include
Measurement of relevant strength (Resilient
Modulus, ITS, UCS)
Field density test
Measurement of layer thickness
QUALITY CONTROL
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Field Test
Prepare of Sample
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Testing
Field Density Test in progress tocheck degree of compaction
Strength of material test
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Unconfined Compressive Strength Test (UCS)
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QUALITY CONTROLGeneral Requirements for Cold Recycling
No. Parameters Test Method Requirements
1. Field
Compaction
REAM-SP 1/2005
Clause 1.5.3 Table 1.8,
BS 1377 (Sand
Replacement Method)
a) 95% for natural gravel /
crushed aggregates.
b) 97% for mixture of
crushed aggregates andRecycled Asphalt
Pavement (RAP)
c) 98% for RAP of Job
Standard Mixture (JSM)2. Cement
Application Rate
REAM-SP 1/2005
Clause 1.5.3 Table 1.8
10% of target rate
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QUALITY CONTROLRequirements for Cement Stabilised Cold
In-Place Recycled Layer Material
Parameter Requirement
Unconfined Compression
Test (UCS), in accordance
with B.S 1881, part 116. 7-
day strength, moist curing@ 25oC, height/width 1:1
Minimum 97%
of Mod.
AASHTO
density
Range (MPa)
(minimum and
maximum limits)
25
Indirect tensile test (ITS)
on 150mm diameter
briquette cured as for UCS
specimens, in accordancewith AASHTO T-198
Minimum 97%
of Mod.
AASHTO
density
Minimum (MPa) 0.2
Maximum cement content by weight 5%
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QUALITY CONTROLRequirements for Bitumen Emulsion Treated
Cold In-Place Recycled Layer Material
Parameter Requirement
Unconfined Compression Test (UCS), in
accordance with B.S 1881, part 116. 7-day
strength, moist curing @ 25oC,
height/width 1:1
Minimum 97% of
Mod. AASHTO
density
0.7
Indirect tensile test (ITS) on 100mm
diameter briquette cured at 40oC for 72
hours, in accordance with AASHTO T-198
Marshall
compaction (75
blows per side)0.2
Indirect tensile test (ITS) on curedbriquettes soaked for 24 hours as above
Marshallcompaction (75
blows per side)
0.15
Minimum Tensile Strength Retained (TSR) 75%
Maximum added cement content by weight 2%
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QUALITY CONTROLRequirements for Foamed Bitumen Treated Cold
In-Place Recycled Layer Material
Parameter
Minimum
Strength
(MPa)
Unconfined Compression Test (UCS), in
accordance with B.S 1881, part 116. 7-day
strength, moist curing @ 25oC,
height/width 1:1
Minimum 97% of
Mod. AASHTO
density 0.7
Indirect tensile test (ITS) on 100mm
diameter briquette cured at 40oC for 72
hours, in accordance with AASHTO T-198
Marshall
compaction (75
blows per side)0.2
Indirect tensile test (ITS) on cured
briquettes soaked for 24 hours as above
Marshall
compaction (75
blows per side)
0.15
Minimum Tensile Strength Retained (TSR) 75%
Maximum added cement content by weight 2%
COLD IN PLACE RECYCLING
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COLD IN-PLACE RECYCLING
(CIPR)
Advantages1. Faster and more efficient as minimal excavation and dump
trucks required;
2. Reused of existing materials and reduces new construction
materials and transport cost;3. The technique can give equivalent pavement structure
condition and cost saving compare with conventional method;
4. Increases the shear strength and reduces the moisture
susceptibility of granular materials;5. Flexible and fatigue resistant (Foamed Bitumen and
Emulsion);
6. Cost savings with approximately 25% - 55%.
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Advantages
7. Consistent Mixing
8. Precise control of layer thickness.
9. Less reliance on fine weather conditions.
10. Greatly reduced traffic disruption and improved safety
COLD IN-PLACE RECYCLING
(CIPR)
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COLD IN PLACE RECYCLING
(CIPR)
Disadvantages1. Doesnt solve problems with base course or subgrade
2. Material and construction variation is greater than for
conventional rehabilitation techniques.
3. The CIPR mixture need to be cured for a period of time inorder to gain strength.
4. Difficulty of controlling the density during works.
COLD IN PLACE RECYCLING PROCESS
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Before Construction During Construction
After Construction
COLD IN PLACE RECYCLING PROCESS
COLD IN PLACE RECYCLING IN PROGRESS
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COLD IN PLACE RECYCLING IN PROGRESS
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THANK YOU