At the California Asphalt Pavement Association (CalAPA) Fall Asphalt Pavement Conference held Oct. 27, 2022 in Sacramento, a presentation titled, "Using Existing Roadway Materials for Pavement Rehabilitation" was delivered by Allen King P.E., Senior Transportation Engineer – Caltrans; Frank Farshidi P.E., Division Manager – City of San Jose; Marco Estrada, Division Manager, Pavement Recycling Systems; Dennis McElroy, FMG Division Manager – Graniterock. Noted experts will share their field experiences and provide the best practices to maximize the use of on-site materials for pavement rehabilitation.

1. Dennis McElroy
Estimating & Business Development – Recycling Group, Graniterock
President – RSA, Recycling Industry Member ATG Caltrans PMPC Program
Noted experts will share their field experiences and provide the best practices to
maximize the use of on-site materials for pavement rehabilitation.
Using Existing Roadway Materials for
Pavement Rehabilitation

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3. © 2018 Graniterock and/or its affiliates. All rights reserved.
• Pavement rehab cost saving techniques.
• In-place recycling uses the material that we
already paid for. 100% RAP products.
• Binder and aggregates are a non-renewable
resource. When they are gone they are gone.
As scarcity increases then cost increases.
• We’re experiencing a major shift in how
owners need to approach the work. These
methods are the first strategy to consider.
3
Why Are We Here?

4. © 2018 Graniterock and/or its affiliates. All rights reserved.
Map Sheet 52 (2018)
Aggregate
Sustainability in
California

5. © 2018 Graniterock and/or its affiliates. All rights reserved.
Why Recycle?
✓ Proven technology with a range of strategies to suit most
rehabilitation challenges
✓ More sustainable if designed and constructed correctly
✓ Uses all existing, paid for materials
✓ Requires limited new materials
✓ Minimizes trucking operations
✓ Shorter construction time, less traffic disruption
✓ Cost effective / lower life-cycle cost
✓ Removes distresses instead of covering them
✓ Selected strategies enhance structural capacity
✓ Extended pavement life
✓ Recycled roads can be recycled again
✓ Specifications / nSSPs are already in place
#urbanquarry

6. © 2018 Graniterock and/or its affiliates. All rights reserved.
© 2018 Graniterock and/or its affiliates. All rights reserved.
Cold Central
Plant Recycling
(CCPR)
Partial Depth
Recycling
(PDR)
Full Depth
Recycling
(FDR)

7. © 2018 Graniterock and/or its affiliates. All rights reserved.
Pavement Deterioration Curve
CCPR
CCPR

8. Top-Down Distresses in AC Layers
Mill & Overlay
or
Surface Maintenance

9. Top-Down Distresses in AC Layers
• Use Partial Depth Recycling (PDR) or Cold Central Plant
Recycling (CCPR)
Recycled

10. Bottom-Up Distresses in Pavement Layers
• Distresses originating from base
• Use Full Depth Recycling (FDR)

11. FDR Construction Sequencing

12. Bottom-Up Distresses from Subgrade
• Mill surface + base, stabilize subgrade with cement and/or lime,
then place CCPR layer, then place wearing course.
Recycled
Stabilized

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A Few Things
• Owner, Consultant &
Industry need to be focused
on partnership & working
together
“Ounce of prevention
is worth a pound of
cure”
• Project site investigations
need to be done during
design. Lowers Cost.
• Don’t overdesign the
pavement structure. Get
better traffic data.
• Owners need to be proactive
in updating their
specifications. Lowers Cost.
We can help.
• Focus on training staff – high
turnover is a problem
• RSA is doing their part to be
a solution by actively
educating throughout the
industry.
• We can do workshops or talk
about specific projects you
have in currently in design.
• These processes are not
new. Used worldwide.
• They work.
• We’re beyond the research
phase.
• Environmentally less impact
than alternatives. It’s 100%
RAP
• Cost Effective (15% - 40%
lower than alternatives)
• Shortens Construction Time
1. 2. 3.

14. rsa-california.com
#urbanquarry
dmcelroy@graniterock.com
Cell: 408-639-8063
Dennis McElroy

15. Cold Recycling
Presented by:
Allen King, PE
Senior Transportation Engineer
Division of Maintenance
October 2022

16. Cold Recycling within Caltrans
• Updated terminology
• Updating FDR SSs
• Updated PDR nSSPs
• Created CCPR nSSPs
• Current working groups
• Completed construction for 3 pilot
projects and others currently in
construction
• 2021/2022 SB-1 report
• Initiative to report efficiencies and GHG
Reference Document

17. 17
Cold RecyclingTerminology within Caltrans

18. •Updated PDR nSSPs
•Created CCPR nSSPs
•Current working group to
update FDR-C test methods and
specifications and examine PLC
in FDR-C
•Upcoming working group to
update FDR-FA specifications
18
Caltrans Specifications

19. •Updated the 10-year-old PDR
nSSP
•Reflects recent advancements in
equipment and testing
•Streamlined specifications to
decrease cost and increase
usage of PDR
19
Partial Depth Recycling (PDR) nSSP

20. • Completed final draft for CCPR nSSP, CT 316, and
MPQP
• CCPR can be used on projects that are far away
from asphalt plants to reduce costs, greenhouse
gas (GHG) emissions, and construction-related
trucking of materials.
• Specifications are developed based on the
merged foamed asphalt and emulsified asphalt
PDR specifications and modified to reflect
variations in construction methodology,
application, and end-product capabilities of
CCPR.
• Promote more recycling strategies as directed by
SB1.
20
Cold Central Plant Recycling (CCPR) nSSP

21. CO RTE Project Name Status
GLE 162
Partial Depth Recycling with
Foamed Asphalt (PDR-FA) and
Additional Fines
Constructed
SB 135
Partial Depth Recycling with
Emulsified Asphalt (PDR-EA) vs.
Partial Depth Recycling with
Foamed Asphalt (PDR-FA)
Constructed
SBD 2
Partial Depth Recycling with
Emulsified Asphalt (PDR-EA)
Gradations
Constructed
IMP 78 High Rubber Content PDR
In
Construction
21
PDR Pilot Projects
GLE-162 PDR Pilot Project

22. CO RTE Project Name Status
SBD 18
Piloting CCPR
specifications
Upcoming
TUL 63
Piloting CCPR
specifications
Upcoming
22
CCPR Pilot Projects

23. “To the extent possible and cost effective, and where feasible, the
department and cities and counties receiving funds under the program shall
use advanced technologies and material recycling techniques that reduce
the cost of maintaining and rehabilitating the streets and highways, and that
exhibit reduced levels of greenhouse gas emissions through material choice
and construction method”
23
Senate Bill 1

24. Reduce statewide greenhouse gas emissions to 40% below the 1990
level by 2030.
24
Reducing GHGs

25. •Calls for a strong action to develop and
implement sustainable practices to reduce
greenhouse gas emissions from material
production, transportation and
construction operations in constructing
Caltrans projects.
25
Caltrans 2020-2024 Strategic Plan
Goal: Lead Climate Action
(PhotoSource:Caltrans 2020-2024Strategic Plan)

26. •Senate Bill 1, the Road Repair and Accountability Act of 2017,
was signed into law on April 28, 2017.
•This legislative package invests $5.4 billion per year to fix
roads, freeways and bridges in communities across California
and puts more dollars toward transit and safety.
•The legislation also requires that Caltrans report efficiency
savings to the California Transportation Commission annually
•As defined by SB-1, efficiency results in cost avoidance or a
reduction in support or capital costs
26
Senate Bill 1 Efficiency Reporting

27. SB-1 Reported PDR Cost Savings
FY 19/20
• 6 projects – 86 lane miles of paving
• Approximate cost savings of $2 million
FY 20/21
• 9 projects – 205 lane miles of paving
• Approximate cost savings of $7 million
FY 21/22
• 5 projects – 75 lane miles of paving
• Approximate cost savings of $1.2 million
The Office of Asphalt Pavements began reporting Cold Recycling efficiency savings starting
in FY 19/20

28. •100+ PDR projects constructed since
2007
• Over 12 million SQYD of paving
• 1730 lane miles of PDR paving
•26 FDR projects constructed since
2001
• Over 3 million SQYD of paving
• 450 lane miles of paving
28
Past Recycling Numbers

29. Recent Recycling Numbers
Fiscal Year
PDR Projects FDR Projects
No. of Projects
Total Lane
Miles
No. of Projects
Total Lane
Miles
FY 17/18 5 78 2 15.1
FY 18/19 5 60 3 103.7
FY 19/20 6 86 0 0
FY 20/21 9 205 1 1
FY 21/22 6 75.48 2 22.5

30. 30
Same Info in Graph Form
FY
17/18
FY
18/19
FY
19/20
FY
20/21
FY
21/22
PDR 78 60 86 205 75.48
FDR 15.1 103.7 0 1 22.5
0
50
100
150
200
250
Lane
Miles
Paved
Fiscal Year

31. • Less IPR programmed and
constructed the past fiscal year
compared to the previous year
• Only $1.2 million savings for FY 21/22
• FY 20/21 reported $7 million in
savings
• Overdesigned cold recycling projects
= less $$ savings
• Overdesigned cold recycling projects
= less GHG savings
• Don’t overdesign road due to
concern that pavement won’t
perform
31
SB-1 Reported PDR Cost Savings Lessons Learned
FY 19/20 FY 20/21 FY 21/22
GHG
Savings
(MT CO2-eq)
3,350 9,525 3,549
Equivalent
Gallons of
Gas Saved
376,991 1,071,804 399,312
Equivalent
Miles of
Driving
Saved
12,566 35,727 13,310
*Note:This is Cradle to Gate (Materials Only).A full
LCA is cradle to grave.

32. • Completed a 2-day statewide training in
November 2020 on IPR technologies
• Collaboration with Industry and
Academia
• Over 150 Caltrans attendees
• Updated specifications to reflect the latest
construction practices and technologies
• Provided additional funds for cold recycling
pilot projects, such as CCPR
• Assisted Districts at different project stages
such as site investigation, design, and
construction phase
32
Past:
What We’ve Done to Encourage Cold Recycling
Site Investigation
Design
Construction

33. • Encourage the use of sustainable practices
such as cold recycling, high RAP, and RAS
• Sustainability is a collective Caltrans-wide
effort – Pavement Program, METS,
Construction
• New pavement sustainability team
• New pavement sustainability webpage
• Resources, technologies, savings
reporting
• New pavement sustainability coordinator
33
Present:
Current Caltrans Pavement Sustainability Efforts
• Concrete
• Asphalt
Pavement
Program
Sustainability
• Programming
• Management

34. •Increase pavement sustainability efforts
•Continue evaluation and data-driven
updates of specifications
•Increase the use of sustainable practices
such as recycling
•Exploring new materials
•Upcoming Caltrans Trainings
34
Future:
Moving Forward

35. Questions?

36. Cold-in-Place Recycling Foamed
Asphalt Technology in San Jose
Frank Farshidi, Ph.D., P.E.
Division Manager, City of San Jose-DOT

37. Pavement Condition Overview
Street Network Miles 2019 PCI 2020 PCI
Major 944 75 75
Local/Neighborhood 1,490 60 60
Combined 2,434 66 66

38. CIR-foam in action in San Jose

39. Recycling Train

40. Spreading cement (1%) ahead of train

41. Compaction and finished surface
Compaction
Finished surface

42. Historical CIR in San Jose
YEAR Lane Miles Square Yards
2014
20.6 144,848
2015
46.5 327,888
2016
45.2 318,560
2017
32.3 227,392
2018
37.5 263,472
2019
20 141,379
2020
95 671,304
2021
43.5 305,562
TOTAL
341 2,400,405

43. Our usage over time

44. Carbon Reduction by using CIR (2014-2021)
• 80% GHG reduction compared to alternative Mill and
Fill and other conventional methods
• 78% Energy Savings compared to alternative methods
• Equivalent to taking 3,232 cars off of streets per year
• Energy savings to supply 4,914 homes with electricity
for an entire year

45. Why do we use CIR-foam?
• Environmentally-friendly: 100% Recycled material in
place
• Significant reduction in truck traffic during construction
• Increased durability and better performance in the field
• Increased resistance to cracking and resolving problems
at its root cause
• Cost effective approach both initially and over life cycle
of pavement life
• Quick opening of traffic daily

46. Why foamed technology?
Flexibility of asphalt binder (2-2.75%) and stiffness of
cement (1%)

47. What streets do we treat with CIR-foam?
• Major streets: Arterial and collectors with high traffic volumes
• Streets in fair conditions: 25<PCI<60 with sever block cracks,
longitudinal cracks, and HMA layers greater than 5 inches
• Typical thickness: 4 inches of existing HMA
• Pavement structure:
– Cold-in-Place Recycling combined with RHMA overlay
(1.5 to 2 inches)
– CIR combined with conventional HMA (1.5 to 2 inches)

48. A Typical street selected for CIR

49. How do we do ensure materials/workmanship quality?
• ITS soaked must be great than 95% of min design strength
(300 kPa)
• In-place density: Min 98% of max wet density as measured by
CTM 216.
• Pay factors for both ITS Wet and in-place Density for each
2500 linear feet long lots.
• Remove and replace by AC
– Below 90% of ITS wet
– Below 94% of relative compaction as measured by 216

50. Constraints with using CIR-foam
• Requires minimum of HMA thickness of 4-5 inches
• Clearance height
• Proper Ambient temperature for good curing
Sustainability and longer lasting life outweighs the
constraints

51. Lessons Learned & Keys to successful projects
• Simple QC/QA specification of materials
• Focused approach to control field/construction varibilities
• Incentive/disincentive pay factors on key performance
parameters: ITS wet and in-place density
• Trained personnel and staff

52. Questions!
CIR-Foam in San Jose

53. Full-Depth Recycling (FDR)
Versatility in Sustainability
October 28th, 2022

54. Sustainability – Truck Trip Reduction
40:1
Replacement
Less Fuel
Less Damage

55. URBAN QUARRY
Asphalt
Aggregate Base
Subgrade

56. What is FDR?
Full-depth reclamation is an engineered
pavement rehabilitation method that recycles the
existing asphalt and its underlying layer(s),
blends the materials with a stabilizing agent, and
creates a new stronger, more homogenous base
layer that is a part of the structural pavement
section.

57. Benefits of FDR
• Improves Project Safety
• Lowers Construction Costs
• Reduces Community Impacts
• Shortens Construction Time
• Reduces Carbon Footprint –
Sustainability
• Reduces Impact on Surrounding
Pavement Infrastructure

58. Major Streets

59. Residential Streets

60. Caltrans FDR-Foamed Asphalt/Cement

61. County
Roads

62. Rural & Mountain Roads

63. Parking Lot Reconstruction

64. Homeowner’s
Associations

65. Airfield
Pavement
Applications

66. School Yards & Parking Lots

67. City of Industry: Arenth Avenue
CCPR over FDR Cement 2020
15-18” FDR Cement
2.5” AC/6.5” CCPR

68. Sustainable
Reconstruction
Versus
“Remove &
Replace”
• Cost savings of $500,000
• Reduced community impacts by
reducing construction schedule by 30%
• 900 trucks removed from project site
and community
• Fewer carbon emissions by 75%
• 5,864 tons of agency asphalt recycled
on-site
• 1,500 fewer barrels of oil used

69. Post-Bid
Value Engineering
(VECP)
• Engineering Based
• Correct Base or Subgrade
Failure
• Reduce Costs
• Reduce Construction Schedule
• Improve Project Safety
• Reduce GHG Emissions

70. 18
Same Old Thinking Same Old Results

71. Variety of Recycling Strategies (IPR)

72. State Approved Pavement Applications
Caltrans Specifications:
24-2: Lime Stabilized Soil
24-3: Cement Stabilized Soil
27-4: Cement Treated Base
30-3: FDR with Foamed Asphalt
30-4: FDR with Cement
30-5 NSSP: Partial-Depth Recycling (PDR)
30-X NSSP: Cold Central Plant Recycling (CCPR)
2018 GREENBOOK:
301-3.1 Soil Cement
301-3.3: Cement Treated Base
301-3.4: Cement Stabilized Pulverized Base
(CSPB)
301-3.5: Lime Treated Soil
**Cold In-Place Recycling
**Cold Central Plant Recycling
** Will be added into the next book edition

73. Quantifying In-place Recycling Impacts

74. Recycling Making Too Much Sense

75. Reduce Dependency &
Impacts of Construction-
Related Trucking

76. Marco A. Estrada (951) 205-6000
mestrada@pavementrecycling.com