CIPR Technology

8/10/2019 CIPR Technology

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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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(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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(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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(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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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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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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(CIPR)

CONSTRUCTION


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(Cement)

OR

TRAIN ARRANGEMENT


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(Cement)

TYPICAL TYPE OF RECYCLER

RECYCLER WITH

TAMPING SCREED

RECYCLER WITHOUT

TAMPING SCREED


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(Cement)

TYPICAL TYPE OF RECYCLERDirect Injection of Cement

Using WM1000 (Slurry)

At Pasir Puteh Kelantan

Manually Spread

Mechanical Spreader


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(Cement)PLACING THE RECYCLED MATERIAL &

COMPACTION

PLACING THE RECYCLED MATERIAL

INITIAL COMPACTION


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(Cement)

TRIMMING & COMPACTION

TRIMMING (if necessary)

FINAL COMPACTION


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COLD IN-PLACE RECYCLING (Lime)


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(Foamed Bitumen)

OR

TRAIN ARRANGEMENT



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(Foamed Bitumen)



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(Foamed Bitumen)


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(Emulsion)

TRAIN ARRANGEMENT


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(Emulsion)


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(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%



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(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


(CIPR)


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(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

CIPR Technology

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