Evergreen Sustainable PavementsTM Producing High Quality Sustainable Asphalt Pavements 100% Asphalt Reclamation
Total Asphalt Pavement Reclamation A Fiscally Responsible and Environmentally Sound System for Reducing Highway and Road Resurfacing Costs Evergreen Sustainable PavementsTM
Economic Benefits Provides sustainable pavement. Asphalt materials contained in our roads is our nation s most valuable asset. It is 100% reclaimable and can be recycled over and over again! Reduces roadway maintenance costs! Stabilizes project costs. Reduces dependence on foreign oil. Eliminates need of costly virgin aggregates.
Environmental Benefits A Green Perspective 100% asphalt pavement reclamation is a tremendous Green opportunity. 90% of our roads and highways are asphalt. Asphalt roads and highways are 100% reclaimable. Asphalt pavement contains high quality aggregates that do not lose their original properties. Natural resources are preserved by extending the life of quarries which are non-renewable! Promotes clean air and energy savings Significantly reduces greenhouse gas emissions and carbon footprint. Complete reclamation of these valuable resources produces new high quality asphalt pavement (HMA).
An Industry Perspective Why has there been such a cost increase in liquid asphalt cement? Oil refining techniques used in the production of liquid asphalt continually change. More of the heavy crude oil formerly extracted for asphalt cement (A.C.) is now used for more valuable products such as gasoline, plastics, etc., due to new refining technologies. Supplemental polymers can be blended in at added cost to replace the qualities extracted. World-wide demand from various countries effect cost and availability. All of the above - further reasons for total reclamation!
Reasons 100% asphalt reclamation should become a regular practice: Asphalt Cement (AC) found in older pavement actually contains higher quality AC than most liquid binders available from asphalt refiners today. Milling pavement surfaces prior to resurfacing is common practice today in road resurfacing. Valuable asphalt millings (RAP) are available and plentiful. 60% or more of the generated RAP is currently either 1) discarded, 2) stockpiled, or 3) used for lesser economic value. The value of RAP generally speaking is currently wasted. New processing methods now enable 100% reclamation of the valuable millings true sustainability!
Evergreen Sustainable PavementsTM Presenting a 100% Pavement Reclamation Program For Future Roadway Maintenance Plans The SMART Pave System www.smartpavesystem.com Defining Green Technology
How does the SMART Pave System work? When asphalt pavement has reached the end of its useful life due to cracking and shoving, the surface is milled off by conventional means.
SMART Pave System Step One The reclaimed asphalt pavement (RAP) is analyzed for composition qualities. Binder is analyzed for PG properties. Regional Properties may be used in this analysis. Generally, a very small percentage of rejuvenator agent is introduced to adjust the binder to the desired PG grade. This also provides full replenishment of any oxidized asphaltenes, returning the asphalt cement to its original characteristics.
SMART Pave System If the existing milled composition comes from a known source and meets specification gradation as is, no further RAP preprocessing is necessary. Steps Two and Three are not required and we can go directly to Step Four, heating the material.
SMART Pave System Step Two If the milled RAP does not meet gradation specification qualities as is from a specific project site, or if the RAP originates from different specification sources, it is necessary to screen or fractionate the material back to original gradations. The varied gradations of RAP are stockpiled to be fed into the cold feed bins.
SMART Pave System The valuable RAP will be the primary ingredient in the new HMA produced. If the milled composition requires gradation adjustment to meet specific requirements, a predetermined percentage of virgin stone aggregate is added prior to the mix being heated.
SMART Pave System Step Three The variable sized RAP along with any virgin aggregates, which may be added to meet desired gradation specifications, are introduced in the correct proportion into the new mix by a metered cold feed system.
SMART Pave System Step Four A drum plant specifically designed for processing RAP is used for heating 100% reclaimed asphalt or any reclaimed-virgin blend mix. Asphalt Warm Mix comprised of 100% reclaimed asphalt can also be produced with this plant. Rapmaster processor
SMART Pave System Step Five Once the reclaimed material has been fully processed, the HMA is conveyed into silo storage awaiting discharge into trucks for transport to the jobsite.
Step Six SMART Pave System At the jobsite, the HMA is sta transferred se edtot the roadway by the pavement laydown crew.
SMART Pave System The 100% reclaimed HMA pavement is equal to or better in quality and performance than HMA made from new virgin materials and is handled in the same manner.
COMPARISON AFTER 9-YEARS Tinkham Rd., Springfield, MA Left Side 100% RAP Tinkham Rd. Springfield, MA after 5-years Mix Right Side Virgin Mix Left Lane Right Lane 100% Reclaimed Asphalt Virgin Mix
Tinkham Rd., Springfield, MA Left Lane Tinkham Rd., Springfield, MA after 5-years Right Lane Virgin Mix 100% Reclaimed Asphalt Left Side Virgin Mix Right Side 100% RAP Mix
Left Lane Tinkham Rd., Springfield, MA Right Lane Tinkham Rd., Springfield, MA after 5-years 100% Reclaimed Left Side 100% Asphalt RAP Mix Right Side Virgin Virgin Mix Mix
Left Lane Tinkham Rd., Springfield, MA Tinkham Rd., Springfield, MA after 5-years Left Side 100% RAP Mix Right Side Virgin Mix Right Lane 100% Reclaimed Asphalt Virgin Mix
The SMART Pave System can work well in both metropolitan and suburban areas. Metropolitan Areas Milled RAP is reclaimed from the street being repaved and trucked to the stationary plant site for processing. The newly reclaimed HMA is then returned to the jobsite for paving. Suburban Areas Milled RAP from various locations within a geographical region is reclaimed and brought to a central location for temporary storage until a substantial stockpile of RAP is accumulated. A transportable Rapmaster processor is brought to the site for processing the material into new HMA.
A Typical Batch Plant Operation 20% Recycling Capability (All calculations based upon 100,000 tons HMA produced Virgin Disposed or Reclaimed Truck Loads Material Stockpiled Asphalt Required @ Added Millings(RAP) Pavement (RAP 20 -Tons ea. Virgin 76,000 Tons 80,000 Tons 20,000 Tons 8,800 Stone New Asphalt Cement (A.C.) 4,000 Tons 200 TOTALS 80,000 Tons 80,000 Tons 20,000 Tons 9,000 Total 80% Virgin 20% Reclaimed Truck Loads
A Typical Drum-Mix Plant Operation 35% Recycling Capability (All calculations based upon 100,000 tons HMA produced) Virgin Material Disposed or Stockpiled Millings (RAP) Recycled Asphalt Pavement (RAP) Truck Loads Required @ 20 -Tons ea. Virgin 61,250 Tons 65,000 Tons 35,000 Tons 8,062 Stone New Asphalt 3,750 Tons 188 Cement (A.C.) TOTALS 65,000 Tons 65,000 Tons 35,000 Tons 8,250 Total 65% Virgin 35% Reclaimed Truck Loads
SMART Pave System 100% Reclamation (All calculations based upon 100,000 tons HMA produced) Virgin i stone only added d if an aggregate deficiency i is found in the millings. Virgin Disposed or Reclaimed Truck loads Material Stockpiled Asphalt Required@ Millings (RAP) Pavement (RAP) 20 Tons ea. Rejuvenator Agent (1.2%) Reclaimed Asphalt Pavement 1,200 Tons 60 100,000 Tons 5,000 TOTALS: 1,200 Tons 0 Tons 100,000 Tons 5,060 Total 1.2% Virgin 100% Reclaimed Truck Loads
Energy Comparison Drum-Mix Asphalt Plant 35% Reclaimed 20 Fuel Consumption Points 65% Virgin Aggregate Portion Drilling rock in quarry Loading shot rock on trucks Truck shot rock to crusher Crusher / rock processing Screening plant Trucking stone to asphalt plant Stockpiling at asphalt plant Loader feeding aggregate to asphalt plant Asphalt plant processing 35% Reclaimed Asphalt Pavement (RAP) Portion Miller / Milling roadway Trucking RAP to asphalt plant Loader stockpiling Rap Loader feeds Crusher / Screener Screening / Processing Convey sized and stockpiled RAP aggregate Loader feeds Rap aggregate Asphalt plant processing Trucking to job site Paving Rolling 65% of the milled RAP is put into storage which creates ever-increasing stockpiles of valuable reusable RAP.
Energy Comparison SMART Pave System 100% Reclamation 10 Fuel Consumption Points. Fuel consumption approximately 50% less! Miller / Milling roadway Trucking Rap to asphalt plant Loader stockpiling RAP Loader feeds crusher screener Fractionating / Screening / Processing Loader feeds RAP aggregate Rapmaster Processor Trucking Paving Rolling Based upon 550 million tons of HMA produced annually nationwide, using the SMART Pave System vs. a typical 35% drum-mix plant would eliminate i the consumption of 418,000,000 gallons of fuel oil and 3,993,000,000 gallons of liquid A.C. Less dependence on foreign oil!
Taking LEED Steps Leadership in Energy and Environmental Design The U.S. Green Building Council s Leadership in Energy and Environmental Design applies to asphalt pavement as well.
Taking LEED Steps 100% Asphalt Pavement Reclamation meets green practices in road building by: Producing Sustainable Pavement Recycling of Materials and Resources Implementing an Innovative Process Method
Taking LEED Steps Producing Sustainable Pavement Through the proper analysis of the RAP millings composition and the addition* of any virgin ingredients, the SMART Pave System reclaims the material and produces new HMA of equal to or better quality and performance than HMA produced primarily with virgin ingredients. gede * Virgin stone only added if an aggregate deficiency is found in the millings.
Taking LEED Steps Recycling Materials and Resources The need for virgin stone is either minimized or eliminated. This protects our natural resources and extends existing quarry life. Through total reclamation of asphalt pavement millings, disposal of excess material is virtually eliminated. The SMART Pave System recycles/reclaims 100% of the milled pavement!
Taking LEED Steps Innovative Process Method Through indirect heating of the material, the Rapmaster processing plant used in the SMART Pave System is capable of 100% reclamation of asphalt pavement. The processing plant has a dedicated combustion chamber that collects and incinerates any blue smoke by-product created. The final plant exhaust is virtually crystal clear. This meets all air quality standards and promotes a Reduced Carbon Footprint. Reclaiming materials already in place diminishes overall fuel consumption for material transport. This is reflected in the reduced truck load requirements noted in the method comparison charts.
Evergreen Sustainable PavementsTM THE SMART Pave System COST EFFECTIVE CLEAN EFFICIENT
Our Evergreen Commitment Evergreen is committed to provide you a highly efficient and cost effective state-of-the-art sustainable asphalt maintenance program. Through implementing the SMART Pave System of maximized recycling by reclaiming your extremely valuable road millings, maintenance costs can be substantially ti reduced d now and stabilized into the foreseeable future. The Evergreen Team is prepared to review your pavement maintenance goals and present a cost effective program to meet your needs. Evergreen Sustainable PavementsTM (800) 531-7771 www.smartpavesystem.com U.S. Patents 5,294,062, 5,520,342, 7,669,792 B1, Patents Pending