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Jim DykesPresidentDykes Paving & Construction Inc.Atlanta, Georgia
Presented at:
The 3rd ASPHALT SHINGLE
RECYCLING FORUM
Why We Recycle
• Rising costs and increased restrictions Rising costs and increased restrictions for landfillsfor landfills
• 11million tons of shingle waste is 11million tons of shingle waste is produced each yearproduced each year
• Less than 5% of shingle waste is Less than 5% of shingle waste is recycledrecycled
Benefits to Recycling
• Shingles are composed of 20% to 40% Shingles are composed of 20% to 40% liquid ACliquid AC
• Fiber and polymers from shingles can add Fiber and polymers from shingles can add strength to mix designstrength to mix design
• Can be added to HMA to offset liquid AC Can be added to HMA to offset liquid AC costs or to create new mixescosts or to create new mixes
Bottom Line
• An available 11 million tons of shingle An available 11 million tons of shingle waste, containing 20% liquid ACwaste, containing 20% liquid AC
• 2.2 million tons of reclaimable liquid AC2.2 million tons of reclaimable liquid AC
• At $300.00 per ton that’s At $300.00 per ton that’s $660 million$660 million worth of liquid asphalt every yearworth of liquid asphalt every year
DO THE MATH!
The Process
DoubleDoubleDeckDeck
ScreenScreen
DoubleDoubleDeckDeck
ScreenScreen
HammerHammerMillMill
HammerHammerMillMill
PrimaryPrimaryShredderShredderPrimaryPrimary
ShredderShredder
ShingleShingle
WasteWaste
5/16” 5/16” MinusMinus
5/16” 5/16” to 3/4”to 3/4”
Closed Loop System
*Larger material is normally wasted as by product. However, we further process this material.
Sort and Prep
• Remove any unwanted trash from Remove any unwanted trash from shingles such as wood or metalshingles such as wood or metal
• Paper may stay on manufacturer Paper may stay on manufacturer rejectsrejects
Problems to Overcome
• Tear-offsTear-offs Intensive pre-processing More contamination than manufacturer rejects Smell from mold
• Environmental IssuesEnvironmental Issues Dust control E.P.A. regulations concerning stockpile locations and size.
Problems to Overcome
• Allocating spaceAllocating space Locations for equipment Covered or enclosed area to keep stockpile cool
• Crossing the economic barrierCrossing the economic barrier Most unsuccessful attempts to recycle and incorporate shingle
into mixes are due to improper sizing Best approach is to add the extra equipment necessary to
process shingle down to sufficient size
Equipment
Primary ShredderPrimary Shredder
Equipment
Double Deck ScreenDouble Deck Screen
Equipment
Hammer MillHammer Mill
Equipment
Covered StockpileCovered Stockpile
Equipment
LoaderLoader
Shingle Sources
Manufacturer Rejects
Post Consumer Waste “Tearoffs”
Products
• Hot Mix AsphaltHot Mix Asphalt
• Cold MixCold Mix
• Dust ControlDust Control
Hot Mix Asphalt
Shingles breaking down as they enter hot mix
Perma Flex®
Perma Flex®
Solves Reflective Cracking Problems
Dust Control
Cold Mix Asphalt
Cold Mix DesignsBlend Percentages
Blend 1 Blend 2 Blend 3 Blend 4 Blend 5
Oversized RAP %
(3/8” to 3/4”)
70.0 60.0 50.0 40.0 25.0
Oversize Shingle %
(5/16” to 3/4”)
30.0 30.0 30.0 30.0 30.0
Fine RAP(3/8” minus)
0.0 10.0 20.0 30.0 45.0
Combined Gradations
1” 100.0 100.0 100.0 100.0 100.0
3/4” 99.1 99.1 99.2 99.3 99.4
1/2” 72.4 75.1 77.7 80.4 84.4
3/8” 42.5 48.1 53.6 59.2 67.6
#4 15.0 20.5 25.9 31.4 39.5
#8 11.1 14.6 18.1 21.6 26.9
#16 7.6 10.0 12.4 14.8 18.4
#30 4.6 6.1 7.6 9.0 11.2
#50 2.1 2.4 2.8 3.1 3.6
#100 0.3 0.3 0.3 0.3 0.3
#200 0.1 0.1 0.1 0.1 0.1
Loaded Wheel Test
• Study Showed that Blend 1, with no fines, had the greatest strength
• Important to note that strength increases as the mix cures. It may initially be very soft, but with time and traffic, ruts will be significantly reduced.
All lab testing performed by Pavement Technology Inc.
0
1000
2000
3000
4000
5000
6000
1 2 3 4 5
Blend #
Field Test:Field Test: Proving ground for Proving ground for
new asphalt mix new asphalt mix designs at Waste designs at Waste
Management transfer Management transfer station in Norcross, station in Norcross,
Georgia.Georgia.
Dykes Paving & Construction IncDykes Paving & Construction Inc..
Resources
The most complete information The most complete information can be found at:can be found at:
www.shinglerecycling.org or or www.shinglerecycling.netwww.shinglerecycling.net