Road Recycling SolutionsThree processes designed to reduce your carbon footprint and cost

Colas Our road recycling processes Colas Limited operate throughout the UK as a service provider to the highway and airfield sectors. As a part of the International Colas Group, Colas can draw upon the resources and expertise of one of the worlds leading organisations, for construction and maintenance within the roads and airfields industry.

75mm

As required

150mm to350mm

As requiredNew Surface Course

Binder Course

Road base

30mm

20 - 25mm

Surface Course

Sub-base

A hot recycled surface course process, which can be applied throughout the year in most weather conditions. Repave can be combined with any surface course currently available and with Colas proprietary surface course, Colrug.

A cold process used on both carriageways and footways that saves energy and reduces hydrocarbon emissions, while reconstructing the surface layers faster and more economically than conventional surfacing processes.

A fast and economical cold reconstruction process for the complete road surface or for haunches. This process may also be completed ex-situ and material may be mixed off site, with no waste, ensuring controlled quality and the opportunity to include other re-usable materials such as glass, china clay and crumbed rubber.

1. Repave 2. Retread 3. Deep Recycling

Colas are at the forefront of developing and mastering road recycling techniques and have a number of sustainable surfacing options within our portfolio, providing long term preventative maintenance.

Our expertise within the road recycling market have been long established and carried out for over the past 50 years.

These processes re-use existing materials, reduce waste and consequently avoid unnecessary lorry movements and landfill. During consultation, our team of experts are able to independently advise clients on the ideal solution, depending on the current site conditions.

Deep Recycling

Deep recycling is a fast and economical cold reconstruction process which reconstructs the entire road surface or haunches to a depth of 150mm to 350mm and is mixed with new binders to form a uniform and strengthened structure.

Reducedtimeonsiteby up to 60% means less road space occupation and minimal traffic requirements

In-situbenefitsresultinreduced lorry movements and disruption to local communities

Reducedenergyconsumptionby up to 60% in the total construction cycle when compared to conventional road surfacing treatments

Conservesnaturalresourcesthrough recycling materials such as glass and china clay

Greatefficiencyand ultimately cost savings

Treatstar-boundlayers in-situ according to EU regulations without the need of costly disposal.

Rather than removing the existing material, this process recycles the existing material in-situ. This rapid process has the advantage of reducing lorry movements and minimising disruption to both road users and residents. Up to 1500m2 can be treated per day depending on site conditions. Leaving the material in place during operations means that local and emergency access can be maintained.

After initial pulverisation, the surface is compacted and trimmed. Excess material is removed before recycling the existing pavements, after which emulsion and hydraulic binders are then added to the existing material. Fuel ash or cement may be added according to TRL 611 creating FABM, HBM or CBM mixes. During which time the sub-grade is not exposed, reducing the risk of soft spots.

Once the recycling is complete, the material is again compacted and the surface shaped by a grader to the required levels. Finally the surface is coated with bituminous emulsion and sealing grit after which it can be subjected to traffic if necessary.

Depending on design requirements, a final surface is laid appropriate to site conditions.

The process is specified according to TRL 611 and is approved under clause 947 of the Specification for Highway Works.

Before

After

Carriageway RetreadCarriageway Retread recycles the existing pavement in-situ to form a durable reprofiled carriageway rather than planing off and discarding the old material as in traditional methods. Specialist plant is used to breakdown the surface of the carriageway to a depth of 75mm. This material is graded to form the new profile. Retread emulsion is thoroughly mixed into the existing road pavement to ensure uniform distribution and penetration of the binder.

The surface is compacted and an application of binder and 14mm chippings are rolled in to close surface voids. A double 6mm surface dressing finishes the process, on which any choice of surface material can be applied if deemed necessary.

Retread can work to existing levels leaving kerbs and iron work undisturbed, thus reducing costs. Time required on site is significantly reduced in comparison to conventional road surfacing treatments, reducing overall disruption to the community and road users.

RetreadCarriageway and footway in-situ recycling

Retread is a cold in-situ recycling process, with over 30 years proven performance on UK carriageways and footways.

With increasing focus on sustainable procurement, Colas Retread process offers a low CO2 emission alternative. By reducing the output of energy, emissions and waste, Colas are able to aid clients in significantly lowering their carbon footprint.

CAsE sTUdy foR CaRRIaGewayReTReadInKIRKLeeS

Area: 77,442m2

Conventional: Plane out 75mm and replace with HDM binder course

Repave: Pulverise 75mm and Retread

BIndeR

3,142.6

1,770.7

sTRUCTURE

COnVenTIOnaL

RePaVe

aGGReGaTeS

771.3

119

UPsTREAM TRanSPORT

259.2

13.2

ManUFaCTURe

4,550.6

243.4

dOwnSTReaMTRanSPORT

1,571.7

454.2

LayInG

631.2

301.5

RePaVeMaCHIne

1,270

1,270

TOTaL

10,926.5

4,171.6

61.8%Saving in energy conSumption

Total Energy Consumption, GJ

BIndeR

184.8

103.7

sTRUCTURE

COnVenTIOnaL

RePaVe

aGGReGaTeS

27.9

4.3

UPsTREAM TRanSPORT

19.1

1

ManUFaCTURe

294.6

5.9

dOwnSTReaMTRanSPORT

115.7

35.4

LayInG

48.5

3.2

RePaVeMaCHIne

95.3

95.3

TOTaL

758.1

448.6

61.4%Saving in co2 emiSSionS

GHG Emission in Equivalent CO2 tonnes

Any surplus materials can be used to treat soft spots or where levels are low, the remainder is suitable to use as a sub-base elsewhere. Colas uses a footway paver to ensure that our footway work has a superior finish when compared with traditional hand lay methods.

footway RetreadDuring the process specially designed equipment is used to breakdown the surface of footpaths to a depth of 75mm, new Retread binder is added and thoroughly mixed with the old material, rejuvenating it. The level of the completed Retread can be suited to accept a new asphalt surface course or Slurry Seal.

Colas can work in partnership with existing Service Providers for the delivery of this process. Surface course and iron works adjustment can be provided by the client, bringing the benefits of recycling while still supporting existing arrangements.

RepaveA greener road networkRepave is a hot in-situ recycling process which can take place throughout the year in most weather conditions and on any class of road or airfield pavement. It involves the recycling of existing asphalt road material in-situ, reducing traffic disruption, lorry movement, the demand for new aggregate and cost.

Repave can be combined with any type of surface course including HRA.

The site is assessed to determine suitability. If necessary, core samples are taken to confirm the construction and binder penetration value.

The road surface is heated to 150oC forming a plasticised asphalt layer, and the materials are then scarified to a depth of 30mm. This is completed using a two stage passive scarifier with spring loaded tines to avoid damage to street furniture. A vibrating screed reprofiles and corrects levels for the required crown or crossfall.

A new thinner asphalt layer is then super imposed, thereby providing a homogenous asphaltic layer up to 50mm.

Heat from the Repave process penetrates 25-30mm deep into the surface of the road, allowing the final layer to be laid even during wet, cold weather.

The surface to be treated can be either HRA, SMA or bituminous macadam. Gullies may not need to be adjusted saving time and money, Repave can provide a faster and more economical alternative.

The Repave process is approved under clause 926 of the Specification for Highway Works.

Achieved savings compared to conventional

Conventional: Plane out 50mm and replace with 50mm SMA

Repave: Plane out 25mm, repave and replace with 25mm Masterphalt-P

50%Increasedrecycledcontent

Reducedtimeonsitemeanslessroadspace occupation and minimal traffic management requirements

Recyclingmaterialsconservesnaturalresources and extends the life of the existing infrastructure. Reduced use of virgin materials promotes retention of habitat and green spaces

ReducedGreenHouseGasand Co2 emissions

Reducedenergyconsumptioninthetotalconstruction cycle when compared to conventional road surfacing treatments.

wastereduction-Thepercentageofwaste produced is negligible, avoiding unnecessary landfill

Costsavingsduetoshorterconstructionperiod and reduction in the use of new materials.

Project A64 Malton Bypass March 2011

UnIT COnVenTIOnaL RePaVe SaVInGS %

PLanInGSOFFSITe Ton 3,099 1,549 1,549 50

MaTeRIaLTOSITe Ton 3,507 1,712 1,794 51

LORRyMOVeMenTS No 331 164 167 51

dURaTIOn Nights 10 8 2 10

CO2eMISSIOnS Ton 275.2 173.7 101.5 37

eneRGy GJ 4,226.7 2,589.1 1,637.6 39

CosT 705,562 440,992 264,570 37

32,696m2total reSurfaced area weStbound & eaStbound uSing repave

Colas Limited Wallage Lane Rowfant, Crawley West Sussex RH10 4NF T: 01342 711000 F: 01342 711199 E: info@colas.co.uk

www.colas.co.uk

Our approach to sustainabilityResearch, development and innovation are firmly embedded within the Colas culture and have proven to be an integral part of Colas growth strategy. Development of our products and operational processes are tailored towards meeting the changing needs of our clients.

We recognise the importance of safe guarding our environment and conserving natural resources, Colas is at the forefront of developing and road recycling processes providing sustainable highway maintenance solutions for our clients.

Environmental Calculator Our environmental calculator software allows us to measure the carbon footprint of our processes through measuring energy consumption and greenhouse gas emissions.

The calculator achieves this through including details such as aggregate type, laying process and transport distances. The software allows alternative processes or methods to be displayed alongside each other, providing a quick and easy comparison tool for designers and project managers.

The introduction of this calculator allows us to offer clients tangible and numerical data on the energy consumption and emission savings made, when using our road recycling processes.

Furthermore the analysis allows for accurate assessment of environmental impact and these savings maybe used towards sustainability targets.

Customers who choose our road recycling processes receive a complimentary report on the savings made towards energy consumption and emissions.

Typical savings achieved can be up to 60% for energy consumption and greenhouse gas emissions.

Thecalculatorallowsusto measure the footprintof any of our productsand processes

accuratelyassessingtheirimpact in terms of energyuse and emissions

Providesuniquestatisticalcomparison betweenalternative techniques

Resultsrevealgreatvariationsin the environmental impactof differing constructiontechniques

Thecalculatorenablesus to determine the mostsustainable method ofworking for any project.

Regional officeCakemore RoadRowley RegisWarley West Midlands B65 0QUT: 0121 561 5561F: 0121 561 4364 E: recycling@colas.co.uk

Part of the International Colas Group