RT-500 and RX-900

500 TPH (454 MTPH) Cold

Recycling
Nevada (USA) Job Sites
 The Cold Recycling Process
• Partial depth cold recycling is a major innovation
to improve roadways and at the same time
reduce the use of new materials and site
transportation costs.
• Major savings in costs
– Reduces trucking costs and fuel used.
– Reduces new material use.
– Reuses 100% of materials in roadway now.
– Increase service life of the overlay by creating a
“crack barrier” between the existing roadbed and the
new surface.
– Preserves and reuses the existing road base.
The Recycling Train
 Calibration of RT-500
• Roadtec has worked out
calibration routines for the RT-
500 for all materials, stone and
liquids.
• Special weighing vessels and
equipment are available for this
purpose.

Right:
Weigh bridge
calibration and
bitumen pump
calibration.
Left:
BearCat 3785 L /
1000 gallon liquid
calibration trailer.
 Widths and Depths of CIR
• Variable widths are easy to do
with this system. On this job,
material is placed to the side
by the Roadtec RX-60 (2.2 m
width/86”) where the RX-900
(3.8 m/150”) can walk over the
top of it and incorporate the
material into the next milling
pass.
• Precut and final cut could be
variable to 6 m width (20’).
Shown here is about 4 m (13’
4”).
• Depth of cut has to do with
ability to compact the material
to design specification.
Normal depths are between 50
and 125 mm (2” to 5”).
 Mix Designs
• The mix design can be as
varied as the conditions
require, in this instance, the
emulsion was 2.2% with 2.5%
lime slurry solids by weight.
• The slurry was approximately
30% solids to water by weight.
500 lbs of gypsum was added
per 10,000 gallons of slurry to
slow down the reaction time.
• Various materials can be
added to an existing roadway
to create a new layer of
recycled pavement.
• The Bearcat system is shown
to the right.
 Slaking Plant
• The lime slurry is
prepared at a slaking
plant and sent to the train
by tanker truck.
• On this project, lime and
emulsion were the main
additives along with
water.
• Bituminous emulsion,
lime, Portland cement, fly
ash, foamed asphalt or
other stabilization
materials can also be
used in this process.
 Tank trailers deliver the asphalt emulsion
and lime slurry to the job site
• Tankers stay with the train
during work and tank trailers
shuttle to the supply point
and return with materials.
• The production of the train is
dependent upon the timing of
these materials and the
careful planning of transport
to the supply point.
• Material can be laid on the The “construction” job required
surface ahead of this water, emulsion and lime slurry. This
job was on Highway 93 south of
process as well by using a Lages Station, Nevada (USA) and on
dry material spreader. Hwy 93 between Lages Station and
Curie.
 Roadway Grade and Slope
The milling machine
rebuilds the proper grade
and slope to the roadway
using state of the art
automated grade and
slope controls.

An Asphalt Paving machine will be

used with grade controls to place the
recycled mixture back onto the
roadway in a uniform lift of material.
 Down Cutting drum
• The Roadtec RX-900 matches
the grade and slope
predetermined by the
engineer.
• This RX-900 used a 3.8 m
(12’6”) wide down cutting
drum. Drum units are
replaceable between 2.2 m
(87”) and 3.8 m (12’6”).
• This sizes the material at the
point of cut and is preferred by
this contractor.
• One could up-cut with this
same machine in this same
rear loading configuration if
desired.
 The Roadtec RT-500 Mixing Trailer
• The mill’s conveyor puts milled
material on the screen.
• If oversized, it goes through the
crusher and back to the screed via a
two conveyor return circuit.
• Material that passes the screed drops
onto the 1.2 m (48”) weight belt. This
sends a signal to the blending
computer which adjusts the flow of
additives to the pugmill mixer.
• After a full mixing cycle it is
discharged onto the roadway.
 The Roadtec RX-900

The mill can work in either direction and has 950 HP diesel power.
Front or rear loading, UP or DOWN cutting, widths from 2.2 m to 3.8 m.
Shown here is a 3.8 m (12’6”) drum down cutting and rear loading to
the RT-500.
The RX-900 tows the RT-500 Screening, Mixing and Blending Trailer
as well as the emulsion trailer and pushes the additive trailer.
RX-900 and the Train
 The Screen Deck
• The RT-500 has a JCI
5142-24 Screen (5’ x 14’
– 1.5 m x 4.27 m) Double
Deck Screen with 120mm
bearings to give a uniform
size to the milled
material.
• Uniform size will yield a
more uniform mixture.
• A crusher and conveyor
circuit reduces the
oversize.
 Over size material crusher
• Telsmith Crusher – 3048
Impactor
• 152 mm mainshaft and
110 mm bearings for
maximum service life
• Shaft and Rotor Assembly
feature Ring-Feders™ to
provide lock of shaft and
rotor without press-fits or
keys (allows for easy •Precision machined surfaces provide 100%
removal of shaft from backing for hammers
rotor) •Two - Moveable Aprons to allow for proper
• 2 Rows of Massive sizing of material
Hammer Bars •Spring Return on Moveable Aprons to
• Patented Hammer and eliminate shear bolts for tramp iron relief
Wedge Design provides 4 •1” (25 mm) Thick AR400 Liners on Aprons, ½”
wear surfaces for (13 mm) AR400 frame or wall liners
maximum life •Hydraulically Lifted Upper Frame - Opens for
• Hammer Bars are 28% complete internal access
Chrome Iron Alloy •150 hp (112 kW) electric motor drive.
•Fully enclosed belt guard
 Crusher Circuit back to Screen
• Two Return Conveyors
• 24”(610 mm) return
conveyors
• Cleated belt for maximum
production
• Covered for safety and to
prevent roll-off
• Lagged head pulleys for
non-slip traction
• Water sprays to prevent
rap dust build-up on
rollers
 Weigh Bridge and Mixer
• Under the Screen
deck there is a 48”
(1.22m) wide belt and
belt scale system to
provide accuracy ±1%
• JCI/KPI Model 52
Pugmill 48” (1.2 M)
Wide Box with Twin
24” Shaft mixers x 6’-
0” (1.83M) long or (9
cu. yards.) 600 TPH
 Bearcat™ Emulsion System
• Full display and input screens
both Metric and Imperial
measures.
• Variable speed electric motor
driven 3" (7.62 mm) positive
displacement asphalt pump (240
gal/min or 908 liter/min) with
reverse capability.
• Positive displacement gear type
flow meter.
•Dual 8" (20cm) X 18" (45cm) spray bar
• Optional Mass flow meter
strainers with a pair 3-way valves allowing the
• Full circulating system to prevent selection of either canister so the other one
plugging in spray bar circuit while
in non-spray (circulate) mode. can be cleaned while in operation.
•Automated flushed system with onboard
• Thermostatically controlled electric flush solvent recovery tank.
heat in asphalt circulating circuit to
prevent material from cooling •System is capable of spraying paving grade
while circulating. asphalt.
• Pneumatic spray valve operation, •Optional foam system can be added.
computer controlled. •Hydraulic 3” (7.62 mm) variable drive positive
• Spray valves submersed poppet displacement asphalt pump (240 gal. or 908
style. liter/min) with reversing capability
 RT-500 Generator Power
• Caterpillar C-9
Generator Set
• Caterpillar C-9 Tier III
Diesel Engine at 375
hp
• 250kw Output on
Marathon Generator
• The RT-500 is run by
electric motors.
 Discharge to Roadway
• The material is mixed in
the pugmill and dropped
onto the roadway.
• Roadtec drops the
material as close to the
milling drum as possible
to keep the open areas to
a minimum aiding start up
and shut down of work
each day.
 Windrow and Windrow Loader
The cold recycled material is left
in a windrow for three reasons:
– Drying & curing effect
– Surge control – if there is a
dip or hump you are correcting
with the milling process you
can move the material to
compensate and allow a
uniform lift of recycled mix to
be placed.
– Allows for maximum
production, the paving and
compaction progresses at is
own optimum rate.
– The recycling and supply of
additives go at their
optimum rate.
 Paver and Placement
• The windrow loader is
pushed by the asphalt
paver and placed onto
the roadway.
• The paver uses an
automated grade
control to place a
uniform lift of material.
• There will be a new lift of
material placed on top of
this material after the
curing period. Normally
about two weeks.
Nevada Maintenance - Mix design

Added at 2.2 to 3.0 percent “Reflex” emulsion, and approximately

2.5% water. “Reflex” emulsion, is a Sem Material product, No
lime in this design, see
http://www.semmaterials.com/productsandbrands/reflex.aspx
for details on the emulsion.
 Compaction
• Compaction of cold
materials is done
differently than hot mix
asphalt.
• Normally a 30 ton multi-
tire pneumatic roller and
two double drum vibratory
rollers are used to push
the water content out of
the emulsion and
consolidated the recycled
materials.
Elimination of Cracks coming to the Surface

The new layer of recycled material will create a barrier to keep

the sub-base cracking from coming to the new surface.
 The Roadtec Bonus

•Unlike and unique to the industry, Roadtec’s design

allows all the units to be used as separate units when
not recycling.
•The milling machine can also be a front loading
milling machine on normal milling projects.
•The RT-500 can be used as a stand alone mixing
machine, it can be fed by a front end loader and is
powered by its own generator set.
•The paver, the rollers and the windrow pickup
machine can be used on other jobs as well.
The RX-900 is a normal Milling
Machine useful elsewhere
 Summary
• A final overlay will be added to the CIR material.
CIR is a base material, a material that is not
solid as HMA and retains the ability to keep the
underlying base cracks from migrating to the
surface.
• The water content of the emulsion must be
eliminated by compaction and drying.
• Often a fog seal is placed on this material shortly
after compaction to keep rain from adding
moisture to the material before the final paving is
completed.
 For more information
contact:
Roadtec, Inc.
sales@roadtec.com
800-272-7100 or 423 265 0600
www.roadtec.com