THE EVOLUTION
of
CONCRETE RECYCLING
Rethinking Concrete Recycling
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Recycling Concrete in Place
Increase the Aggregate Base Material Specification
 Increase to 5-6” Minus Flexible Aggregate Base Course
 Add Thin Layer of Traditional Aggregate Base Material
Elimination of the Majority of Crusher and Hauling Expense
Massive Construction Savings in Time and Costs
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$2.50 - $3.00 per Ton Crushing Cost Eliminated
$1.90 per Ton Savings in Hauling Costs
Equivalent of $2.20 per Square Yard
20-25% Construction Job Efficiency
Value Engineering – Total Reconstruction
Traditional Design
New Value Designed
Construction Process
1)
2)
3)
4)
5)
6)
Resonant Recycle PCC in Place
Excavate Fractured PCC, Place on Shoulder
Excavate Base Material, Level SubBase Course
Place Fractured PCC as Aggregate Base Material
Thoroughly Compact Aggregate Base Material
Lay new PCC / HMA in accordance with Plans
Resonant Recyle Concrete in Place
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7,000 yds per Shift
Breaking to 5” Minus
Removal of Reinforcing
Removal of Reinforcement
Excavate PCC and Dig Base
Stockpiled Reusable Material
The Savings
Crushing Cost Typically Averages $2.50 - $3.00 per Ton
 Hauling Cost Averages $80 / Hour
 Average 3.5 Trips Per Hour
 Average Hauling Cost Per Ton $1.90
 Savings on 9” PCC = $2.20 square yard
 Estimated Construction Time Efficiency is 20-25%
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Kansas Turnpike Cross Section
Wisconsin I-94 Cross Section
Recommended State Specification
 Select Crush Material or Flexible Aggregate Base Material
 Conform to Following Gradation:
Sieve Size
Percent Passing
(by Weight)
5 inch (125 mm)
1 ½ inch ( 37.5 mm)
No. 10 (2 mm)
90-100
20-50
0-10
 Compaction Shall Conform with Traditional State Specification
 May Consider “Sheep’s Foot” Prior to Smooth Roller