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RECYCLING OF CONCRETE ROADS IN

AUSTRIA
Recycling of Worn Concrete Pavements into New Concrete Pavements

Mario Krmek
Austrian Motorway and Expressway Financing plc.

Content

Austria?
Key Figures
ASFINAG? Company Overview
How?
Regulations Concrete Pavements and Recycling
Experiences? Case Study
In Detail?
Steps of the Recycling Procedure
2
10/16/16

Austria

Source:
www.wikipedia.de

RELIABILITY ALL THE WAY.

Ecuador - Austria
Highway Network

Source:
en.wikipedia.org
RELIABILITY ALL THE WAY.

ASFINAG Company Overview


Austrian Motorway and Expressway Financing plc.

RELIABILITY ALL THE WAY.

ASFINAG Company Overview


Austrian Motorway and Expressway Financing plc.

ASFINAG was founded in 1982 as a financing company


(fully state-owned)
Since 1997 ASFINAG holds usufruct rights related to land
and facilities belonging to the primary federal road network
Today ASFINAG plans, finances, maintains and tolls the
entire Austrian motorway and expressway network
Today ASFINAG is a completely user-funded company and
receives no money from the federal budget

RELIABILITY ALL THE WAY.

ASFINAG Company Overview


ASFINAG-Network Key Figures (End of 2013)

Length of network: 2,178 km


(appr. 40 % concrete pavements)
Number of tunnels in operation: 150
Kilometres in tunnels: 354
Number of bridges: 5,192
Kilometres on bridges: 340
Existing noise protection facilities: 1,275 km (at the roadside
and along central reservations)
2,670 employees
RELIABILITY ALL THE WAY.

ASFINAG Company Overview


ASFINAG-Network Age Distribution of Concrete Pavements (2011)
from 31 to 35
from 26 to 30

> 35

age in [years]

<5

from 21 to 25

from 16 to 20

from 11 to 15

RELIABILITY ALL THE WAY.

from 6 to 10

Regulations Concrete Pavements


Austrian Standards and Guidelines

RELIABILITY ALL THE WAY.

Regulations Concrete Pavements


Austrian Standards and Guidelines

Main Regulations:
Pavement Design - Guidelines and Specifications for
Roads RVS 03.08.63
Pavement Construction - Guidelines and Specifications
for Roads RVS 08.17.02
Concrete Production - NORM B 4710-1 Concrete - Part
1: Specification, production, use and verification of
conformity (Austrian Rules for the implementation of
European Standard EN 206-1 for normal and heavy
concrete)
RELIABILITY ALL THE WAY.

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Regulations Pavement Design


Guidelines and Specifications for Roads RVS 03.08.36

concrete layer
HMA layer
unbound base course

relevant for
motorways
concrete layer
HMA layer
cement stabilised layer

Source: RVS 03.08.63

RELIABILITY ALL THE WAY.

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Regulations Construction
Guidelines and Specifications for Roads RVS 08.17.02

Two-Lift Jointed Plain Concrete Pavement (JPCP)


Source: Betonstraen
- Das Handbuch

cross section

upper concrete layer (top lift 4 cm)


lower concrete layer (bottom lift
18 to 21 cm)
dowel bar (in longitud.: tie bars )

22 cm (load class I)
h=
25 cm (load
class S)

asphalt layer (5 cm)


unbound base course (45 cm)
or
cement stabilised layer (20 cm)

RELIABILITY ALL THE WAY.

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Regulations Construction
Guidelines and Specifications for Roads RVS 08.17.02

Jointed Plain Concrete Pavement (JPCP)

longitudinal joint (sealed)

tie bar

transverse joint (sealed)

L 5,0 m (motorway load classes S and I)


L < 25 h
Source: Betonstraen
- Das Handbuch

dowel

RELIABILITY ALL THE WAY.

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Regulations Construction
Guidelines and Specifications for Roads RVS 08.17.02

Requirements for Reuse of Recycling Material:


recycling material only allowed in lower concrete layer
min. aggregate size > 4 mm
freeze-thaw resistance
no alkali-aggregate reactivity (according to NORM B3100)
sieving and dedusting before using
percentage of bituminous parts < 20 %
removal of joint sealant and steel
RELIABILITY ALL THE WAY.

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Regulations Construction
Surface: Exposed Aggregate Concrete
Upper concrete
layer (top lift
4 cm):

increased
requirements
concerning
aggregate

higher
quantity of
cement

no recycling
material
allowed

RELIABILITY ALL THE WAY.

Source: Betonstraen Das Handbuch

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Regulations Construction
Austrian Standard NORM B 4710-1

Grain Size Distribution (Bottom Lift):


maximum aggregate
size < 32 mm

a
pr

a
tic

ou
v
fa

RELIABILITY ALL THE WAY.

bl
ra

grain size
> 4 mm:
recycling
material in
3 particle size
groups

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Recycling Case Study


West Autobahn A 1

Milestones
1990

recycling pilot project to develop a

recycling concept
1992

prove of concept

1996-1998
1998

final report with recommendations

1999-2011

RELIABILITY ALL THE WAY.

detailed preliminary assessments

general refurbishment

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Recycling Case Study


West Autobahn A 1

construction started in 1930s


essential new construction: 1955 1969
total length: appr. 292 km

Source: Archive of the former Upper Austrian Motorway Administration


RELIABILITY ALL THE WAY.

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Recycling Case Study


West Autobahn A 1

Detailed Preliminary Study


economic size of the section
max. length of construction lots
space for the preparation of the recycling material
economic distance from removal location
ranking by condition

composing optimal construction lots

RELIABILITY ALL THE WAY.

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Recycling Case Study


West Autobahn A 1

Concept for General Refurbishment


assessment of condition of
pavement (damages, rut depth, longitudinal and
transverse evenness, skid resistance)
and furthermore
bridges
structures
assessment matrix to prioritize

RELIABILITY ALL THE WAY.

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Recycling Case Study


West Autobahn A 1

Concept for General Refurbishment


traffic engineering study:

Mid- and Long-term Development of Traffic


(Traffic Growth)
additional lanes ( new cross section)
structural design ( thickness design)
RELIABILITY ALL THE WAY.

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Recycling Case Study


West Autobahn A 1

Concept for General Refurbishment


traffic engineering study:
traffic routing during construction
construction site traffic

composing of construction lots

RELIABILITY ALL THE WAY.

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Recycling Case Study


West Autobahn A 1: Recycling from old to new

Usage of the Recycling Material

Source: Betonstraen Das Handbuch


RELIABILITY ALL THE WAY.

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Recycling Case Study


Summary Case Study - West Autobahn A 1

refurbishment in total:
5,700,000 m
230 km
costs in total:
approx. 1.3 bn. (appr. 50% for Pavement)
economical savings in construction:
approx. 1,85 /m
ecological savings appr.
- 1,700,000 km of transport
-1,445 tons CO2
RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Main Steps

1. Demolishing of worn pavement


2. Removing and transport to recycling area
3. Crushing and preparing for reuse in new concrete
4. Production of new concrete with reused material
5. Construction of new concrete layer

RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 1: Demolishing of Worn Pavement

Demolishing:
Guillotine

Source: Asamer Holding AG

RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 1: Demolishing of Worn Pavement

Demolishing:
Pneumatic
hammer

Source: ASFINAG
RELIABILITY ALL THE WAY.

Source: Asamer Holding AG

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Recycling - Steps of the Recycling Procedure


Step 2: Removing and Transport

Source: ASFINAG
RELIABILITY ALL THE WAY.

Source: Asamer Holding AG

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Recycling - Steps of the Recycling Procedure


Step 3: Preparing for Recycling

Interim
storage

Source: Asamer Holding AG


RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 3: Preparing for Recycling

Recycling
facility

Source: Asamer Holding AG


RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 3: Preparing for Recycling

Source: Betonstraen - Das Handbuch

RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 3: Preparing for Recycling

Crushing
machine

Source: Holding
ASFINAG
Source: Asamer
AG
RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 3: Preparing for Recycling

Dedusting
and
washing

Source: Asamer Holding AG


RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 3: Preparing for Recycling
Source: ASFINAG

Sieving

Source: Asamer Holding AG


RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 4: Concrete Production

Mixing
plant

Source: Asamer Holding AG


Source: Betonstraen Das Handbuch
RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 5: Concrete Pavement Construction

Two-lift
paving

Source: VZ/sterreichische Betondecken ARGE


RELIABILITY ALL THE WAY.

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Recycling - Steps of the Recycling Procedure


Step 5: Pavement Construction Exposed Aggregate Surface

Source: Asamaer Holding AG

RELIABILITY ALL THE WAY.

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Summary
Additional Attention
preparation of project ( preliminary investigations)
composition of reasonable sections (appr. 6-10 km)
quality control and assurance concrete production
Benefits
ecological
economical
Disadvantages
difficulties in urban sections
space for recycling facilities needed
RELIABILITY ALL THE WAY.

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