Full-Depth Recycling is a full pavement rehabilitation process in which some of the underlying base materials as well as the road surface are milled into a new and completely reclaimed material. This revitalized gradation is then preferably mixed with an asphalt emulsion or calcium chloride and used to rebuild the road. This process completely rehabilitates and reinforces the structural strength of the underlying base of the road. It addresses reflective cracking problems by completely recycling base and sub-base structural deficiencies.

Full-depth is different from Cold-in-Place Recycling due to the fact that it always penetrates as deep as the underlying base or sub-base. This structural upgrade is used when the pavement has been deemed structurally unsound. Examples of such would be roads in constant need of maintenance repairs and those riddled with potholes.

Process:

Core samples are taken from the desired construction site. These samples undergo testing and after proper analysis a mix design is developed for the project. With these steps completed, construction can begin.  The existing surface is milled 6 to 10 inched deep. Milling down this deep will bring up the surface, base layer, and some soil.  The materials are pulverized to a specific aggregate size which is determined within the mix design. During the second pass of the pulverizing process, the addition of calcium chloride (or preferably an asphalt emulsion) occurs. The step that follows the mixing process is the re-application of the product.            

The newly pulverized and blended material is then passed over a second time. This is done to ensure the homogeneity of the rehabilitated layer and proper moisture levels. After the second pass, the material is shaped and compacted to form the new road surface. Compaction can be completed by use of one of the following roller types: Double-Drum Steel, Sheep's/Pad Foot, or Pneumatic Rubber Tire.

Water is continuously applied to keep the surface from drying out until it is able to support traffic. The final step is the application of the chosen surface treatment (i.e. FiberMat®, chip seal, hot-mix asphalt, etc).           

Midland Asphalt utilizes multiple pass reclamation in which the initial pass is simply to "pre-pulverize" the existing surface. The second pass then unifies the size of the aggregate gradation and a second addition of stabilizers (emulsion or calcium chloride) occurs. Multiple pass reclamation is a superior method to single pass reclamation because it helps to unify material size and may contain double the amount of stabilizing materials.

Uses:

• Complete structural repair
• Analyze and correct base layer distress
• Improvement of pavement layer drainage
• Shoulder strengthening
• Road widening/ lane additions

Benefits:

• Recycles existing materials
• Addresses reflective cracking
• Grade and cross slope can be re-established
• Allows roadway use by local traffic
• Cost effective
• Eliminates material disposal concerns
• Saves natural resources (environmentally friendly)