Abstract: A method of reconstructing a bituminous-surfaced pavement is provided. This method includes evaluating the pavement to determine if it is an appropriate candidate for full-depth reclamation; mixing an emulsion with reclaimed asphalt pavement particles from the pavement to form an asphalt emulsion mix; and testing the asphalt emulsion mix for performance using a cohesion test, a moisture susceptibility test, and a modulus test. In many instances, dirt and/or aggregate from the base layer of the pavement are also included in the asphalt emulsion mix. The invention also includes designing a full-depth reclamation (FDR) layer based on this test data. Once the layer is designed, the bituminous surface of the pavement is pulverized, an emulsion is mixed with the pulverized reclaimed asphalt pavement particles from the bituminous surface and possibly dirt and/or aggregate from beneath the bituminous surface of the pavement, and this mixture is applied to the pavement.

Abstract: A system for repairing roads is provided. The system includes a highly strain tolerant, substantially impermeable, reflective crack relief interlayer. The interlayer includes a polymer modified asphalt binder mixed with a dense fine aggregate mixture. About 100% of the aggregate should be able to pass through about a 9.5 mm sieve. The interlayer mix is designed using volumetrics and verified using a Flexural Beam Fatigue test and a Hveem Stability test. Preferably, an HMA overlay that is compatible with the interlayer, as well as the demands of local traffic, is placed over the interlayer so that a protected, smooth road surface is provided. The system may delay the first appearance of cracks and the severity of cracks for several years compared with traditional hot mix overlays and extend pavement service life.

Abstract: A roadway paving system for chipsealing a roadway surface comprising a novel roadway paving vehicle and a novel supply truck is provided. The roadway paving vehicle comprises an asphalt binder material dispensing system and an aggregate material dispensing system. The asphalt binder material dispensing system includes an asphalt tank and a sprayer that sprays a first layer of the asphalt binder material over the roadway surface. The aggregate material dispensing system comprises an aggregate hopper and conveyor mechanism that discharges a second layer of aggregate material over the roadway surface. No wheels run over a freshly laid surface. Supply trucks are linked to the roadway paving vehicle to refill the roadway paving vehicle on a continuous basis without the need of stopping the vehicle.

Abstract: A method of reconstructing a road is provided. This method includes taking representative cores of the road, analyzing the cores, selecting a substantially solvent-free emulsion based on climate history, mixing the emulsion and reclaimed asphalt pavement particles to form an asphalt emulsion mix, testing the asphalt emulsion mix for performance using a raveling test, a thermal cracking prediction test by an indirect tensile testing, a moisture susceptibility test utilizing vacuum saturation, and a dry Marshall stability test. It also includes designing a CIR layer based on this test data. It further includes grinding off a layer of the existing asphalt road leaving at least about an inch, adding an emulsion to the reclaimed asphalt pavement particles, applying the designed cold in-place recycling layer to the road, and compacting it.

Abstract: A method of paving a gravel and/or dirt roadway is provided. This method includes evaluating the roadway to determine if it is an appropriate candidate for emulsion stabilization, rotating a milling head down a roadway to break up gravel and dirt, injecting an asphalt emulsion into the broken up gravel and dirt, and mixing the emulsion with the gravel and dirt so as to form an emulsion stabilized layer. The emulsion stabilized layer is then spread and compacted to create a paved roadway. Following this, a wearing surface may be applied to the emulsion stabilized layer.

Abstract: A method of reconstructing includes taking representative cores of the road, analyzing the cores, selecting a substantially solvent-free emulsion based on climate history, mixing the emulsion and reclaimed asphalt pavement particles to form an asphalt emulsion mix, testing the asphalt emulsion mix for performance using a raveling test, a thermal cracking prediction test by an indirect tensile testing, a moisture susceptibility test utilizing vacuum saturation, and a dry Marshall stability test. It also includes designing a CIR layer based on this test data. It further includes grinding off a layer of the existing asphalt road leaving at least about an inch, adding an emulsion to the reclaimed asphalt pavement particles, applying the designed cold in-place recycling layer to the road, and compacting it.