This consists of the processing of old degraded pavements to form a high-quality structural layer.

IN-SITU RECYCLING

SAT Cold Recycling employs the most advanced technologies in order to make complete use of older built-in road construction materials, including redundant tar pavements that may prove harmful to the natural environment. Suitable processing of these materials along with a suitable binder (both hydraulic and bitumen-based) and aggregate batching allows degraded pavements to be transformed into balanced structural layers (base course featuring high flexibility and fatigue strength). The individual phases of this cold recycling technology are:

• Crushing and granulation of the old pavement,
• Batching a specific grain-control mixture in compliance with the laboratory-developed formula,
• Automatic batching of emulsified bitumen, cement, and water,
• Several stages of mixing the input materials,
• Spreading the resultant mixture of aggregate, cement, and emulsified bitumen using a table equipped with all the necessary automatic controls (thickness, cross falls, initial thickening),
• Final thickening using vibrating rollers.

Thanks to the many controllable variables of the cold recycling technology you can:

• Reduce the consumption of raw materials,
• Reduce the volume of waste products, specifically tar matters,
• Save electrical energy,
• Eliminate refuse disposal and new raw material supply,
• Reduce the earthwork equipment stock,
• Reduce time consumption,
• Produce minor traffic disturbances only.

RECYCLING IN FIXED MIXING PLANT (IN PLACE)

This method ensures on-line management of the old bitumen pavement after milling off €and mixing with the grain-control material as well as water, cement, and emulsified bitumen in a continuous computer-controlled process. The mixing plant can produce up to 200 tons/hour. The process ensures exceptional mixing of all the compounds and achievement of a uniform bitumen-aggregateemulsion or, if required, an aggregate-cement or aggregate-emulsion composition.

The stages of manufacturing an aggregate-cement-emulsified bitumen mixture are:

• Installation of a production plant at the raw material storage yard,
• Milling off the old pavement and supply of the same to the storage yard,
• Mixing all the compounds in compliance with the KMA 200-developed formula,
• Loading on vehicles,
• Incorporation of the mixture using paving machines or graders,
• Thickening using vibrating rollers.

Individual compounds are batched automatically using the formula and the pre-programmed process control. This helps reduce material losses down to a minimum, ensures improvement in soil fatigue strength (fatigue life category up to G1) and the spread of a drainage layer, as well as the elimination of heaving spots and vertical alignment profiling using the recycled mixture.