Enviro-Paver R1015 Hot In-place Recycler

PATTERSON Industries (Canada) Limited "The Process Equipment People" are 
licensed manufacturers of the
Enviro-Paver Hot-In-Place Asphalt Recycling machine.

The Enviro-Paver R1015 is the ideal machine for all 100% Hot In-place Recycling 
(H.I.R.) single stage processing of highway, municipal, airport and commercial asphalt 
pavements. The
Enviro-Paver  R1015 not only offers superior thermal bonding 
between layers and joints but also cost savings of up to 50%, compared to conventional 
paving methods.

The Enviro-Paver R1015 uses a single stage process of scarifying, milling, mixing/
rejuvenating, storing/metering and finally, screed levelling of heated, recycled 
asphalt, without lifting or removing asphalt from the heated surface. All major 
processing elements are closely spaced to reduce material heat loss and segregation.

Other processes using a separate windrow conveyor and standard paving machine 
suffer reduced asphalt temperatures, higher emission (smoke) levels and increased 
aggregate segregation.

Processes that remove heated asphalt from the surface for processing result in complex 
conveying systems, reduced asphalt temperatures, higher emission levels and increased 
aggregate segregation.

Enviro-Paver R1015 shown operating at a depth of 50mm (2") at 6.7m (22ft.) per min. at a width of 4.26m (14ft.)

Enviro-Paver R1015 is available to the contractor in three 
configurations for the following methods:



A. 100% H.I.R. method (recommended)
This is the recommended method for recycling asphalt pavements with a structurally 
sound base, if:

 

Enviro-Paver R1015 Extension Rake leading Extension Mill Processing depth of 50mm (2")

• The surface is rutted up to 50mm (2"), 
   cracked or has deteriorated.

• The surface requires levelling and minor 
  grade corrections.

• Modifications to asphalt mix design using
  pre-engineered specifications are required.

• A finished long-term wear surface is 
  desired.



• Asphalt material is 100% recycled to depths of 50mm (2") without the addition of 
  new asphalt, using the following equipment:

• Three self-propelled, propane-fired Pre-Heaters (Heat Master HM-16 or equivalent) with 
  variable width heating and heating output. The Pre-Heater ahead of th
e
Enviro-Paver  
 
R1015 deposits aggregate on to the heated asphalt surface.  The on-board 
  computer controls and monitors the application of washed aggregate (sand, stone, 
  etc.) to reconstitute recycled asphalt to pre-engineered specifications.   Kiln dried 
  sand (required by other processes) is not required, thereby reducing recycling costs.

• One Enviro-Paver R1015 recycling machine with an on-board computer, which 
  controls and monitors the application of rejuvenator fluid and machine processing 
  systems to reconstitute the recycled asphalt. 



B. Remix method
Recommended applications are as outlined in 100% H.I.R. method. The remix method 
is used when:

• New asphalt is to be mixed with recycled asphalt (pre-engineered into the 
  specifications).  The addition of rejuvenator fluid and/or
aggregate into the recycled 
  asphalt and the ratio of new to recycled asphalt are also determined by 
  pre-engineering.

• Additional material is required to correct minor grade and/or material deficiencies.


The remix method requires:
•
A detachable, pin-on, front-mounted asphalt hopper/slat conveyor, equipped with a 
  truck pusher bar.  
  The on-board computer controls and monitors the discharge of new asphalt 
  proportionally to the volume of asphalt being recycled.
  Existing asphalt is generally recycled to a depth of 40 – 50mm (1 1/2 – 2"
).




C. Integral overlay with 100% H.I.R. method
The integral overlay method is recommended for highway, secondary and county roads 
with a structurally sound base, if:

• High-grade wear surfaces are required with thermal bonding to (pre-engineered) 
  recycled asphalt.


•
Major grade changes are required or existing pavement needs to be strengthened with
  additional material.


• Shoulder widening (up to 1m or 3.3 ft.) using recycled or new asphalt is required. For 

 
shoulder widening, an adjustable strike-off blade is attached to the side of the R.H. 
  extension rake frame.
  Note: Gravel shoulder must be graded and compacted before processing.



The integral overlay method requires:
•
A detachable, front-mounted asphalt hopper/slat conveyer equipped with a truck 
  pusher bar, central conveyor, secondary
auger, secondary screed and additional 
  control systems. Removal of the asphalt surge bin/elevator makes way for the central
 
conveyor.  Existing asphalt is generally recycled to a depth of 40mm (1 1/2”) using 
  rejuvenator fluid and/or washed
aggregate. A simultaneous overlay of new asphalt 
  (thermally bonded to recycled asphalt) is generally applied to a depth of 13 – 25mm 
  (1/2 – 1”).

Enviro-PaverR1015 Pug Mill Main Mill Ext. Mill Rakes Heater Box Processing depth of 50mm (2")

How the unique Enviro-Paverฎ works
Asphalt pavement, previously heated by 
three or more Pre-Heaters is reworked 
(recycled) by the following computer-
controlled and monitored systems:

 

 

 

 

 

 
Enviro-PaverR1015 Extension Rake leading Extension Mill Processing depth of 50mm (2”)

1. Rake Scarification system
•
The Enviro-Paver R1015
 
rake system dislodges the top 
  50 – 75mm (2  – 3") of heated 
  asphalt, without damaging the 
  aggregate (other systems 
  such as multistage heating
  and milling increase damage 
  to the aggregate).

•
All rakes provide full 
  scarification around utility 
  structures without being
  monitored or raised.

 

2. Milling system (extension mills, main mill and pug mill)
• Left and right extension mills are hydraulically variable (on-the-fly) in widths from 3m – 
  4.5m (9.8 – 14.6 ft.).

• Left and right extension mills are hydraulically variable (on-the-fly) in widths from 3m – 
  4.5m (9.8 – 14.6 ft.).


•
Left and right side grade controls automatically maintain the main mill grade.

•
Rejuvenator fluid, sprayed on to the main mill rotor provides complete mixing with the
  recycled asphalt.


•
Twin-shaft pug mill collects and mixes the milled asphalt, forming a windrow.

•
Extension mills, main mill and pug mill rotors are hydraulically and directly driven; 
  they are fitted with replaceable
carbide teeth. Mills provide base material grade and 
  premixing of additives in front of the pug mill.


• Main mill, extension mill and pug mill rotors are all quickly replaceable for servicing.

Enviro-Paver R1015 Surge Bin/Elevator, Auger/Divider and Screed. Processing depth of 50mm (2")

3. Material control system
• Carson screed. Hydraulically operated
  and equipped with ultrasonic grade and 
  slope controls.


• Auger/divider. Hydraulically raised and
   lowered for better control of the asphalt 
   head (recycled material), in front of the 
   screed.

• Surge bin/vertical elevator. Allows
  collection and storage of excess recycled
  asphalt to be used as supplementation 
  (e.g. when milling to grade).

 

4. Quality control system
Computer control and monitoring of all Enviro-Paver R1015 on-board machine 
systems reduce operator input and the possibility of error.

This covers:  Proprietary speed control, air/propane heading system, rejuvenator 
dispensing system, heat management and system, material volume measuring system.

Enviro-PaverR1015 (shown in 100% H.I.R. configuration)
Covered under Patent No. 6,769,836 as well as other Patents applied for

The Enviro-Paver R1015 (shown above) uses a single stage process of scarifying, 
milling, mixing/rejuvenating, storing/metering and finally, screed levelling of heated, 
recycled asphalt, without lifting or removing asphalt from the heated surface. All major 
processing elements are closely spaced to reduce material heat loss and segregation.
 
Other processes using a separate windrow conveyor and standard paving machine suffer
reduced asphalt temperatures, higher emission (smoke) levels and increased aggregate 
segregation.  Processes that remove heated asphalt from the surface for processing result
in complex conveying systems, reduced asphalt temperatures, higher emission levels 
and increased aggregate segregation.

 

5. Major Technical Advantages of the Enviro-Paverฎ R1015
• Single stage process

• Quality control of recycled asphalt. The on-board computer controls and monitors 
  the addition of rejuvenator fluid and other additives.

• Quality control of finished mat (surface behind the screed). Automated grade 
  control of extension
main mills and grade/slope control of the screed, combined with 
  the machine’s long wheel base, produce excellent riding asphalt pavement.

•  Low emission process. Enviro-Paver R1015 single stage processing allows 
   Pre-Heaters to operate at high temperatures without degrading asphalt surface.  
   Fracturing of aggregate is practically eliminated.

• Rake scarification. Rakes loosen the heated asphalt (releasing moisture) before the 
  mills profile the surface, reducing mill rotor teeth wear and fracturing of the aggregate. 
  They also provide complete scarification around iron utility structures.

• Mill and pug mill rotors. Quick-change rotors allow the removal and installation of 
  exchange units, reducing maintenance and down time. 

• Pug mill. Twin-shaft pug mill provides complete mixing and measures the volume of 
  asphalt being recycled. Moisture (steam) trapped in the tumbling asphalt is removed 
  by an air extraction system and safely vented to the top of the machine.

• Material control system. The surge bin/asphalt elevator and auger/divider provide the 
  screed with a constant supply (head) of recycled asphalt. The ability to store excess 
  material and release material when a deficiency exists results in greater screed 
  accuracy, especially when automatic grade/slope controls are used. Other systems 
  that do not have surge storage capacity have to manually adjust the screed to release 
  or collect material, resulting in unwanted changes to grade and/or slope.

• Major components.  From leading world class manufacturers. Parts and service are 
  readily available through-out the world.

• Transportation. The Enviro-Paver R1015 is easily transported to the job site by 
  attaching a rear clip-on, three axles, air ride attachment. The front of the machine is 
  attached to a standard heavy duty highway tractor by a hydraulically extendible 5th 
  wheel pin stinger or front asphalt hopper/5th wheel pin. Hook-up only requires minutes,
  using the machine’s hydraulic system. No trailer is needed.

• Modular design.  Pin-on and/or clip-on attachments are available for various 
  processing applications. 

• On-board computer. The computer is programmed to monitor and control all system
  operations.
  Parameters outside programmed limits result in four levels of machine operator 
  warnings:
  Level 1 warnings are for advisory service schedules based upon operating hours.
  Level 2 warnings require corrective action by the machine operator.
  Level 3 warnings reduce or shut down the systems operation.
  Level 4 warnings result in engine and computer shutdown.

• Industrial colour graphics terminals. Used by machine and screed operators, 
  allowing graphical monitoring of all major control and monitoring systems. Numerical
  keypads and touch screens allow entry of operating parameters.
Processing at 
  depth of 50mm (2").

Please note:  For pictures on the latest Enviro-Paver R-1015 Model 2004, 
please click on Section
Image Gallery.

Covered under Patent No. 6,769,836 as well as other Patents applied for

 

Preheating of Pavement to be recycled 

 

The most important equipment in the equipment train apart from the Enviro-Paverare 2 to 3 Preheaters with sufficient heating capacity to heat - penetrate the top layer of the pavement to a depth of approx. 2" without breaking the asphalt surface.  This will allow the Enviro-Paver 100% Hot-in-Place Recycler to reprocess the top layer of the pavement properly and efficiently. 

 

Before and after using the Enviro-Paver 100% H.I.R. at a processing depth of 50mm (rejuvenator fluid and washed sand added). Note: utility structure required no adjustment 
and is flush to compacted recycled asphalt.

 

  

Saving our environment, minimizing traffic disruptions! 

  Copy Right 2001ฉ   All rights reserved.  Do not reproduce without the express permission of 
ENVIRO-PAVE INC.