Asphalt Surface Recycling
Single Pass Method

Almost half of the roads in the world are in the United States. Over 90% of them are made of asphalt. Even before the increase of asphalt, an oil product, it has been known that the most economical method in the world to resurface is by hot-in-place recycling. . .

The most economical way to do that is using Pavement Savers and Thermal Power Corp. recycling equipment such as the Heat Master and the Road Master with their
100% radiant heating (No Flames) panels. Pavement Savers is also the originator of the single pass recycling method that is being used on this project.

How does it work? First the asphalt surface is heated. Out in front is the Heat Master pre-heater which uses the exclusive Thermal Power
radiant heating (No Flames) panel.

This heating panel produces almost 2,000 degrees of radiant heat in one minute distributing more than 80,000 BTUs per square foot evenly throughout the entire heating panel. This is like no other heating equipment made in the world. In addition to this, the heating panel ignites instantly and after it is turned off it is cool to the touch in less than a minute. This makes it the cleanest, safest, most economical and virtually smoke free heating system in the world.

The Heat Master Pre-heater is followed by another Pavement Saver exclusive, the Road Master hot-in-place recycler. In addition to other exclusive features the Road Master also uses the same Thermal Power 100% radiant heaters as the Heat Master for the final heat.

After the surface has been heated, Pavement Savers applies their exclusive recycling oil, PSI 540T just ahead of the scarifiers using the exclusive spinner-droplet application.
Then the heated asphalt is scarified and the rejuvenating oil is mixed with the scarifying asphalt not once, but twice before it is re-leveled by the Road Master’s screed

Pavement Savers does not recycle the existing asphalt and install the new pavement with one machine for many important reasons. First, it gives the rejuvenating agent time to soak into the recycled asphalt where it is needed, keeping it from soaking into the new asphalt where it is not needed. This process also allows the inspector to verify that the total required thickness of the asphalt including the rejuvenator is at least 200 degrees Fahrenheit. Yet another advantage of this process is the inspector can repeatedly check the depth of the recycled asphalt before the new asphalt is applied.

Now the new asphalt can be placed with a DOT paver, not just a spreader box attached to the rear of a recycling machine.After the new asphalt is placed it is rolled as it would be in a conventional paving operation using a steel roller followed by a traffic roller.

Another advantage of separating the recycling machine with the paving is that the municipality could do the asphalt paving behind it with their own forces, or a local paving contractor could bid to do the paving.

Pavement Savers with Thermal Power technology also offers maneuverability. We can recycle smaller streets. We say if one can drive a dump truck down a street, Pavement Savers can recycle it. There are many pavement managers that take advantage of hot-in-place asphalt surface recycling only on their main arteries because the larger combination recycler/re-pavers cannot do the smaller streets. Pavement Savers can.

As you can see there are many advantages in the Pavement Savers method of recycling.Our method was adapted in the Asphalt Road Recycling Association’s specification handbook and has been there since 1988 under the heading Method (B).

There has been much success in hot surface recycling using our original one pass method. We are proud to have developed the process that has proven to out last any other hot surface recycling project in the world. We have streets that are more than 18 years old that we would be very proud and happy to show you.

What does the Federal Highway Department have to say?

1 + 1 = 2 1/2

“A commonly excepted rule of thumb is that, one inch surface over the one inch recycled pavement out performs two and a half inches of new overlay over the original pavement,”

What this means to you is that with the Road Master we are able to deliver identical quality road surfaces from 2 ” down to 1” for half the cost.

So Ladies and Gentlemen: The smooth roads of tomorrow are in your rough roads of today. All one has to do is hot-in-place surface recycle at half the cost of the standard conventional method.

Hot In-Place
Asphalt Surface Recycling
Multi-Phase Method

The multi pass method of Hot in-place asphalt surface recycling is when the street is recycled and the new asphalt or other surfaces such as slurries, micro surfacing, chip sealing, etc, are placed at another time. This picture shows the street before recycling.
This picture shows the street being recycled.
The street in this picture has been recycled and will be repaved at a later date. It could be a week or several months.
The asphalt being applied over the recycled street is much coarser, requiring a tac coat.
The finished street recycled and repaved.

Pictures Below Show Pavement Savers Hot In-place Asphalt Surface Recycling A Road That Was Severely Cracked Due To Shrinking Of The Lime Stabilized Base Under The Asphalt

Hot in-place asphalt surface recycling, 1986. Block cracking is one of the biggest, most difficult and expensive problems on a pavement surface. In 1986 this street suffered form block cracking from 1/4” to 3/4” wide, about 7 feet square. The crack extended through the 3” asphalt and the 8” limestabilized base.
Notice the core sample. This picture shows the crack in the middle of the core.
This picture shows the crack on the very edge of the lime stabilized base, indicating that the asphalt had moved about 1” away from the crack in the base.
This picture was taken in 2008, 22 years after we hot in-place recycled it. Amazingly only about 35% of the cracks re-appeared but never did any of them open up to more then 1/64".
This picture was taken in 1986. It shows the recycled asphalt.
Picture of the same area as picture above 2008, 22 years later.
In 1986 Pavement Savers hot in-place recycled 1” and installed 1” of new asphalt.
Picture of the same area as picture above 2008, 22 years later.
Picture of this severely block cracked road being Hot-In-Place Recycled in 1986, 22 years ago.
Picture of the same area as picture above 2008, 22 years later.
Taking a core sample in 1986 after recycling and resurfacing
Close up of this same core sample. Notice the Thermal Bond between the recycled asphalt and the new asphalt. Also, just as important, notice the Thermal Bond between the recycled asphalt and the asphalt below.

Play Our "Smooth Roads 1/2 Off" Video
Single Phase Method
Click Link Below For File Type You Prefer

You MUST have a High Speed Internet connection using DSL or CABLE MODEM for the video to play correctly.
If you are using a dial-up connection please call us at 800-677-9442 so we can send you a video.

Play Video Options
Please click links below
to play video:

Hot-In-Place Movie - Windows Users

Hot-In-Place Movie - Mac Users

If you get an error msg that says you need a plugin please go to the locations below to down load and install them

Windows Media Player plugin

QuickTime plugin

If you want to be more informed about Hot-In-Place Asphalt Surface Recycling then most Pavement Managers ask us to send you A Slide Presentation we have installed on a DVD for your convenience, running time 30 minutes. You are now the Expert in Hot-In-Place Asphalt Surface Recycling the most economical was for smooth roads.

Additional Links to Specifications & References are below:

ARRA Specifications for Hot In-Place Asphalt Surface Recycling

Pavement Savers Specifications for Hot In-Place Asphalt Recycling

NEW Pavement Savers Generic Recycling Specifications at One and A Half Inch (1 1/2”)

NEW Pavement Savers Generic Recycling Specifications at Two Inches (2”)

Guidelines For Setting Up a Hot In-Place Asphalt Recycling Program

Invitation To Bid

Cost Comparison Chart

Letter of Reference from the City of Orlando, Florida