hall brothers recycling & reclamation

We've engineered much of the recycling train and the central plant system ourselves to prevent quality-control problems that can occur when modified general construction equipment is used for recycling. These systems represent a major investment in time, testing, and money. We have selected the equipment configuration and controls with one goal in mind: To give you the most stable and long-lasting pavement possible.

Hall Brothers Recycling & Reclamation Quality-Controlled Central Plant Cold Recycling provides durable paving and reduced maintenance at a fraction of conventional material costs.

• Saves natural resources and paving costs by recycling existing material.

• Plant design allows easy transport to work sites.

• High production capacity allows for speedy project completion.

• Cuts costs from 25% to 75% versus conventional hot or cold mix asphalt.

• Recycled surface resists raveling and stripping.

• Improves road safety by resisting rut and pothole formation.

• Allows stockpiling for maintenance with special emulsion formulation.

Hall Brothers Recycling & Reclamation Quality-Controlled In-Place Recycling offers you these extra advantages and rehabilitation savings.

• Maintains original roadway profile: There is no need to modify guardrails, bridges, signs, shoulders, or other highway features.

• Resists reflective cracking.

• Facilitates application of strengthening additives, such as lime, fly ash, portland cement, and asphalt.

• Improves roadway durability and long-term safety.

• Saves fuel and energy: There is no heating and no hauling of materials except additive.

• Saves time: Most asphalt pavements can be milled and resurfaced at a rate of 2 lane-miles per day.

• Speeds return to normal traffic flow: Lanes may be reopened daily, and completed sections can remain open prior to the application of a seal coat or asphalt-mix surface course.

• The train's powerful milling machine can cut a full depth and full-lane swath in a single pass. That's an obvious advantage in time saved and reduced traffic disruption. Full-lane milling accurate to 1/8 inch also gives us precise control of depth and pavement profile -- to help achieve a smoother, safer road that drains evenly. Nurse trucks (not shown) supply the recycling train with water and additional additives, as required.

• "Closed-circuit" design of the crushing system eliminates waste and ensures a more uniform aggregate by reprocessing oversized material to break up matrix without creating fines.
• Our microprocessor-controlled blending system keeps additive/aggregate mix within precise limits. The end result is a more durable, longer-lasting asphalt pavement.
• Our continuous-flow pugmill is specially designed and regulated to ensure thorough coating of milled material and a uniform mix that enhances performance.
• With in-place recycling, the treated material is normally deposited directly on the roadway following blending with additives in the pugmill. A conveyor at the rear of the pugmill gives operators the option of placing the recycled asphalt in windrows or loading it onto trucks -- thus reducing handling time and potential contamination.

Hall Brothers Recycling & Reclamation Quality-Controlled Asphalt Recycling provides long-term, economical, environmentally friendly, and energy-efficient renewal for roads and other paved surfaces. We know of no other cold recylcing method or operation that delivers comparable quality.

Both our in-place and central-plant recycling offer economical solutions to roadway rehabilitation. To further enhance pavement longevity and performance, we can incorporate a variety of additives, or combinations of additives, in dry or liquid form, including lime, cement, fly ash, and various forms of asphalt cement into the recycling mix.

1. In-place and central-plant recycling enable us to rebuild pavements by removing and reprocessing the old asphalt surface into a new, thoroughly remixed course. Existing cracks are eliminated. Ruts and potholes disappear. Independent research studies indicate that recycled asphalt pavements perform as well as, or better than, the original pavements.

2. During in-place recycling, the powerful milling machine at the front of our custom-built recycling train removes the existing asphalt pavement to a precisely controlled depth. Depending on sample analysis, hydrated lime slurry or water can be added at the cutting head to enhance performance of the recycled mixture and produce the optimum liquid content for compaction.

3. 3.A conveyor carries the chunks of milled pavement to our screening/crushing machine. This double-deck "closed-circuit" system diverts oversized material into an impact crusher to further break up the asphalt matrix. The screening and crushing process continues until all the reclaimed material has been sorted through the vibrating screens and conveyed to the pugmill mixer.
   

4. A high-precision belt scale weighs the moving material before it enters the pugmill mixer. An on-board microprocessor continuously adjusts the flow of asphalt emulsion, water, or other liquid additive so that the correct ratio of additives to the milled material is maintained regardless of variations in the milling depth and speed. The pugmill is also regulated so that the final mix is homogeneous.

5. The millings are uniformly coated for maximum long-term cohesion and surface strength before the recycled mix is deposited behind the train and spread by the paver. Optional windrow placement of recycled asphalt adjacent to the roadway allows for the subgrade modifications or stabilization.

6. Conventional hot-mix pavers equipped with automatic screed controls spread the recycled asphalt to the specified depth and width.

7. Heavy rollers provide the compaction needed to achieve a uniform density throughout the recycled layer. Typical rolling equipment includes a 30-ton seven-wheel pneumatic-tire roller and a double-drum vibratory roller.

8. A uniform mix results in a smooth, uniform road surface. Roads may be reopened to normal traffic within hours. Cold recycling produces a durable pavement ready for years of service. Typical highway construction includes the application of a sealcoat, or wearing course, after laydown and compaction.

Central Plant Recycling Installation

Our stationary central plants are capable of high production. This high level of productivity keeps recycling costs low. Plants can easily be transported to follow the roadwork. The high-quality cold mix produced is ready for delivery to a construction site, or it can be stockpiled for maintenance use.