Global Convention on Cold Central Plant Recycling (CCPR)

A Milestone in Road Sustainability at the Ghaziabad-Aligarh Section of NH-91 with record paving of 112.5 lane-km of Bituminus Concrete in 100 Hrs.

The Global Convention on Cold Central Plant Recycling


The convention also celebrated the completion of 112.5 lane kilometer of Bituminous concrete surfacing in just 100 hours

The Global Convention on Cold Central Plant Recycling (CCPR), hosted by Cube Highways Advisors and Cube Highways Technologies, was held on December 4, 2024, at Welcome Hotel by ITC, Dwarka, New Delhi. The event aimed to disseminate the knowledge and experience of implementing Cold Central Plant Recycling (CCPR), and its role in enhancing the sustainability and longevity of road construction. It also served as a platform for sharing knowledge, discussing challenges, and building capacity for the industry's future.

The Convention, supported by NHAI and IIT Madras and partnered by Indian Oil, Wirtgen Group, BITCOL, OOMS India, and L&T, brought together leaders, experts, and stakeholders from the infrastructure and technology sectors. The event was honored by the presence of Shri Santosh Kumar Yadav, Chairman of NHAI, and Shri S. K Nirmal, former DG & SS, MoRTH.

Welcome Address by Dr. Harikrishnan K. Reddy

Chairman, Cube Highways Advisors

Dr. Harikrishnan K. Reddy, Chairman, Cube Highways Advisors, in his welcome address, highlighted the need for advanced road technologies for building efficient and environmentally sustainable roads in India, which boasts one of the largest road networks in the world. He informed that the lifespan of many roads in India was far shorter than expected, with pavements failing after just a few years of construction. Local factors such as overloading and extreme climatic conditions can also contribute to road deterioration, often leads to frequent repairs. In such a scenario, adopting advanced recycling methods like Cold Central Plant Recycling (CCPR), would offer significant benefits, including reduced repair needs and improved road quality and longevity.

Referring to the Ghaziabad-Aligarh section of NH91, he emphasized how the successful implementation of CCPR, demonstrated the effectiveness of CCPR in restoring and extending the life of roads. He encouraged industry collaboration and knowledge sharing to further advance road maintenance practices and contribute to sustainable infrastructure development across the country.

Dr. Reddy also shared another momentous achievement of the same highway strech- Cube Highways had set a world record by completing 112.5 lane kilometer of surfacing of Bituminous concrete in just 100 hours in the Ghaziabad-Aligarh section. This was a remarkable feat, given the challenges of land acquisition, utility shifting, and logistical concerns. The success of this project showcased the effectiveness of innovation, project management, teamwork and demonstrated Cube Highways' leadership in the industry.

Address by Dignitaries

Former DG & SS of MoRTH and a key figure in India’s road sector

S. K. Nirmal, former DG & SS of MoRTH and a key figure in India’s road sector, emphasized the importance of CCPR and other technologies in India’s road infrastructure and commended NHAI for implementing them and setting higher standards in road construction. He acknowledged the valuable feedback from NHAI, which helped guide the development of the National Recycling Policy in 2015.

He shared his experience with early recycling projects, , and highlighted the roles of the Bureau of Indian Standards (BIS) and the Indian Roads Congress (IRC) in setting construction standards. He pointed out IRC's focus on eco-friendly technologies aimed at reducing carbon footprints, in alignment with the United Nations’ 2050 zero-emission goal.

He recalled the Ministry of Road Transport’s 1985 recycling guidelines and his involvement in the Jammu-Pathankot recycling project in 1986. Despite initial challenges with costs, recycling became more efficient, and by 2002, guidelines for hot-mix and cold-mix recycling were published, helping expand its adoption. He emphasized the importance of using recycled materials like Reclaimed Asphalt Pavement (RAP), especially given the scarcity of raw materials, as over 90% of India’s roads are flexible pavements.

He also discussed the need for updating current recycling guidelines based on industry feedback, particularly concerning the maximum percentage of recycled material that can be used. He acknowledged quality control as a key challenge and expressed hope that the discussions at the Convention would lead to advancements in road construction practices. He urged Cube Highways to continue exploring new technologies and providing feedback on existing codes.

Chairman, NHAI

Santosh Kumar Yadav, Chairman, NHAI and Chief Guest discussed his extensive career in infrastructure development and his commitment to leveraging innovative technologies like CCPR to create better, more sustainable roads. He acknowledged the efforts of all stakeholders, particularly Dr. Harikrishnan K. Reddy and his team, for their continuous work in the highway sector. He highlighted the remarkable contributions of Cube Highways, citing their involvement in several capacity-building sessions aimed at strengthening the sector. He also praised the collaboration with engineers and contractors, which has led to the successful implementation of innovative technologies.

One of the significant milestones under his leadership has been the implementation of CCPR, the construction of 534 lane kilometers of road sections in the Ghaziabad-Aligarh Road, using 90% recycled materials. This project’s success resulted in a reduction of about 78,000 tons of carbon dioxide emissions, demonstrating that development can occur without having an adverse impact on the environment.

He emphasized that while economic progress is essential, it must be achieved using new technologies that align with environmental goals. While acknowledging the challenges faced in advancing new technologies, he expressed his appreciation for the team's spirit of innovation.

He laid stress on continuous monitoring of project quality, independent audits and certifications, as well as awareness and training for fieldworkers and supervisors, for maintaining high construction standards. To support this, the NHAI has created instructional videos on the implementation of new practices in the field of road construction. He called for continued innovation, knowledge sharing, and the wider adoption of new technologies. He assured the audience that NHAI is fully committed to innovation and research, with the goal of delivering world-class infrastructure.

Unveiling of the GAEPL World Record 100 in 100 Coffee Table Book

During the inaugural session, Cube Highways unveiled the ‘GAEPL 100 in 100’ coffee table book which celebrates the completion of 112.5 lane kilometers of surfacing in just 100 hours. The book documents the journey of this achievement. Dr. Reddy expressed his pride in the achievement and acknowledged the collaborative efforts of the teams involved.

The Global Convention on Cold Central Plant Recycling

 

Technical Sessions

The inaugural session was followed by a series of technical sessions, each addressing key aspects of CCPR such as Design Aspects of CCPR; Field Implementation of CCPR; Strategic Perspectives and Initiatives on Bituminous Materials in CCPR; and Global Experience of CCPR, Performance Evaluation, and Sustainability. These sessions were conducted by experts with discussions on sustainable road technologies.

The Global Convention on Cold Central Plant Recycling


Bhanoj Dokku, Vice President – Strategies & Analytics, Cube Highways, provided valuable insights into the strategies behind employing CCPR. He discussed the research, investigations, and traffic studies that guided the design process; and the challenges posed by existing pavements that were in a poor condition or had no remaining life. Investigations revealed issues with binder content, aggregate properties,. Traffic studies were conducted to estimate the design traffic, which showed a substantial increase compared to the initial design.

To address the deteriorating pavement, multiple options were evaluated. Cold In-Place Recycling (CIR) and CCPR were considered due to their sustainability and cost-effectiveness. However, due to time constraints and challenges in implementing CIR, CCPR was selected for its superior quality control. In the Ghaziabad-Aligarh road sections, the design and implementation strategy focused on using higher-quality binder materials and addressing weaker road sections with CCPR. This approach allowed the team to effectively handle material challenges while ensuring sustainability by recycling 650,000 metric tons of Reclaimed Asphalt Pavement (RAP).

The Global Convention on Cold Central Plant Recycling


The most distressed areas were treated with CCPR, while conventional methods were used for the less damaged sections. The project successfully blended innovation with practicality, ensuring durability and sustainability within the required timeframe.

Dr. Stéphane Charmot, Technical Director at Ingevity, USA, discussed the design of emulsions for superior results in cold recycling projects, the chemical properties, selection criteria, and the development of tailored emulsions to achieve superior results in recycling projects.

With over 30 years of experience in pavement engineering, Dr. Charmot has been involved in more than 100 recycling projects in the US and Asia, focusing on cost-effective maintenance and rehabilitation technologies, particularly using RAP, cold recycling, warm mix asphalt, and asphalt emulsion-based methods. He explained how asphalt emulsions are produced and optimized for specific applications, especially for CCPR; the emulsification process; the importance of particle size; and how the emulsion’s behavior (such as its breaking rate) impacts performance. He also discussed different types of emulsions—rapid, medium, and slow set—and explained that CCPR typically requires a slow-set emulsion.

He explained that engineered emulsions are specially formulated for each project to achieve the desired mixture properties. He highlighted the need for quality control, compatibility with recycled materials, and the importance of environmental conditions in the emulsion’s performance. His presentation provided valuable insights into optimizing CCPR applications for sustainability and efficiency.

J. Murali Krishnan, Professor, Department of Civil Engineering, IIT Madras, has expertise in highway engineering and pavement engineering, having worked as an asphalt engineer on NH1 and NH45 during one of India’s earliest cold in-place recycling projects in the 1990s.

The Global Convention on Cold Central Plant Recycling


Professor Krishnan emphasized the importance of understanding material properties to create stable and durable cold recycling mixes, and provided valuable insights into CCPR complexities. He gave a presentation on the mix design of immersion-based cold recycling mixes, and emphasized the importance of consulting reference manuals, including the TG2 guidelines, UC Davis manual, AASHTO, and JTG T5521 guidelines, which offer valuable insights into cold in-place recycling practices.

He discussed the importance of distinguishing between recycling and reclamation, as there are common misconceptions about the two processes. He explained that according to Caltrans' definition, recycling involves using the material for the same purpose, while reclamation reduces the material’s quality. Regarding challenges in mix design, he noted that while one might assume a straightforward mix of 90% reclaimed asphalt pavement (RAP), 10% virgin aggregate, 2.5% water emulsion, and 2% cement, the actual design process is far more complex due to the dynamic interactions of the materials.

He presented guidelines for selecting appropriate materials such as emulsions, cement content, and active fillers and highlighted the challenges posed by temperature, particularly in regions like Ghaziabad, where RAP material could undergo significant changes at high temperatures.

He informed that different standards from regions like JTG, South Africa, and AASHTO recommend various approaches to mix design, focusing on factors such as binder content, moisture susceptibility, and the compaction process. The use of a two-stage compaction method and rut wheel testing for assessing material properties were also explained. In conclusion, the mix design was finalized after extensive trials, resulting in a carefully sequenced combination of materials, with binder and cement content determined through rut wheel testing.

Dr. Nivitha M.R., Assistant Professor at BSC College of Technology and a graduate of IIT Madras, gave a presentation on the structural design of CCPR pavements, material mechanics, load-bearing capacity, and design guidelines. She explained the mechanistic-empirical method used globally for pavement design, including traffic, climate, and material parameters and elaborated on how stress and strain calculations inform the pavement's load-carrying capacity, and the importance of understanding modulus variations across pavement layers.

She discussed various design approaches from South Africa, Australia, and the US, highlighting the need for tailored distress transfer functions, especially for Bitumen Stabilized Materials (BSM), and demonstrated how the design principles help optimize pavement longevity and performance, especially under varying traffic and climatic conditions.

President – Engineering, Cube Highways Technologies

Arpan Ghosh, President – Engineering, Cube Highways Technologies, gave a presentation on the implementation of CCPR and the importance of a Standard Operating Procedure (SOP). He discussed the challenges encountered on the Ghaziabad-Aligarh road, emphasizing the need to select the right technology to maximize recycling effectiveness CCPR, however, proved to be more efficient in using larger percentages of RAP.

He highlighted the difficulties in maintaining consistent material properties due variation of the reclaimed material. As a solution, a controlled process with rigorous quality checks was implemented at every stage, ensuring high precision, and underscored the importance of maintaining strict timelines and extensive testing to ensure the solution’s long-term viability.

As regards production, he said that a well-defined SOP is needed to maintain consistency across all phases of the project. He shared that the team focused on precise milling speed, moisture control, and compaction to avoid any inconsistencies in construction process. A detailed dashboard was used to monitor performance metrics and ensure all processes followed the established guidelines. The collaborative effort from engineers, contractors, and designers was key to the success of this challenging yet rewarding project.

To view presentations by other experts, please scan the barcode provided.

CCPR Technology: Revolutionizing Road Construction with Speed, Sustainability, and Safety

Ghaziabad Aligarh Expressway Private Limited (GAEPL), under the guidance of Cube Highways, has achieved a remarkable feat in road construction. The project completed a record-breaking 112.5 lane-km of Bituminous Concrete (BC) in just 100 hours, showcasing speed, efficiency, and the benefits of advanced technology. A key contributor to this success is the Cold Central Plant Recycling (CCPR) technology, which is transforming highway construction and rehabilitation in India.

The Global Convention on Cold Central Plant Recycling

The Role of CCPR Technology

CCPR, developed in collaboration with IIT Madras, focuses on reusing reclaimed asphalt pavement (RAP). This technology reduces the need for virgin materials, cutting costs and minimizing environmental impact. The process involves mixing RAP with a special emulsion binder and water at an in-plant facility, which is then used to create durable base layers at the construction site. Importantly, the cold recycling method avoids heating, reducing fuel consumption and greenhouse gas emissions, making CCPR an eco-friendly solution for road construction.

Environmental and Economic Benefits

CCPR technology significantly lowers the environmental impact by minimizing the use of virgin materials, conserving natural resources, and reducing carbon emissions. This approach not only aligns with sustainable practices but also results in substantial cost savings for large-scale projects. The rehabilitation of 89 km of the Ghaziabad-Aligarh section using CCPR, which included over 5 lakh metric tons of cold mix, is a landmark achievement in the Indian highway sector.

Economically, CCPR reduces material costs, contributing to overall project savings. Its use ensures long-term pavement durability while limiting the environmental and financial costs associated with traditional construction methods.

Speed and Safety: A Record Achievement

In May 2023, GAEPL set a world record by paving 112.5 lane-km of BC in 100 hours, a milestone made possible by the efficient use of CCPR technology. The project's success was driven by extensive planning, with over 2000 workers, 250+ engineers, and a fleet of 100+ trucks working in harmony to meet stringent timelines. The project also adhered to rigorous safety protocols, ensuring that the record was achieved without accidents or incidents.

A Sustainable Future for Road Construction

GAEPL’s successful integration of CCPR technology exemplifies the future of road construction. With a focus on sustainability, speed, and safety, the project is setting a new standard for infrastructure development in India. The use of advanced materials like Performance Grade (PG) Polymer Modified Bitumen, along with energy-efficient machinery, showcases how modern road construction can be both cost-effective and environmentally responsible.

GAEPL's achievements with CCPR technology will undoubtedly inspire future road construction projects, encouraging the adoption of sustainable, innovative practices across the industry. The project serves as a model for how collaboration, research, and technology can drive the future of highway construction while reducing environmental footprints and ensuring long-term infrastructure success.

 

NBM&CW - January 2025

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