FAQs About Cold-In-Place Recycling (CIR)
+62%

Overall energy savings

+52%

Less greenhouse gas emissions

  90%

Reduction in truck traffic

  0  

Zero waste approach

  • “It is a beautiful thing when a Green solution is also the most cost effective solution.”
    Michael J. Murdter P.E.,
    Director Roads and Airports Department, County of Santa Clara

  • “This is very meaningful for us primarily because we do not have enough funds to take care of our roads. CIR is very successful in terms of quality, ease of construction and minimal impact on our community.”
    Hans F. Larsen P.E.,
    Director of Transportation, City of San Jose

  • “We are very committed to CIR and we want to close the loop on Recycling by your soon-to-be-deployed Cold Central Plant Recycling (CCPR), where we can utilize millings from our roads, which are currently going to dump sites and increasing our landfill, to be recycled and reused in our road projects.”
    George M. Bolton III,
    Construction Manager, County of Alameda Public Works Agency

  • “We liked CIR on our projects. It is fast and the minimal dust during construction is huge for us and our residents.”
    Ashraf I. Shah,
    Assistant Engineer, City of Foster City

  • “It is a beautiful thing when a Green solution is also the most cost effective solution.”
    Michael J. Murdter P.E.,
    Director Roads and Airports Department, County of Santa Clara

  • “This is very meaningful for us primarily because we do not have enough funds to take care of our roads. CIR is very successful in terms of quality, ease of construction and minimal impact on our community.”
    Hans F. Larsen P.E.,
    Director of Transportation, City of San Jose

  • “We are very committed to CIR and we want to close the loop on Recycling by your soon-to-be-deployed Cold Central Plant Recycling (CCPR) where we can utilize millings from our roads, which are currently going to dump sites and increasing our landfill, to be recycled and reused in our road projects.”
    George M. Bolton III,
    Construction Manager, County of Alameda Public Works Agency

  • “We liked CIR on our projects. It is fast and the minimal dust during construction is huge for us and our residents.”
    Ashraf I. Shah,
    Assistant Engineer, City of Foster City

What is it?
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It is a rehabilitation technique that reuses existing pavement material without the application of heat. It involves grinding off the top 2 to 6 inches of the existing asphalt surface, reclaimed asphalt pavement (RAP). The RAP is sized per design specifications, and mixed with a recycling agent and/or asphalt binder, before it is put down on the same road.

It is typically delivered via: multi-unit, using a “train” of equipment which includes an emulsion tanker, milling machine, sometimes a crusher and a screen, and an asphalt paver and a combination of pneumatic and vibratory rollers – because of the length of the train this process can be difficult on tight, curvy and narrow streets;

Or, a single-unit where the milling, mixing and placement of recycled asphalt is completed in a single machine similar to Wirtgen 3800CR. This single unit machine is suited for large roads as well as tight, curvy, and narrow roads.

P1010780

Why do it?
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Cold-In-Place Recycling (CIR) is becoming a popular method for rehabilitating asphalt roads.

Recycle
  • Overall energy savings of 62% +
  • Greenhouse gas emissions reduction of 52% +
  • 90% reduction in truck traffic during project
  • Zero waste approach to pavement rehab
City of Foster City, 2011:
  • Bid as alternate with 23% base repairs
  • Total savings of $100,078 or 23%
City of San Jose, 2011:
  • Bid as alternate with .25’
    Mill/Off-haul
  • Total savings of $418,070 or 16%
Alameda County, 2012:
  • Value Engineering Project
  • Total savings of $550,000 or 31%
Before / After side-by-side Before / After side-by-side
Night OperationNight Operation
Single lane closureSingle Lane Closure
  • 100% Access to all emergency vehicles during the process
  • Construction times typically 50% shorter than traditional methods
  • Minimal truck traffic (eliminate off-haul)
  • Single lane closure
  • 60-90 minutes to reopen roads to traffic
  • Immediate access okay
  • Night operations okay
  • Never leaves a hole
City of San Jose Fire HouseCity of San Jose Fire House
Unlike conventional remove and replace methods, cold in-place recycling utilizing a single unit train does not leave a lowered section or hole that limits access for emergency vehicles. The roadway is ground, treated, wind rowed, and placed utilizing a vibrating tamping screed all within the recycler. The CIR surface can be traveled across by vehicle or foot within minutes. This all translates into no disruption of services when performing work in front of hospitals, firehouses, schools, and police stations.
When to consider it?
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  • If you are considering value engineering alternatives to your traditional road reconstruction methods that will save you 20-40% of your total budget
  • Top 3”-6” surface failure, including excessive surface cracks, thermal distress, and oxidized asphalt
  • If your project exceeds 80,000 sqft. with greater than 30% dig-outs
  • When short construction times are critical
  • When traffic control demands single-lane closure
Top surface failure
Why choose FMG?
+
  • Completed over 10M sf of Cold-In-Place Recycling Expanded Asphalt Method (CIR-EAM) across numerous Bay Area Agencies.
  • CalTrans certified Quality Control and Quality Assurance (QC/QA) mobile laboratory and technicians.
  • We stand behind our service and product.
  • Experienced Crew—We love what we do!
Performance Value Reliability Seal

Public agency corner
Cold-In-Place Recycling is not new—it has been around for over thirty years

Learn more about the Cold-In-Place Recycling Expanded Asphalt Method (CIR-EAM):

Quality Control and Quality Assurance the FMG Way

QC Ext 1

We provide in-house Quality Control Testing and Inspection Services for all of our projects as part of our cold in-place recycling (CIR) services. We believe that owning the Quality Control testing procedures is a sure way to speed up turnaround time and address any defects immediately.

Towards that goal, we invested in customized mobile equipment a “laboratory on wheels,” and highly trained personnel that brings over ten (10) years of QA/QC experience working for well known engineering inspection firms.

QC Int 1 
QC Int 3

Our mobile laboratory is California Department of Transportation, Caltrans Certified (certification #531), and enables us to deliver real time results allowing for a high degree of quality control.

We achieve this higher degree of quality control by decreasing the turnaround time of test results. Final Compaction test reports as well as material grain size distribution reports are available for review in real time, with strength verification reports available within 72 hours. This quick turnaround allows us to make real time, critical adjustments to our procedure to ensure the highest quality product available.

We are so committed to Quality Control that we routinely test at a higher than required frequency to ensure nothing goes unchecked.

CIR one year later
This is a cross section of Monterey Highway in San Jose, one year after we completed CIR.
The homogenous CIR mix is as durable as virgin mix and behaves in the same manner when cut across.
We can come to you and your team and present a brief demonstration as well as showcase samples of the finished product
We can come to you and your team and present a brief demonstration as well as showcase samples of the finished product
We can come to you and your team and present a brief demonstration as well as showcase samples of the finished product.
For more information, please contact Dennis McElroy

Some State and Federal Case Studies

Highway 80, California (2005) Highway 80 Oct 2005

In 2005 State of California Department of Transportation (CalTrans) awarded a CIR Project, contract no. 03-0A6004, on Highway 80 in Marysville – State Highway in Placer County 80 PM 14.3/33.3.

Highway 80, California (2011)Highway 80 Jan 2011

CalTrans went back nearly six years later, 2011, and conducted a study to evaluate CIR performance on this section of the highway.

Some findings from the study:
  • Daily Traffic: 100,000 Vehicles, 8.5% Trucks.
  • Aggregate Traffic Over 5-Year Period:
    • 137,000,000 Vehicles.
    • 11,500,000 Trucks
Conclusion:

No Maintenance Calls During 6-Years of Operation!

US 64 Project, New Mexico (1984)

The first CIR Project, according to The Federal Highway Administration, was completed in 1984 on Highway US 64 in New Mexico.

Conclusion:

The FHWA went back and surveyed that specific section of the highway, twelve years later, in 1996 and deemed it ‘performing adequately!’

Download Case Study

CIR Equipment
The equipment to install CIR, since its beginnings some thirty years ago, has evolved into technologically automated machinery

We own Wirtgen Cold Recyclers, model 3800CR Downcut with integrated Vögele screed.  This is a single-train unit that pulverizes existing asphalt, to a maximum depth of six (6) inches, which is then mixed with an asphalt binder (oil) and water in the machine’s heavy-duty milling and mixing chamber to create a new mix.  This mix is deposited back and spread uniformly across the entire width by the machine’s spreading auger, thus allowing the machine’s paving screed to place and compact in a single sweep.

With our 3800 CR machines, we can recycle curvy roads, busy intersections as well as wide-open roads without the “package” that snarls traffic and creates dust.

Contact Us

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Cold-In-Place Recycling & Asphalt Milling

Dennis McElroy
dennis@fmgcoinc.com


Miguel Zarate
miguel@fmgcoinc.com

Mariana Viera
mariana@fmgcoinc.com

Ed Schwartz
ed@fmgcoinc.com

Mailing Address
5225 Hellyer Ave. Suite #220
San Jose, CA 95138

T (408) 573-9364
F (408) 573-8364