innovative reconstruction process

This innovative reconstruction process is a cost-effective alternative to more traditional methods of rebuilding asphalt roadways. It is used when the existing asphalt pavement has aged, cracked, or deteriorated in other ways beyond the point of when normal road maintenance practices are feasible.

Cold In-Place Asphalt Recycling is the method of milling in-place and reusing existing asphalt material (RAP). Sometimes the underlying good quality aggregate (RAM) is used to rebuild and repave a roadway without the use of heat. 

The process involves milling the top 3 to 5 inches of the existing asphalt surface. Next we use a down-cutting milling machine. We then size and mix the milled asphalt with bituminous emulsions and/or chemical additives to produce a restored pavement layer.

Once mixed, the material is conveyed into a bituminous paver and placed to the desired depth and elevations of the project plan.

Compaction of the Cold In-Place Asphalt material is completed using a 12 ton or more double-vibratory roller and 23-25 ton pneumatic tired rollers.

The CIR processes can correct cross-slope percentages, fill areas of depression, and restore curb reveal to its original curb design.

Cold In-Place Asphalt Recycling Applicability

  • Raveling
  • Pot Holes
  • Bleeding
  • Skid Resistance
  • Rutting-Wear
  • Corrugation
  • Block Cracking
  • Longitudinal and Transverse Cracking
  • Reflective Cracking
  • Utility Patching and Trenching 
  • Swells, Bumps and Depressions


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innovative reconstruction process

Utilizing the existing roadway materials will eliminate the need for importing and exporting additional materials on the project site. It also reduces truck impacts and excess strain on adjacent roadways. All of the work is done in place on the pavement being recycled.

Weather, traffic, oxidation, and loading will cause asphalt roadways to become distressed and to deteriorate with cracking, surface disintegration, and pavement surface deformation. As the deterioration becomes more severe, the conventional approach of simply applying an overlay becomes ineffective, both in performance and economic value. Cracks and other distresses can quickly reflect through the overlay.


  • 30-50% cost savings over conventional reconstruction, saving tax dollars.
  • Minimal interruptions to normal traffic flow, roadway typically stays open during construction to lessen the impact on local residents and businesses.
  • Improvements to pavement cross slope.
  • Returning pavement curb reveal to help with storm water flow.
  • Additionally, energy is being conserved because the process does not use heat.
  • Stronger Roads, thicker asphalt bases provide a stronger foundation and renew the road lifespan.
  • Environmentally Superior Processes, natural resources are preserved.
  • No waste materials going to landfills.
  • Roadway widening can be achieved, utilizing the Cold In-Place Asphalt Recycling.

The images below are road candidates for CIR.

CIR Process

This innovative reconstruction process is a cost-effective alternative to more traditional methods of rebuilding asphalt roadways.  

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1: Down Cutting

The heart of the operation is the “down cutting milling machine”. These machine are the most environmental-friendly asphalt recycling machines made in the USA. The Milling Machine can cut width’s of 10 or 12 feet wide and depths of 3-6 Inch’s. Down cutting improves the control of material sizing and is advantageous in CIR applications. An additive spray bar is mounted on the cutter housing to inject emulsion into the cutter housing. The additive (emulsion) is then thoroughly blended with the milled material by the cutter drum and fed by conveyor directly into the bituminous paver.

Milling Machine features

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2: Lay with Paver

The material from the mill is conveyed by way of two conveyors into the hopper of a bituminous paver.
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3: Lay to Depth & Scope

The bituminous paver will then relay the mixed material to the depth and scope of the new plan.
The Cold In-Place Asphalt Recycling. The tanker is attached to the Down-Cutting- Milling Machine. The tanker is carrying the new liquid binder CSS-1h Emulsified Asphalt. The down-cutting-mill produces a gradation of -2 inch sized material. After the material is mixed in the cutting chamber it is moved by way of first and second stage conveyors directly into the bituminous paver.

4: Apply Additive

At the front of the milling machine a tanker holding the new additive (emulsion) and is pushed by the milling machine, in most cases the new additive is CSS-1h Emulsified Asphalt.

CIR in Action!

Hover over each image to understand and read a description of what is being shown!