This is a knowledge sharing programme to share experiences in

HIPR and CIPR.

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Prior to understanding about HIPR and CIPR it is better we refresh
our pavement maintenance works a little bit. So we can have
bigger picture on HIPR & CIPR position in pavement rehabilitation
works.

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This is a little info about myself.

Involved in HIPR and CIPR during my 10 years service with PROPEL

all the way from Bukit Kayu Hitan – JB.

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Pavement layers originally are four layers, however within this
programme we shall categorize the pavement into two layers:

1. Bituminous
2. Non-bituminious

Reason is when we in real working scene, pavement layers shall be

more than four layers (from what we learnt in textbook) as each
layer with certain specific functionalty.

As shown in slide, the thickness may also varies depending on the

design that governed by traffic loading.

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Introduction to type of defects

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Introduction to type of defects

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For easy determination of defects, we categorize the defects based
on failures:

1. Functional
2. Structural

These defects categories can assist us in determining type of

suitable treatment.

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The chart shows type of pavement repairs categories.

HIPR & CIPR as the name have given us it own category – recycling.
We recycle in-situ, the existing pavement layers as long as it comply
with requirements.

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HIPR – to cover defects within the surface area only, within 50 mm
of surface.

CIPR – for deep crack, most of the time covering non-bituminous

layers. But some repair design also include certain final layer from
the bituminous layers. The depth of treatment normally more than
250 mm of non bituminous layers – really depending on type of
machinery used.

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History.. Now no more HIPR in Malaysia. But CIPR is getting
popular.

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Definition..

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There 3 main criteria before we choose HIPR for our pavement
rehabilitation works:

1. Surface defect thickness – the heat can penetrate about 50 mm

of pavement surface.
2. Surface bitumen not too oxidized – penetration test of
recovered bitumen should less than 20. Otherwise a lot of
rejuvenator needs to be used, not economical.
3. Uniform surface grading – not to much potholes patching.

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The process…

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The flow chart..

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A sample of core log..

Observe the cracks from below the pavement – showing the

structural defect not functional defect as such, HIPR is not suitable.

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The main machines:

1. Preheater
2. Remixer

This is of German technology; but we also have tried machinery from Japan.

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Using liquefied gas, Japanese approach using diesel for hot air to
soften the pavement surface. This German preheater using infra
red.

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Observe the dimensions.

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Observe the dimensions, it really big.

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Observe the remixer parts.

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Preheater.

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How the infra red heat penetrate the pavement surface. Observe
the temperatures.

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What it looks like beneath the preheater.

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The temperature chart as the train moves..

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Scarifier..

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Pugmill, to mix the loosened wearing course.. Here rejuvenator is
also added.

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Two type of recycling methods:

1. Remix
2. Remix Plus

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Remix – blend together with virgin mix, mainly to correct the existing grading.

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Remix Plus – add another layer above the recycled wearing course.

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Observe the processes involved during HIPR work.

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More photos on the last HIPR in Malaysia. This a
trial/demonstration of HIPR using Japanese machinery. Observe
the preheater is using the hot air system.

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Preheater.

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Surface temperature.

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Wearing course is really soft.

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Scarifying the existing wearing course.

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Recycled wearing with virgin mix is laid, however for Japanese
approach no reju was used; the existing bitumen grade in
compensated with higher bitumen content in the virgin mix.

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Leading technologies for road construction

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Observe the CIPR area and type of additives that can be used for
recycling works.

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CIPR aiming at deep cracks within the pavement layers, normal

overlay approach is not suitable as the cracks is still in pavement.
CIPR can remove the cracks and pavement last longer.

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The process...

The binding dosage is based on the design. The deisgn dosage is

determine from samples taken from the trial pit. Also important is
the moisture content of existing materials.

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Combinations of binding agents.. In Malaysia the most popular is

with cement and emulsion (the first two of the chart).

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Machines of different models with different capacity and suitability.

Most popular in Malaysia is 2200CR because besides recycling it can also be used
for milling works.

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Trial pit is a must in CIPR; during preconception stage – to

determine existing grading that still comply with specifications,
therefore CIPR can proceed. During this stage a design mix can be
proposed (percentage of additive and water to be used).

During construction stage, the existing materials to be recycled also

need to be checked on the moisture content – so we can regulate
how water to use during the mixing stage.

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Observe the mix consistencies.

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In CIPR, it is a norm to use motorgrader to get the level and profile

as per design.

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Compaction using vibro-roller – the compaction can be checked

using:

1. Field density test

2. Non-destructive test with nuclear radiation, can refer
http://www.nuclearmalaysia.gov.my/malay/RnD/industry/indus
trialTec/pat/compactionControl.php
We used this method in Simpang Renggam –
Sedenak (Expressway), 1999. We can have faster
result compared to FDT test.

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This is the most popular in Malaysia.

Refer diagram.

For small stretches, cement is spreaded evenly on pavement

surface – the ratio is by volume – based on the design mix obtained
from the samples in the trial pit.

After the cement is spreaded, 2200CR is used to pulverised the

pavement layers together with the cement. During this stage, it is
critical to observe the water content as established in the design
mix. We must also not forget about the existing moisture content
in existing pavement layers – too much or too little water shall not
produce a mix with appropriate consistencies and correct moisture
content. Thus, the recycled materials shall not achieve the required
strength as mentioned in the specifications.

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