On this 1997 project contracted by SemMaterials, millings were crushed to 1" maximum size, treated with emulsion, placed through a paver, compacted, and opened to traffic on the same day.

Because the millings had a high sand content and Seneca Road has a high percentage of truck traffic, early strength and long term stability were major concerns. The SemMaterials system of strict control on sizing, processing, emulsion quality and construction turned out to be key. The emulsion treated material coated well and built strength quickly.

The project called for approximately 5300 tons of RAP Mix, with part to be placed in one lift and the rest in two lifts. Because of the location of the project, traffic could not be blocked off during construction. The equipment was calibrated, with processing and laying the next day. After some adjustments in the formulation, the paver-placed material set up within 30 minutes and was rolled with a 25 ton pneumatic breakdown roller almost immediately. A steel wheel was used to take out roller marks, followed by re-opening the lane to traffic. Traffic was maintained without delays.

Part of this experimental project was sealed with slurry and part was fog sealed. The project is performing very well, with some minor cracking during the winter. The city is pleased and is anticipating using more of this process in the future.