By Chris Moretti
Asphalt is comprised of a bitumen binder with aggregates, oil, and tar, forming HMAC (hot mix asphalt base course). This mixture creates a more flexible pavement than other materials, providing drivers with a smoother, more consistent ride quality. Asphalt is recyclable, and during road resurfacing, contractors use large milling machines that act like giant tillers to grind off two to three inches of the existing asphalt surface. The milled material is then collected by a dump truck.
Historically, asphalt was discarded until recycling became common practice. It can be easily recycled since asphalt doesn’t contain steel rebar or other metal reinforcements. Continue reading to learn more about crushed asphalt.
Production Process and Recycling Techniques
Our crushed materials production process starts with raw materials being delivered to us rather than being milled on-site. All incoming rubble comes directly from cities, counties, the state, or contractors working with municipalities and government agencies. These contributors bring the material to our yards.
There are no size restrictions on the incoming loads—if it fits in a dump truck, we’ll accept it. Once the material arrives, it is dumped on-site and stockpiled. We categorize this raw material as rubble and stage it until we’re ready to begin processing.
Production begins with loaders that feed the rubble into the crushing plant. The material then passes through the crusher and moves through various screens and conveyors, where it is sorted by size and quality. The finished products are then stockpiled accordingly.
Each facility is carefully organized for efficiency, providing customers with quick access to their needed materials. The process itself is fast. Cleaner rubble processes more quickly, while dirtier rubble may slow things down slightly. However, we are fully equipped to produce large volumes of crushed asphalt in our facility.
Applications in Construction and Roadway Projects
Recycled asphalt is commonly used in the same applications as other flexible base materials. In rural areas, farmers often use recycled asphalt for road bases. Once compacted, its dark black color mimics the appearance of a paved road, adding aesthetic value to farm or country landscapes. Additionally, the residual oils in recycled asphalt reduce dust once compacted, enhancing its visual appeal and functionality, particularly on scenic farm roads where aesthetics and practicality are important.
Industry Standards, Quality Control, and Regional Trends
Several key quality control measures are implemented when producing or using crushed asphalt. We conduct monthly testing through a third-party laboratory for all of our materials, especially flex base products. This external lab provides unbiased results, ensuring we aren’t grading our own work.
One critical test is the Atterberg Limits test, which measures the plasticity of the material, specifically its liquid and plastic limits. These measurements are vital because various specifications set maximum allowable plasticity levels for specific materials.
Gradation testing is another key quality control measure. This process involves a sieve analysis, using a series of screens with different mesh sizes to ensure that the material meets the acceptable range of particle sizes defined by the Texas Department of Transportation (TXDOT) or other government agencies. This process ensures the crushed asphalt is graded correctly.
Additionally, we conduct the Texas Wet Ball Mill Test to evaluate the durability of the aggregate. In this test, the material is placed in a rotating drum with steel balls and spun for about an hour, simulating stress under wet conditions. The aggregate is weighed before and after the test to measure mass loss. There is a strict limit on acceptable weight loss, ensuring the material is durable and long-lasting.
All of these tests are performed monthly at each of our crushing plants. We take great pride in consistently monitoring and validating the quality of our materials to ensure reliability and performance across all applications.
Environmental Impact
By reprocessing materials such as asphalt that would otherwise end up in landfills, we help contribute to cleaner, more sustainable construction practices and better waste management.
Conclusion
At Arcosa Crushed Concrete, we take environmental responsibility seriously. We are committed to sustainability and reducing landfill usage in everything we do. If you need to order crushed asphalt in bulk, look no further than Arcosa Crushed Concrete.
As a company, Arcosa is involved in a broad range of infrastructure-related operations and is well-equipped to handle diverse needs. I’m proud to be part of a team that consistently delivers and leads the way in responsible, forward-thinking construction material solutions.
Chris Moretti
Chris Moretti is the Regional Production Manager for Arcosa Crushed Concrete in the Dallas–Fort Worth area, where he oversees operations across seven plants—including six concrete and asphalt recycling facilities and one cement-stabilized materials plant. With nearly two decades of experience in the construction materials industry, Chris began his career with Texas Industries before moving on to Martin Marietta. His expertise spans cement-stabilized products, both recycled and virgin aggregates, and cement stabilization techniques. Known for his deep passion for the stabilized materials market, Chris joined Arcosa Crushed Concrete as a sales representative and was promoted to area operations manager within his first two years. He is currently spearheading a new venture in the Dallas-Fort Worth area that brings cement-treated material to North Texas.
