The Next Generation of HIR

Resurfacing using the Re-HEAT process runs $9 to $11 per square yard compared to conventional resurfacing methods, which typically cost $12 to $15 per square yard. Lancaster officials believe Re-HEAT can reduce the carbon footprint of roadway projects by 65%. The repaved streets are also expected to last longer. “Depending on the cost-per-ton for virgin mix in a given area, there may well be a savings of 10% to 35% over conventional mill and fill,” says Faster.

Other benefits of Re-HEAT

John Danello, Jr., pavement recycling superintendent for Gallagher, says there were many benefits to using Re-HEAT in Lancaster.

“The process uses 100% recycled materials and offers a 60% less carbon footprint than traditional processes,” he explains. “We feel it’s a benefit for everyone and the environment. Additionally, as a contractor, you lower your liability by not having 20 to 30 heavy dump trucks in traffic and putting unnecessary wear-and-tear on the existing roadways.”

Faster agrees about truck traffic, adding, “Heavy truck traffic is virtually eliminated. Trucks to haul grindings out and mix in are just are not there. On another project we completed with Re-HEAT — a 10,000-square-yard segment of a larger project in the Chicago area — we eliminated 250 truckloads of material, had no lane closure and was completed in three days versus two and half weeks for the conventional method.”

No lane closures is a huge benefit of Re-HEAT. “The Re-HEAT-processed roadways are done at the end of the day,” says Faster. “There is no lane closure, rather lane restriction, for a short period.”

“This is a single-pass process,” adds Danello. “When we’re done for the day, the roadway is open to traffic, and the public can travel on a finished product. This minimizes the amount of lane closures needed and lowers everyone’s exposure to traffic incidents and delays.”

Challenges

One of the greatest challenges of using a process like Re-HEAT is in transporting the equipment. Shepley Motors, an equipment-hauling company based in Thornton, IL, was a great asset to Gallagher for this purpose.

“Mobilization through multiple states with an oversized load was a challenge,” says Danello. “Permits had to be procured in every state, and each state was unique in its requirements and regulations. Thanks to some help from Shepley Motors, the process went smoothly.”

Danello says Shepley handled all the logistics —from procurement of permits to routing and working under tight time constraints — in order to get the equipment to Lancaster.

California regulations had to also be considered during the Lancaster project. “Specialized emission systems needed to be fabricated and installed in the equipment to comply with California regulations,” says Danello. “Our engineering staff worked closely with the manufacture to develop a system that complied with all regulations and fit our machinery while working under tight time constraints.”

One of the steepest challenges is getting municipalities and others to even consider trying a process like Re-HEAT.

“Educating municipalities, counties and DOTs is truly missionary work,” says Faster. “Attracting their attention with a cost savings is a start, coupled with quicker more efficient technology and less user delays keeps them in the game. The fact is most agencies have $100 worth of problems and $50 to fix them. They have to be looking at things like Re-HEAT.

“The best way to show an agency person is to have them roadside while the machines are performing,” he adds.

As always, the correct team of people can make or break a project. During the Lancaster project, many Gallagher team members had to travel across the country.

“Leaving your family to work across the country for 35 days isn’t an easy task,” says Danello. “We put together a core group of individuals that exceed the industry standards in many ways. They all operate under the same principals of SQP — safety, quality and production. By being safe, we keep a healthy work force, which promotes cross training and growth. Taking pride in what we do and providing a quality product, allows us to consistently set the industry standards and grow our business.

“Finally, staying focused, communicating and completing the first two tasks in order, allows our productions to continually increase without sacrificing safety or quality,” he concludes.