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🌍 Milling and Recycling Pavement Process

1️⃣ Milling (Cold Planing)
• What is it?
• Milling is the controlled removal of a portion of the existing asphalt pavement surface using a milling machine (cold planer).
• Why?
• To remove damaged, worn, or uneven surface layers.
• To maintain proper road profile and smoothness.
• To prepare the surface for new asphalt overlay.
• Process:
• A large rotating drum equipped with cutting teeth grinds and removes the top layer of pavement (usually 25–100 mm, but can go deeper if needed).
• The milled material (called Reclaimed Asphalt Pavement — RAP) is collected and transported for recycling.

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2️⃣ Recycling (Reusing Milled Material)
• What is RAP?
• Reclaimed Asphalt Pavement (milled material), consisting of aggregates coated with aged bitumen.
• Why recycle?
• Cost saving on materials.
• Environmentally friendly (reduces landfill waste and conserves natural resources).
• Reduces energy consumption and emissions.
• Process:
• The RAP is crushed and screened to desired sizes.
• It is mixed with new aggregates and fresh bitumen binder, sometimes rejuvenating agents are added to restore bitumen properties.
• The mixture can be used:
• In hot mix asphalt plants (producing new asphalt mixes with a portion of RAP).
• In cold recycling processes (emulsified asphalt or foamed bitumen methods).
• Directly for base or sub-base layers (in situ recycling).

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3️⃣ Laying New Surface
• After milling and preparing the base, a new layer of asphalt is laid over the milled surface.
• Compaction is carried out using rollers to achieve proper density and smoothness.
• Finally, road markings and finishing touches are added.

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✅ Advantages
• Saves cost on new materials.
• Improves surface drainage and smoothness.
• Extends road lifespan.
• Promotes sustainability.