Greg Miller
Andrew Deane
Nicole Martin
Western New England University
Stacie Chappell
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Palmer Paving Corporation is utilizing the innovative process of Warm Mix Liquid Asphalt with its road construction projects. The company is also active in the practice of using 100% Recycled Asphalt Pavement (RAP) where applicable. These innovative technologies benefit the world in many ways, including several of the following:
One of the innovations is a Warm Mix Liquid Asphalt. This process allows a reduction in production temperature of the asphalt mix by 40 to 110 degrees Fahrenheit (235 to 295 degrees Fahrenheit production temp). The technology first emerged in Europe and has begun being adopted by United States construction companies over the last 15 years. In 2002 N.A.P.A. (National Asphalt Paving Association) went to Europe and researched the different methods being used and made recommendations to its US members on warm mix asphalt solutions.
In 2010, The Federal Highway Administration approved the use of Warm Mix Liquid Asphalt as part of an initiative method to improve the quality and safety of roads. Palmer Paving actually began using the technology in 2008; they were ahead of the curve!
Initially a vendor approached Mike Barry, the quality manager, to sell foaming technology. Foaming is an alternate method of lowering asphalt temperatures, by injecting water into the mix and then relying on the heat from the roller to steam it out and increase compaction. Palmer invested in the foaming technology but was not allowed to use it on Massachusetts state contracts because, in Mike's words, "The state doesn't want to pay extra for water." Through the initial foam technology, PPC saw the benefits of warm mix asphalt and the increased quality of the product so they moved forward with using additives as an alternative to the foaming technology.
Secondly, an effort worth mentioning as an innovation is the use of 100% Recycled Asphalt Pavement (RAP). PPC takes previously used Asphalt, where as it would normally be sent to a recycling facility, and adds the product to its Warm Mix; in an amount defined by the specifications in each contract. Chemical additive rejuvenators improve this asphalt's "pliability" (workability) when mixed; improving the "surface life of the pavement," and saving costs on creating a fresh new surface.
Palmer Paving's driving factor is its commitment to quality. These new processes (the use of RAP and Warm Mix Asphalt) have improved the life of the roads they pave. When Mike Barry was asked if he ever worried that longer lasting roads would lead to less business for the company, he replied that company founder Charlie Callahan, "Told me never to worry about making a product that's too good - there is no such thing as too good."
At the same time, the corporation clearly outlines that it has a "longstanding commitment" to Environmental Stewardship. According to the website, the company aims to "invest in the communities where (they) live and work and (their) “greener” operations benefit employees, neighbors, and our planet." PPC recognizes that, "the public are stakeholders," and work to ensure this audience is "affected and impacted," in a positive light.
Furthermore, PPC views "Sustainability" as it relates to their company in three tiers: "the Environment, the Economy, and General Society (as mentioned in the Business Overview). Therefore, the company and its employees have a high regard for how their product and operations will affect the "health," "safety," and "well-being," of their stakeholders. It is also documented on their website that they focus on how they will "continue to enhance (their) sustainability management system while positively impacting all aspects of business."
One of the greatest impacts this technology has had is the benefit to our environment. The benefits include fuel consumption reduction and decreasing the production of greenhouse gases. The additives in a Warm Liquid Asphalt Mix are commonly organic and plant-based.
There have also been significant benefits made to the health and safety of the workers who work with the Warm Mix Asphalt, as opposed to the Hot Mix Asphalt. This innovation decreases the exposure to harmful fumes that employees typically come into contact with; therefore allowing them to live a healthier lifestyle in conjunction to their work setting.
It is also important to note the Warm Liquid Mix allows for greater "pliability" or workability. In other words, the innovation allows the product to have a great longevity without sacrificing its quality as it relates to performance. One of the benefits to the durability of this asphalt is less repaving. A greater pliability allows for a greater compaction of the paved surfaces. In fact, Mike Barry mentions, "For every percent compaction you achieve because of improved workability, the surface life of pavement improves by 10%."
Additionally, using 100% RAP (Recycled Asphalt Pavement) not only saves raw materials from being mined from the Earth, but also saves the environmental impact and carbon footprint of the vehicles and fuels used to mine those materials.
What is likely the greatest business benefit is the fuel saving, which is consumed during the mixing process. On projects where the Warm Mix Liquid Asphalt is used, fuel savings are estimated to be approximately 10-30%. One might argue that the significant reduction in production temperature (40-100 degrees F) also saves money with regard to energy expended.
The recycled product has also played a role in saving money. New asphalt mix is manufactured from rock and sand, which requires excavation. Recycled mix allows for money saving on the excavation of the materials.
PPC has also come to the conclusion that the primary innovation's improvement in pliability allows the product to sit for longer periods of time, and be used effectively in colder temperature. Where as the company traditionally had a radius of business, and typical operating months, the innovation has allowed them to adapt and increase their revenue. PPC can now travel further distances to perform road construction, as well as work longer into/start work sooner in the colder months of the year.
Meanwhile, they are not the only business benefiting. As the point out several times on their website, their product is designed to connect "commerce." Because they are able to provide a quality product to many, that has longevity, local businesses and services can benefit due to the improvement of the roads used to travel!
PPC, its product, and operations offer the following benefits to society and the environment:
PPC also makes efficient use of Recycled Asphalt Pavement (RAP) – considered to be solid waste which can be brought to a hot mix asphalt plant or a licensed recycling facility. Palmer Paving regularly accepts RAP for free (not a licensed recycling facility) and adds it to their warm mix. The amount of RAP that can be used is limited/defined by the contract for sustainability purposes.
Rejuvenator chemical additives are used to make the older mix (RAP) more pliable and increase the amount that can be used. As previously mentioned, Mike Barry stresses “For every percent compaction you achieve because of the improved workability, the surface life of the pavement improves by 10%”. Therefore, the product they are putting out into the environment is not only safe, but of a higher quality than what was previously achieved with Hot Mix Asphalt.
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Mike Barry, Quality Control Manager
