Recycled Asphalt: A Guide to Production & Equipment

Search
Home / Blog / Recycled Asphalt: A Guide to Production & Equipment

Table of Contents

 

Is asphalt recyclable? Asphalt can be removed, crushed, and reconstituted into fresh asphalt indefinitely, providing a product of similar quality, durability, and strength. Recycled asphalt, or reclaimed asphalt pavement, gives you a more efficient alternative to relying on virgin materials. Using recycled asphalt in the mix can speed up production, reduce material costs, and limit the need for additional drilling and mining.

For contractors and operators managing tight margins, rising material costs, and production demands, recycled asphalt offers a practical way to stay competitive. Here’s a look at the asphalt recycling process, the equipment involved, and some lesser-known challenges to plan for.

 

Understanding Recycled Asphalt

Recycled asphalt, or RAP (Reclaimed Asphalt Pavement), is created when existing asphalt from roads or lots is removed, crushed, screened, and reused in new asphalt production. This typically happens during reconstruction, resurfacing, or excavation projects.

Once processed, RAP is combined with virgin aggregate and additional oil to produce new pavement. Because the original material already contains binder, less oil is required, helping reduce overall production costs.

Asphalt recycling also cuts down on the need for newly mined rock and sand, which take time and effort to extract, crush, and size. For contractors and operators, that means faster production timelines and more control over material costs, especially as oil prices fluctuate.

Tip: In addition to paving, RAP can be used as fill for roadbeds and parking lots, or to create shim stock to level a site or fill in dips.

RAP remains one of the most practical material options available. It can be recycled and reused continually, reduces reliance on natural resources, and helps reduce the amount of drilling and mining required.

 

The Asphalt Recycling Process

At a high level, the asphalt recycling process starts with milling and removing asphalt, then involves processing and sorting the crushed product before it is used as the stock material for new asphalt.

How to Recycle Asphalt

  1. Milling and removal – Asphalt is removed in one of two ways: with a milling machine that removes it a layer at a time, or with an excavator that breaks it up and removes it.
  2. Transport and stockpiling – The broken asphalt is transported by dump trucks to a yard where it is dumped and stockpiled until it's ready for processing.
  3. Crushing – The asphalt pieces are sorted by size so they can be directed to the right crushing equipment:
    1. A jaw crusher or shredder is used to break up large sections or pieces into a size that can be fed into an impact crusher. Jaw crushers crush material by compressing it between a movable plate and a stationary plate.
    2. Before feeding into an impact crusher, a large magnet is used to remove metals that could damage the equipment.
    3. An impact crusher breaks down the asphalt by throwing it at a high rate of speed against a hard surface called an apron.
  4. Screening – A screen is then used to ensure that the crushed product is of uniform size. The screen may be either an integral part of the impact crusher or a separate piece of equipment.
  5. Asphalt production – The RAP is used to create new asphalt pavement through the introduction of virgin aggregate, sand, and additional oil. There are state limits on the amount of recycled asphalt that's allowed in the mix.

 

Choosing the Right Crusher for RAP

There are two main types of asphalt recycling crushers: an impactor (stand alone) and jaw/cone crushers (used as a pair). Choosing the right setup depends on the size and condition of the material you’re starting with.

Jaw crushers can be used with both an impactor or a cone crusher, and are used to break down large, hard chunks of asphalt into smaller, manageable pieces using compression. If you’re working with oversized material or full sections of pavement, this is typically the first step.

Once the material is reduced to the right size, an impact crusher is used to produce the final product. Impact crushers are built to handle softer materials like RAP, breaking them into smaller, more uniform pieces by propelling material against a metal plate.

There are several reasons why impact crushers are often preferred for recycled asphalt:

  • They produce small, cubical, and more uniform material
  • Larger chunks can often be reduced to spec in a single pass
  • High-speed impact improves material separation, resulting in cleaner, more usable RAP

Consistent sizing and aggregate content are required to meet project and state specifications. Impact crushers provide the uniformity needed to meet those requirements in a cost-effective way.

 

How Crushers and Screeners Work Together in Asphalt Production

Crushers and screeners work together to control the final gradation of asphalt made with RAP. After crushing, screening ensures the material is sized correctly and free of debris or oversize aggregate. Material that doesn’t meet spec can be reprocessed or used in other applications.

While screens and crushers are available as separate pieces of equipment, using a crusher with an integrated screen can reduce equipment costs, as only one piece of equipment is required instead of two. This means lower fuel consumption and a minimized footprint on-site.

Screening also plays a key role in reducing contamination. Magnets remove metal materials such as steel or rebar, while screens prevent oversize aggregate from entering the mix, helping maintain consistent, high-quality RAP.

 

Equipment Selection: Mobile vs. Portable Plants

Both asphalt recycling crushers and screeners are available in mobile and portable models, offering greater flexibility in choosing the right equipment for the job. Here are some points to consider when choosing between them:

Mobile Plants

Mobile plants are track-mounted, which makes them the fastest option to reposition. A tracked unit can run on its tracks when needed, so it can usually be moved sooner than a portable spread.

That matters when the job is changing, space is tight or the crew needs to get in, process material and move on without turning setup into its own project.

Portable Plants:  More Setup, More Structure

Portable plants are typically larger machines built on a rubber tire chassis and designed to be hauled into place, set up and run in a semi-stationary position.

They can be dropped into a site and pulled back out when the job is done, but they take more work to set up than a tracked mobile unit. Depending on the layout, a portable plant may take a half day to a full day to get ready.

Portable setups may also include:

  • Jacking legs that raise the machine into position
  • Wheeled stackers
  • Multiple transportation loads
  • Electric power requirements
  • Generator support, depending on the site

It is a strong setup for the right job, but it is not as quick or simple to move as a tracked mobile plant.

In regions like New England, mobile equipment dominates RAP processing due to flexibility and lower upfront investment. Read our Crushing Equipment Guide for ROI Strategies if you’re exploring mobile crushers for project-based flexibility or a stationary plant for long-term production. Some operators maximize equipment utilization seasonally, repurposing machinery for RAP processing during periods when traditional aggregate production slows.

 

Impact & Cost Benefits of Asphalt Recycling

Recyclability is a highly prized trait in a world where accessing raw materials is increasingly harder. According to the National Asphalt Pavement Association (NAPA), asphalt is one of the most recycled aggregate materials in the USA. Over 94–95% of RAP is repurposed into new hot or warm-mix asphalts rather than being discarded.

Other benefits of RAP include:

  • Reduced demand for raw materials such as oil and rock
  • Lower transportation costs and less greenhouse gas emissions
  • Reduced landfill use
  • Improved profit margins for contractors

 

Common Challenges in Asphalt Recycling

Producing recycled asphalt comes with a unique set of challenges. Many of them are manageable with the right setup, timing, and maintenance practices, but overlooking them can quickly impact performance and profitability. Here are a few of the common but lesser-known challenges of producing recycled asphalt and how to avoid them:

Contamination

Proper screening and the use of magnets can help reduce product contamination caused by debris, rebar, or other metal objects.

Equipment Wear

Using the correct size and type of equipment, along with strong preventive maintenance practices, helps protect against excessive wear and unplanned downtime. In RAP operations, small issues can escalate quickly if they aren’t addressed early.

Preventive maintenance is one of the biggest drivers of profitability. Daily checks and routine servicing directly impact uptime, cost control, and overall production efficiency.

 

Achieving Consistent Gradation

Selecting the proper crushing and screening equipment can help ensure that RAP meets the requirements for both size and quality.

Environmental and Operating Conditions

RAP processing is more sensitive to environmental conditions than most aggregate operations. In hot summer weather, material becomes sticky and dusty, which can lead to buildup in your equipment. In cold winter conditions, material can freeze inside machines and slow production. Running equipment in the wrong season or in poor conditions can quickly turn a profitable job into a loss.

 

How We Can Make Recycled Asphalt Work for Your Operation

No matter how big your operation is, Thompson Equipment is here to help. We provide support with choosing equipment such as crushers and screeners, as well as preventive maintenance and servicing to keep your equipment operating optimally.

When it comes to asphalt crushing machines, we carry Kolberg-Pioneer (KPI) jaw crushers (models GT125 and FT2650), and RUBBLE MASTER impact crushers (models RM90, RM100, and RM120X).

We offer additional asphalt recycling equipment through our partnership with 3R Machinery, including Pronar double-shaft low-speed shredders with tracked or rubber-tired options. We also carry Screenpod dust cannons, which help reduce dust hazards during mining or crushing operations. , including Pronar double-shaft low-speed shredders with tracked or rubber-tired options. We also carry Screenpod dust cannons, which help reduce dust hazards during mining or crushing operations.

Our sales and equipment experts can help you ensure that you get the right equipment for the job. Reach out to us today to learn more.