NEW: Falcon Asphalt Millings Recycling Demonstration 


Asphalt Recycling

“Versatile Asphalt Maintenance Equipment – An Asphalt Recycler and a Hot Mix Transporter in one!”  

Chunks of reclaimed asphalt pavement (RAP), hardened virgin hot mix and asphalt millings can be placed in the hopper of a Falcon asphalt recycler & hot mix transporter, recycled and then reused to repair roads, commercial parking lots, driveways, bike paths, etc. without an auger trailer or an auguring trailer system.

The time it takes to recycle a load of asphalt depends on the age of the material, density of the material and the ambient air temperature. The typical asphalt recycling procedure is:

  1. Load the hopper (add rejuvenator if necessary) at the end of the workday then park the asphalt recycler & hot mix transporter outside of a building
  2. Plug in the battery charger male receptacle to a working 110v outlet
  3. Set the 24-hour timer to start the diesel fired burner at a predetermined time during the night
  4. When the operators arrive for work the next morning a load of hot mix asphalt will be ready

Note: Recycling asphalt with a Falcon asphalt recycler & hot mix transporter does not require the use of an auger or an auguring system.

The three types of recyclable materials are blacktop cookies, RAP and asphalt millings:

    1. Uncompressed Virgin Asphalt or Blacktop Cookies – “Blacktop Cookies” are chunks of virgin (new), un-compacted hot mix asphalt. New asphalt is by far the easiest material to recycle because it is low in density and will reflect heat well. To make “Blacktop Cookies”, simply tailgate or strike off your waste new asphalt material to a thickness of 6” to 12”. Allow the material to totally cool to ambient temperature then break into pieces with a backhoe or loader bucket. Chunks of asphalt ranging in size from a golf ball to a car door can be recycled without an auger or an auguering system.

    1. Asphalt Chunks or RAP (Reclaimed Asphalt Pavement) – Chunks of compacted hot mix asphalt that have been removed from the street when repairing a water main or gas line, replacing manholes or catch basins or generally making “full depth” pavement repairs is commonly referred to as RAP. Because it has been compacted, RAP is a denser material and therefore typically takes a little longer to recycle.

    1. Asphalt Millings – Golf ball size pieces of asphalt produced by mechanically grinding asphalt surfaces are commonly referred to as asphalt millings. Larger millings that have a rich, black tint indicating a high bituminous content are best. Surface millings vs. full depth millings are recommended. Full depth millings will contain sub-base contaminants such as dirt, sand and gravel. Asphalt milled from asphalt vs. asphalt milled from concrete is recommended because the Portland dust that is created when milling from concrete is not compatible with bituminous products. Avoid very small pieces and asphalt dust.


Additional Falcon Asphalt Recycling Demonstration Featuring:
Falcon’s Rejuvenator Spray System

Variables in Recycling

Some of the variables are obvious (ambient temperature & moisture) while others vary with geography. Since asphalt is produced differently in different parts of the country not all asphalt reacts the same when re-heated. However, after you have recycled asphalt from your geographic region a few times you will become acclimated to the way your material recycles enabling you to “fine tune” your recycling process (i.e., time and temperature).

Ambient Temperature – Since the ambient temperature of the material to be recycled varies during different times of the year you will need to adjust your recycling times to compensate for recycling 20 degree material versus 80 degree material.

Moisture – Recycling wet asphalt or asphalt covered with snow or ice requires 25% longer recycling time to boil off excess moisture. When recycling wet or snow covered asphalt, elevate the trailer hitch slightly to drain away water.

Size and Density of Aggregates – The objective of recycling (re-heating) hot mix is to warm the bituminous materials to a “malleable state” without heating the stone to the point that it repels the oil (i.e. bleeds). The density of the aggregates used to manufacture asphalt can vary depending on the available materials that are native to a given region. A soft “limestone” aggregate will absorb heat at a faster rate than a denser aggregate such as washed river stone or a fractured granite chip.

Falcon asphalt recyclers allow you to recycle asphalt chunks and asphalt millings for less than $20.00 per ton without the use of an auger or an auguering system.