Hot-in-place asphalt recycling machine and process

A method for providing hot-in-place recycling and repaving of an existing asphalt-based pavement, comprising the steps of

• heating a surface of the pavement using at least one preheater unit;
• scarifying the heated surface of the pavement in a first scarification process using a first set of scarifying rakes;
• collecting scarified asphalt in a first collection process from around utility structures and releasing moisture contained in the scarified asphalt in a first moisture release process;
• dispensing new aggregate onto the heated and scarified asphalt surface to form a recycled, preheated asphalt and aggregate mixture, using an aggregate bin for the dispensing;
• and
• providing a recycling machine performing the following steps:
• a. heating the recycled preheated asphalt and aggregate mixture to within a predetermined temperature range using one or more heaters;
• b. scarifying the recycled heated asphalt and aggregate mixture in a second scarification process using a second set of scarifying rakes to premix the recycled asphalt and aggregate mixture and form a new recycled asphalt and aggregate mixture, the second scarification process releasing moisture contained in the new recycled asphalt and aggregate mixture in a second moisture release process;
• c. collecting the new recycled asphalt and aggregate mixture in a second collection process;
• d. milling the pavement surface to grade and width by applying a mixing application of the new recycled asphalt and aggregate mixture using a plurality of extension mills having a main frame, the extension milling process releasing moisture contained in the new recycled asphalt and aggregate mixture in a third moisture release process;
• e. remilling the pavement surface to grade by applying a mixing application of the new recycled asphalt and aggregate mixture using a main mill, the main milling process releasing moisture contained in the new recycled asphalt and aggregate mixture in a fourth moisture release process;
• f. introducing in the main mill a first application of rejuvenator fluid containing first liquid additives to the new recycled asphalt and aggregate mixture using a rejuvenator application system, and mixing the first liquid additives and the new recycled asphalt and aggregate mixture;
• g. introducing in a pug mill a second application of rejuvenator fluid containing second liquid additives to the new recycled asphalt and aggregate mixture using the rejuvenator application system, the pug mill having first and second downwardly rotating rotors for mixing, wherein a substantially homogenous mixture of rejuvenator-enriched, recycled asphalt and aggregate windrow is formed, and wherein during mixing moisture contained in the windrow is released in a fifth moisture release process;
• and
• h. laying the homogeneously mixed windrow to grade using at least one screed.