Does Recycling Compromise Long-Term Performance and Life-Cycle Costs? A Comparative Analysis of Full-Depth Reclamation and Overlay Pavements

To reduce the environmental effect of transportation, departments of transportation are incorporating cold recycling technologies, such as full-depth reclamation (FDR) in their rehabilitation strategies. One of the limitations of FDR is the paucity of available information on the material properties of these mixtures and their long-term performance. The aim of this project is to compare the long-term performance and life-cycle costs of FDR with those of traditional mill-and-overlay. For each alternative, a set of reference sections across Colorado was analyzed. Historical information of costs, maintenance history, and pavement roughness conditions were characterized using statistical analyses. This information was then incorporated in a probabilistic analysis using Monte Carlo simulation to estimate life-cycle costs, long-term roughness conditions, and cost-effectiveness for both rehabilitation alternatives. FDR was found to be a more cost-effective rehabilitation solution than overlays. On average, the life-cycle cost of FDR pavements is $259,886 per lane mile less expensive than overlay pavements, resulting in a potential cost saving of 38%. FDR pavements also have a better long-term roughness performance than overlays. Over the 10-year analysis, FDR pavements have an average roughness, measured using the International Roughness Index, of 100 in./mi, compared with 107 in./mi for overlays. Future research to analyze the environmental effects of these alternatives is recommended to fully capture the benefits of FDR rehabilitation.