Apparatus for use in a paving operation

Abstract

A primary furnace device is adapted to heat a paved area to a first predetermined temperature. A secondary furnace device is adapted to heat the paved area to a second predetermined temperature via a multi-stage process having at least two heating zones interspersed with at least one soaking zone. A heater/shaver is adapted to heat the paved area to a third predetermined temperature and to shave the heated paved area to a predetermined depth to create a first mixture located upon a substrate. A mixer/finisher is adapted to collect the first mixture, mix the first mixture, and produce recycled pavement. The primary furnace device, secondary furnace device, heater/shaver, and mixer/finisher travel in series along the paved area in a longitudinal direction. A method of recycling pavement is also provided.

1 . An apparatus comprising:
 a primary furnace device adapted to heat a paved area to a first predetermined temperature;   a secondary furnace device adapted to heat the paved area to a second predetermined temperature via a multi-stage process having at least two heating zones interspersed with at least one soaking zone;   a heater/shaver adapted to heat the paved area to a third predetermined temperature and to shave the heated paved area to a predetermined depth to create a first mixture located upon a substrate; and   a mixer/finisher adapted to collect the first mixture, mix the first mixture, and produce recycled pavement;   the primary furnace device, secondary furnace device, heater/shaver, and mixer/finisher traveling in series along the paved area in a longitudinal direction.   
   
   
       2 . The apparatus of  claim 1 , wherein the heater/shaver includes a shaving blade supported by a variable-height suspension system, the shaving blade being adapted to shave the pavement from the paved area to a variable shaving depth responsive to the variable-height suspension system. 
   
   
       3 . The apparatus of  claim 1 , further comprising at least one aggregate source adapted to supply aggregate to the first mixture. 
   
   
       4 . The apparatus of  claim 1 , further comprising at least three additive sources adapted to supply at least three additives to the first mixture. 
   
   
       5 . The apparatus of  claim 1 , wherein the mixer/finisher includes:
 a suspension system adapted to support the mixer/finisher for movement along a paved area;
 a mixing plant including a drum and an auger, the auger being rotatable relative to the drum, the drum extending substantially parallel to the paved area, and the mixing plant being adapted to transform the first mixture into recycled pavement; 
 an intake device adapted to deliver the first mixture to the mixing plant; and 
 an output device adapted to deliver the recycled pavement from the mixing plant. 
   
   
   
       6 . The apparatus of  claim 5 , wherein the auger includes a rotatable helical flange, and the pitch of the flange is in the range of 20-30 degrees from the vertical. 
   
   
       7 . The apparatus of  claim 5 , wherein the mixing plant includes at least two additive sources, adapted to supply at least two additives to the first mixture within the mixing plant. 
   
   
       8 . The apparatus of  claim 5 , wherein the mixing plant is configured to mix the first mixture for a time period of at least ninety seconds. 
   
   
       9 . The apparatus of  claim 5 , wherein the mixing plant is configured to add heat to the first mixture during the mixing process. 
   
   
       10 . The apparatus of  claim 1 , wherein the primary furnace device heats the paved area to the first predetermined temperature using a plurality of adjacent heating zones. 
   
   
       11 . The apparatus of  claim 10 , wherein at least one heating zone includes an air box adapted to direct airflow to at least one heating head through at least one circulation duct. 
   
   
       12 . The apparatus of  claim 1 , wherein the heater/shaver is adapted to place the first mixture on the paved area in a predetermined arrangement. 
   
   
       13 . The apparatus of  claim 12 , wherein the heater/shaver includes at least one material handling tool adapted to place the first mixture in the predetermined arrangement. 
   
   
       14 . A furnace device for heating pavement during a paving operation, the furnace device comprising:
 a heating system with a plurality of heating zones, the plurality of heating zones being arranged in a longitudinal direction relative to the direction of movement of the furnace device relative to the pavement, each of the heating zones being separately controllable and spaced apart from each other by at least one soaking zone; and   a suspension system that supports the plurality of heating zones for movement along the paved area.   
   
   
       15 . The furnace device of  claim 14 , further comprising:
 a heating frame and a heating system for heating the pavement, the heating frame being adapted to support at least one heating zone, and the heating system being adapted to circulate combustion air through the furnace device to cool the heating frame.   
   
   
       16 . The furnace device of  claim 15 , wherein an air box directs combustion air to at least one heating head through at least one circulation duct. 
   
   
       17 . A pavement mixer/finisher for processing pavement during a paving operation, the mixer/finisher comprising:
 a suspension system adapted to support the mixer/finisher for movement along a paved area;   a mixing plant including a drum and an auger, the auger being rotatable relative to the drum, the drum extending substantially parallel to the paved area, and the mixing plant being adapted to transform the first mixture into recycled pavement;   an intake device adapted to deliver the first mixture to the mixing plant; and   an output device adapted to deliver the recycled pavement from the mixing plant.   
   
   
       18 . The pavement mixer/finisher of  claim 17 , wherein the auger includes a rotatable helical flange, and the pitch of the flange is in the range of 20-30 degrees from the vertical. 
   
   
       19 . The pavement mixer/finisher of  claim 17 , wherein the mixing plant includes at least two additive sources, adapted to supply at least two additives to the first mixture within the mixing plant. 
   
   
       20 . The pavement mixer/finisher of  claim 17 , wherein the mixing plant is configured to mix the first mixture for a time period of at least ninety seconds. 
   
   
       21 . The pavement mixer/finisher of  claim 17 , wherein the first mixture is heated within the mixing plant. 
   
   
       22 . A method of recycling pavement, the method comprising the steps of:
 heating a paved area to a first predetermined temperature;   heating the paved area to a second predetermined temperature via a multi-stage process with a furnace device having first and second heating zones fixedly connected to each other and spaced apart from each other;   heating the paved area to a third predetermined temperature;   shaving the heated paved area to a predetermined depth to create a first mixture located upon a substrate;   collecting the first mixture;   mixing the first mixture; and   producing recycled pavement; wherein   the steps of heating the paved area to the first predetermined temperature, heating the paved area to the second predetermined temperature, heating the paved area to the third predetermined temperature, shaving the heated paved area, collecting the first mixture, mixing the first mixture, and producing recycled pavement occur in series.   
   
   
       23 . The method of  claim 22 , wherein the steps of heating the paved area to the first predetermined temperature, heating the paved area to the second predetermined temperature, heating the paved area to the third predetermined temperature, shaving the heated paved area, collecting the first mixture, mixing the first mixture, and producing recycled pavement occur in the listed sequence. 
   
   
       24 . The method of  claim 22 , wherein at least one of the steps of mixing the first mixture and producing recycled pavement include the steps of
 supplying aggregate to the first mixture; and   supplying at least three additives to the first mixture.   
   
   
       25 . The method of  claim 22 , including the step of providing a mixing plant including a drum and an auger, the auger being rotatable relative to the drum, the drum extending substantially parallel to the paved area, and wherein the steps of mixing the first mixture and producing recycled pavement are both performed by the mixing plant. 
   
   
       26 . The method of  claim 22 , wherein the step of mixing the first mixture occurs for a duration of at least ninety seconds. 
   
   
       27 . The method of  claim 22 , wherein the step of mixing the first mixture includes the step of providing heat to the first mixture. 
   
   
       28 . The method of  claim 22 , including the steps of:
 evaluating a paved area to determine the properties of the existing pavement; and   responsively producing a plan for recycling the material of the paved area.   
   
   
       29 . A system for recycling pavement, the system comprising:
 means for heating a paved area to a first predetermined temperature;   means for heating the paved area to a second predetermined temperature via a multi-stage process with at least two heating periods interspersed with at least one soaking period, the means for heating the paved area to a second predetermined temperature including a furnace device having first and second heating zones fixedly connected to each other and spaced apart from each other;   means for heating the paved area to a third predetermined temperature;   means for shaving the heated paved area to a predetermined depth to create a first mixture located upon a substrate;   means for collecting the first mixture;   means for mixing the first mixture; and   means for producing recycled pavement; wherein   the means for heating the paved area to the first predetermined temperature, means for heating the paved area to the second predetermined temperature, means for heating the paved area to the third predetermined temperature, means for shaving the heated paved area, means for collecting the first mixture, means for mixing the first mixture, and means for producing recycled pavement operate in series along the paved area in a longitudinal direction.   
   
   
       30 . The system of  claim 29 , wherein the means for heating the paved area to the first predetermined temperature, means for heating the paved area to the second predetermined temperature, means for heating the paved area to the third predetermined temperature, means for shaving the heated paved area, means for collecting the first mixture, means for mixing the first mixture, and means for producing recycled pavement operate in the listed sequence. 
   
   
       31 . The system of  claim 29 , including means for adding at least three additives to the first mixture. 
   
   
       32 . The system of  claim 29 , including means for heating the first mixture during mixing.