The rapidly increasing price of landfills communicates a very clear message to all construction industry stakeholders: Avoid Landfill Use. Disposal of recyclable materials in a landfill not only wastes the material, but also the valuable landfill space and the transportation of that material to the landfill. Diverting materials from landfills is only realistic if those materials have a viable market once they have been reprocessed into a high quality product. Efficient reconstruction projects avoid landfills in the excavation phase by discriminating between materials which can be recycled and those which can not.

P. Flanigan & Sons has been developing and improving its capacity to produce sustainable aggregate products since January of 2006. We have installed a new crushing system comprised of a primary jaw crusher, a secondary impact crusher, and a two deck screen. Our experienced team has assembled this crushing and screening operation in such a manner that we can produce high quality crushed concrete in a clean and efficient manner. In addition to the crushing and screening operation we have installed a custom built pugmill. This plant blends two aggregates (typically crushed concrete and screened millings) while adding moisture and / or foamed asphalt.

RC-6 is an excellent recycled product that can be used as base material for roadways, sidewalk, curb, etc. We also offer RC-2 for construction entrances, stabilization, etc. These products have good performance over time.

This product is a blend of RC-6 and screened millings. It has excellent stability, compactibility, and load bearing characteristics. The blending takes place in our plant, where moisture content is controlled for optimal compaction. It has superior stability to crushed stone / concrete products. The mix gains stability as the cement in crushed concrete and the asphalt in the millings cure.

This product will replace both a stone base course and the asphalt base course. It is 40% screened millings and 60% crushed concrete blended in a pugmill. There is no heating or drying of the aggregates. In the pugmill, 7% water and 3% foamed asphalt are introduced into the mix. This produces a very stable and extremely strong base material. Foamed asphalt base is placed in a conventional paving operation. It bonds extremely well. The joints are nearly impossible to detect. Its stability is similar to asphalt and its load bearing is similar to concrete. Due to 14% air voids in the mix, it is not suitable as a surface course. In addition, it may be stockpiled for up to forty days.

Foamed asphalt is produced by using a specialized manifold to force water and air through conventional PG 64-22 liquid asphalt. The high temperature of the asphalt causes the cool water to expand rapidly. This expansion causes the asphalt to form miniscule air bubbles, in other words “foam”. During blending the foamed asphalt’s volume is ten times the size that the liquid asphalt alone would be. The benefit of the foam formation is that the liquid asphalt has a much greater surface area and much lower viscosity. This causes it to bind more readily with aggregates. Another benefit is that the mix will not compact until the air bubbles have been driven from the liquid. This allows stockpiling of the material.