A Cost-Effective, Sustainable Solution for Intermediate Pavement Lifts

Central mixing plant where RAP is processed into CCPR mix

With road infrastructure demands increasing and budgets tightening, state and local agencies are looking for innovative, cost-effective solutions to keep their roads in top shape. One proven method is Cold Central Plant Recycling (CCPR)—a process that reuses 100% of existing materials to create durable, high-performing pavement layers, while reducing costs and environmental impact. 

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CCPR in Action: Rebuilding Indiana State Route 236 

In 2021, Indiana’s State Route 236 became a showcase for CCPR’s potential. The 13-mile stretch had a failing subgrade and needed deep stabilization. To extend the pavement’s lifespan and improve performance, INDOT partnered with Evergreen Roadworks’ Pavement Maintenance Systems, Asphalt Materials, Inc. (AMI), Milestone Contactors and Heritage Research Group (HRG) to implement a highly efficient and sustainable reconstruction plan. 

How the Road Was Rebuilt Using CCPR 

1. Strengthening the Foundation with Full Depth Reclamation (FDR) 

Before CCPR could be utilized, the existing road needed a stronger foundation. Crews first milled the asphalt to a depth of 8 inches, hauling the reclaimed asphalt pavement (RAP) to a nearby plant for processing. 

• A 10-inch FDR base was created by mixing corrective aggregate with the existing subgrade and stabilizing it with Portland cement. 

• This provided a solid, long-lasting base layer for the new pavement structure. 

2. Creating the CCPR Mix 

At the central mixing plant, the recently milled RAP was sized and processed through a mobile, custom-designed pugmill, where it was blended with a precisely formulated asphalt emulsion to create the final CCPR mix. 

3. Placing the CCPR Lifts

Instead of using conventional hot mix asphalt (HMA) for the intermediate pavement layers, the CCPR mix was placed in two 3-inch lifts, using standard paving equipment. The roadway was then topped with a 2-inch HMA surface course for durability and long-term performance. 

The first lift of CCPR placed on top of the FDR base 

Contractor placing CCPR mix on the second lane

For low-volume roads, agencies can also consider micro surfacing or chip seal (oil and chip) as alternative wearing courses. 

Why More Agencies Are Choosing CCPR 

CCPR is transforming road construction by offering a smarter, more sustainable alternative to traditional materials. Here is why agencies are increasingly adopting this method: 

• Cost Savings – Recycling existing materials cuts costs by 20-50%, allowing agencies to stretch their budgets further. 

• Comparable Performance – CCPR provides the same durability as conventional intermediate layers, ensuring long-lasting roads. 

• Environmental Benefits – By reusing materials and reducing haul truck emissions, CCPR lowers greenhouse gas emissions by up to 50%. 

• Extended Pavement Life – Roads built with CCPR can last 15-20 years when paired with the right surface course. 

CCPR’s Growing Impact in the Midwest 

The success of State Route 236 is just one example of how CCPR is changing the way roads are rebuilt. As of 2024, Pavement Maintenance Systems and AMI have completed over 16 CCPR projects across Indiana, Michigan, Ohio and Illinois—with more to come. 

By rethinking how we build and maintain roads, CCPR is proving that sustainable solutions can also be cost-effective and high performing. 

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Want to Learn More? 

This project was recently featured in AsphaltPro Magazine! Check out the full story here for an inside look at the mix design process, custom mobile mixing plant and collaborative effort behind CCPR. 

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Interested in bringing CCPR to your next project? Contact our team today to learn more about how this innovative technique can help you maximize your road maintenance budget!