Contact Us

The Process of Hot-In-Place Recycling

Explore our cutting-edge equipment and discover the transformative steps of Hot In-Place Recycling – Where budget efficiency meets community impact with high quality roadways.

Interactive Machine Graphic

Click below on the pins to learn more about each feature on our equipment.

Pre-heater

Pre-Heater 1: Hydraulically controlled and adjustable heating bed that takes the temperature of the surface to 180-200 Degrees Fahrenheit.
Specialized Skirting: Protects and Insulates Surrounding Systems.

Operator's Box: Safety shut offs, fully adjustable speed control, remote steering, oven height and temperature control.

Heater Scarifier

Heater Scarifier: Takes the temperature of the surface course to traditional asphalt temperatures allowing the existing bituminous material to be scarified for the mixing process.

Specialized Skirting:   On the bottom of both heaters is heat resistant material that provides consistent heat patterns and optimal heat values throughout the scarification process. Keeping the heat in a more confined system prevents excessive heat from escaping. This is optimal for the safety of tree protection and energy usage.

Skirting: Protects and Insulates Surrounding Systems.

Skirting: Protects and Insulates Surrounding Systems.

Rejuvenating Agent Distributors:
Evenly and uniformly distributes the rejuvenation agent behind the REHEATED surface course. Typically, .10 gallons per SY as prescribed by lab testing.

Scarifiers: Disrupts the bituminous surface course up to 2inches deep. DOES NOT Mill - keeps existing aggregate size the same.

Screed: Traditional Asphalt Screed: fully extendable, adjustable, heated, electronically operated, and vibratory.

Combination Roller

Combination roller for ultimate compaction! Targeting the same densities as traditional asphalt pavement surface courses.

Final Wearing Course of Your Choice

Final Wearing Course of Your Choice:

  • Thin Lift HMA Overlay
  • Chip Seal
  • Micro-Surface

Here’s the 8-step heater scarification process

Lorem ipsum dolor sit amet consectetur adipiscing elit, consequat neque diam accumsan senectus risus nam, quisque platea per tellus himenaeos natoque. Vel est viverra penatibus luctus odio praesent fringilla fames gravida, integer nascetur augue molestie nec sagittis libero nulla proin litora, nisl bibendum quis.

STEP ZERO

Pre-Mobilization

  • Pre-laboratory testing ensures success
  • Agency pulls a set of 6” cores
  • Lab testing:
    • Penetration Number (softness)
    • Feasibility of HIR on Roadway
STEP ZERO
Step One

PRE-HEATING PASS 1

  • Two Step heating process ensures proper heat distribution and thermal penetration
  • First Pre-Heater takes pavement temperature to 180-200 degrees
Step One
Step two

PRE-HEATING PASS 2

  • Allowing material to be scarified at specified depth
  • Second PreHeater takes pavement temperature to 280-300 degrees (traditional asphalt temperatures)
Step two
Step three

REJUVENATING

  • Evenly apply a bituminous rejuvenating agent
  • Core testing in laboratory will help guide this application rate in the field
  • Application rates are typically close to 0.1 gallons per SY
Step three
Step four

SCARIFYING

  • Spring-loaded tines set hydraulically at prescribed depth and will drag over existing structures to avoid damage
Step four
Step five

MIXING

  • Full width reversible augers
  • Used to uniformly blend scarified material and rejuvenating agent together
Step five
Step six

PAVING

  • Re-profiling recycled asphalt through a standard paving screed
  • Eliminating centerline joint
Step six
Step seven

COMPACTING

  • Compaction!
  • Targeting same densities as traditional asphalt pavement surface courses
  • Combination Roller
  • Rubber Tire & Steel Drum
Step seven
Step Eight

Final Wearing Course of Your Choice

The now re-plasticized asphalt is ready to receive its final surface course such as:
  • Thin Lift HMA Overlay
  • Chip Seal
  • Micro-surface
Step Eight

About Services

Lorem ipsum dolor sit amet consectetur adipiscing elit vestibulum tincidunt natoque dis, nmentum, mi vivamus cum turpis dictum sapien accumsan taciti vitae quis.

Tempor donec montes phasellus feugiat habitant dignissim sociis nam natoque leo, himenaeos congue ultricies pulvinar nisl rhoncus facilisis lectus a suscipit vehicula, sollicitudin neque purus velit luctus nibh quisque litora facilisi. 

Contact Us

Benefits of Service

Lorem ipsum dolor sit amet consectetur adipiscing elit vestibulum tincidunt natoque dis, neque nec ante ut non scelerisque blandit platea diam vulputate.

Leadership

Lorem ipsum dolor sit amet consectetur adipiscing elit vestibulum tincidunt natoque dis, neque nec ante ut non scelerisque blandit platea diam vulputate.

Teamwork

Lorem ipsum dolor sit amet consectetur adipiscing elit vestibulum tincidunt natoque dis, neque nec ante ut non scelerisque blandit platea diam vulputate.

Innovation

Lorem ipsum dolor sit amet consectetur adipiscing elit vestibulum tincidunt natoque dis, neque nec ante ut non scelerisque blandit platea diam vulputate.

Our Customers’ Experiences

From start to finish, working with Gallagher Asphalt on our County HIR projects was phenomenal. The staff is extremely knowledgeable and went the extra mile to help ensure the roads we were proposing were great candidates for their HIR process. The construction crews were professional, knowledgeable, and efficient with their work and completed the process with minimal disruption to the traveling public. We completed a wide variety of roads over two construction seasons (2022,2023) from urban to rural cross-sections as well as 19 miles of shoulder/bike lane section and 28 miles of roadways. Hot in place recycling allowed us as a County to pave many more miles with the limited budget we had compared to traditional pavement resurfacing methods, which made a greater impact on our roadway network system. As a small County with limited resources, HIR was a perfect solution to give our roadways life back without breaking the bank and the end results exceeded expectations.
Teal SpellmanDirector of Public Works for Village of Bellevue
Our 26 miles of Hot In-Place recycled roads that Gallagher has built for us over the last 5 years are incredibly smooth and continue to perform well. It has been a very cost-effective way for us to rehabilitate the asphalt surface without hauling anything in or out of the project. Another great tool in our toolbox for fixing roads in Champaign County.
Jeff BlueCounty Engineer of Champaign County, IL
“Gallagher Asphalt, the leader in innovative paving in the Chicago Southland, has been utilizing the process of ‘energy efficient paving’ long before it became glamorous. Hot In-Place Recycling has been the method of choice for savings for many of our clients, and with the latest economic impacts on the world’s oil markets, the past 20% savings are now pushing 50%. That savings allows us to pave many more miles per dollar invested.”
Chris King, P.E.,Robinson Engineering, South Holland, IL"
“I went out there and looked at the process and it’s a wonderful process. We had an old subdivision where the road was all broken up. This procedure melts the pavement that’s there and levels out the road, and then we put asphalt on top of it, and that’s the smoothest road I’ve ever ridden on. That sold me on the process. This is a new tool that Cobb County has to work with.”
Joe Thompson,Commissioner, Cobb County, GA

Gallery