What Is Asphalt Recycling? A Practical Guide for Contractors

Asphalt recycling turns old pavement into reusable material. 

Field crews can save $2–5 per ton on materials and reclaim ~90 million tons annually (preventing them from reaching landfills). However, recycled asphalt needs specialized equipment and quality testing to maintain consistent performance.

For contractors handling regular milling jobs or seeking competitive bid advantages, recycling services offer substantial profit margins. But, success will depend on reliable RAP sources and your mix design abilities. 

Whether you're evaluating RAP for your next project or considering adding recycling services, we’ll explain everything you need to know about.

What Is Asphalt Recycling?

Asphalt recycling crushes old asphalt, removes impurities, and blends it with fresh asphalt binder and aggregates. This process matters because about 90 million tons of asphalt pavement are reclaimed each year, with over 80% of it being recycled.

These are the key aspects of asphalt recycling you should be familiar with: 

• Reclaimed Asphalt Pavement (RAP): The crushed material from existing roads that contains valuable asphalt binder and aggregates.
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• Hot vs. cold recycling: Hot processes heat RAP to 300–350°F for mixing, and cold methods work at regular temperatures using emulsified asphalt or foaming agents.
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• In-place vs. plant mix reuse: In-place recycling mills and remixes pavement without hauling (saves transport costs), whereas plant mix requires trucking RAP to central facilities for processing.
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• Environmental benefits: You use less water and energy, which cuts the strain placed on natural resources.
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• Cost efficiency: Adding 40% of RAP to new asphalt mixtures lowers the costs through the pavement life cycle by 20%.

How Does Asphalt Recycling Work?

Asphalt recycling follows a step-by-step process that maximizes material recovery and helps keep quality standards high. Each step plays an important role in turning worn pavement into valuable construction material.

The 7-Step Asphalt Recycling Process

1. Mill the existing pavement: A milling machine uses a large rotating drum fitted with carbide cutters that grind away the paved asphalt. Typical depths range from 1 to 4 inches, depending on project requirements.
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2. Collect and transport material: The particles are then collected and transported to a facility where they are screened to remove any debris, such as rocks, or impurities.
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3. Screen and size: Contractors sort RAP into sizes like 1/2-inch, 3/8-inch, and fines to maintain mix consistency. Many contractors use equipment systems from recycling machinery manufacturers (like Cams) that screen and size material in one continuous process.
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4. Crush oversized pieces: The collected asphalt is crushed into smaller aggregates and screened for contaminants such as dirt and debris.
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5. Test for quality: Labs analyze the RAP for asphalt content (typically 4–6%), aggregate gradation, and contaminant levels.
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6. Mix with virgin materials: For hot mix asphalt, crews tumble and heat the mixture for about 20 minutes before using it.
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7. Quality control testing: Final mix goes through density, stability, and performance testing before placement.

Common job site example

Consider a real-life municipal paving project carried out by the City of Richmond, Canada, in 2022:

• Project scope: Resurfacing over 4.1 km of busy city roads and 54 multi-use pathways.

• Existing pavement: Deteriorated urban arterial and connector roads.

• Milling depth: Standard, supporting safe removal and reuse of old asphalt.

• RAP generated: Approximately 6,000 tons of reclaimed asphalt pavement (RAP) collected from the project site.

• New mix design: Up to 40% RAP was incorporated into the new hot mix asphalt, with the remaining 60% comprised of virgin materials.

• Cost implications: The high RAP content allowed the city to complete the repaving at no additional cost compared to traditional methods, while aligning with circular economy principles.

• Environmental impact: Diverted thousands of tons of material from landfills, reusing over 2,000 tons of reclaimed asphalt as raw material for new roads, and reducing the city’s carbon footprint and raw aggregate demand.

Asphalt Recycling vs. Traditional Paving: What's the Difference?

The key difference is material sourcing. Virgin mix requires new aggregates and bitumen heated to 300°F, while recycled mix reuses existing pavement materials. Your choice depends on project specifications, budget constraints, and sustainability goals.

Recycled vs. Traditional: An Overview

Key takeaway: When you're tackling high-traffic arterials or projects requiring specific performance guarantees, virgin asphalt provides the consistency you need. 

But for parking lots, residential streets, and base layers where you can control the mix design, RAP offers exceptional value without sacrificing quality.

Pros and Cons of Asphalt Recycling

You can make informed decisions when you understand both benefits and limitations of adding recycled materials to your projects. Let’s zoom in on the pros first:

Pros of asphalt recycling

• Substantial cost savings: Contractors who use 50% RAP in asphalt mixes cut production costs by 12.4%, while 70% RAP delivers up to 16.9% savings, according to a 2023 case study from the Journal of Innovative Engineering and Natural Science.
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• Proven performance: Studies show no significant difference in performance between virgin and recycled pavement sections after years of service.
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• Environmental leadership: Recycled asphalt mixtures can reduce CO2 emissions (around 18 kg less per ton) and save 20% energy per ton.

Cons of asphalt recycling

• Consistency challenges: RAP quality varies based on source material, so you’ll need more rigorous testing and quality control.
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• Processing requirements: You need specialized equipment for screening, crushing, and proper moisture control.
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• Mix design complexity: Higher RAP percentages may require softer virgin binders or rejuvenating agents to maintain flexibility.

Should You Use Asphalt Recycling? 

Your decision to recycle asphalt should match your project requirements, available equipment, and local market conditions. Most contractors find success starting with lower RAP percentages (15–25%) in base courses before expanding to surface applications.

Asphalt Recycling Is Ideal For:

• Base and shoulder mixes where you can use 30–40% RAP content
• Projects with tight budgets that need cost-effective solutions
• Contractors with access to consistent RAP sources and processing equipment
• Areas with strong environmental regulations or sustainability requirements
• Low- to medium-traffic roads and parking lots

Skip Asphalt Recycling If You:

• Need extremely tight performance specifications for high-stress applications
• Don’t have access to quality testing facilities for RAP characterization
• Can't source consistent RAP material within reasonable hauling distances
• Work on projects that require specialized polymer-modified asphalts
• Work primarily on thin overlays where RAP sizing becomes problematic

How to Get Started with Asphalt Recycling: 5 Steps

Getting into asphalt recycling doesn’t require a total overhaul, but you will need a plan. Whether you’re aiming to cut material costs, reduce asphalt disposal, or bid on green projects, here’s how to make RAP (Reclaimed Asphalt Pavement) part of your process:

Step 1: Find a reliable RAP supplier or reclaim your own

You have two options: Buy RAP from a local supplier, or reclaim it from your own milling and demo jobs.

If you’re already tearing out pavement, reclaiming your own can save hauling and dump fees. Just make sure your reclaimed material stays clean and gets stored properly to avoid contamination.

Step 2: Decide between hot mix, cold mix, or in-place

Each method fits a different job type:

• Hot mix is best for high-traffic roads and parking lots.
• Cold mix works well for patching or remote areas.
• In-place recycling works well when you want to reuse existing pavement on-site without hauling.

Step 3: Invest in or rent required mixing/paving equipment

Start by renting mills, screeners, and recyclers to test what fits your jobs. Some cold mix can even be made without heating equipment. 

But if you're doing hot mix, you’ll need to meet temperature and compaction specs. This usually means a reheating trailer or access to a drum plant.

Step 4: Adjust your estimating and proposal workflow

Make sure your takeoffs reflect RAP usage, fuel savings, and haul-off reductions. Update your proposal language to highlight recycled content and sustainability benefits. Many municipalities score these bids higher.

Step 5: Train your crew on handling, mixing, and application

Crews need to know how to screen, mix, and compact RAP correctly. Improper handling can lead to inconsistent results or callbacks. Even small changes in RAP moisture or gradation can throw off the mix; training helps prevent that.

Note: OneCrew makes this easier by letting you track RAP usage, update estimate templates, and sync job specs with the field. You can also standardize workflows across crews so recycled jobs stay consistent, even when teams change.

Asphalt Recycling Best Practices I Wish I Knew Earlier

There’s a learning curve with asphalt recycling, but a few best practices can save you time, money, and headaches. Here’s what experienced contractors always do:

The must-do list

• Always test RAP for binder content and consistency: You can't guess how much virgin binder to add. Lab testing helps dial in your mix design.
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• Store and screen RAP properly to avoid contamination: Keep it dry and out of the dirt. Screening controls particle size and keeps your mix reliable.
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• Track RAP content to ensure consistent performance: Too much RAP or uneven blending leads to cracking or durability issues. Stay within design limits.
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• Educate clients about pros and limitations to set expectations: Recycled doesn’t mean lower quality, but it also isn’t magic. Clear communication helps close deals and avoid disputes.

Common mistakes to avoid

• Using too much RAP without additives: This can lead to brittle pavement. You’ll likely need rejuvenators or softer binders for high RAP content.
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• Ignoring mix design requirements: Every RAP batch is different. Assuming a “one-size-fits-all” design can cause compaction issues or early failures.
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• Assuming RAP is “free”: There’s no material cost, sure, but processing, hauling, and quality control still add up. Don’t forget to budget for it.

Final Verdict on Asphalt Recycling

Asphalt recycling is a smart move for commercial contractors, municipal bidders, and anyone hauling loads to the dump after milling. If you handle asphalt disposal regularly or pay for new material by the ton, it's time to rethink your process.

The payoff grows with scale, crew training, and setup. RAP works best when you have the right equipment, templates, and team processes already in place. Traditional methods still have a place for ultra-precise mixes or high-spec paving, but most jobs benefit from using RAP.

That’s where OneCrew comes in.

Ready to Start Recycling Asphalt More Profitably?

OneCrew is a purpose-built platform for paving contractors, designed to manage everything from leads and estimates to crew scheduling and final invoicing. Unlike generic construction tools, OneCrew is built specifically for paving workflows. That means:

• You get lower costs by tracking RAP usage across jobs
  
• You skip the dump with smarter estimating and disposal planning
  
• You can finish overlays faster with synced proposals, crews, and materials

Whether you're just starting with asphalt recycling or ready to scale it across your whole business, OneCrew helps you quote faster, assign smarter, and keep every job on track. 

Book a OneCrew demo to see how you can run your next RAP job like a pro.

FAQs

1. What is asphalt recycling?

Asphalt recycling is the process of reusing old asphalt pavement (RAP) to create new paving mixes, reducing the need for virgin materials. It helps lower material costs and diverts waste from landfills. Common methods include hot mix, cold mix, and in-place recycling.

2. Can all asphalt be recycled?

Most asphalt can be recycled, but its quality depends on factors like binder content, contamination, and moisture. Material from roads and parking lots is typically good for reclaiming with proper screening. Heavily degraded or contaminated asphalt isn’t suitable without processing.

3. Is recycled asphalt good for driveways?

Yes, recycled asphalt can work well for driveways when properly compacted and installed. It offers good durability and cost savings, especially for rural or low-traffic areas. However, it may require periodic maintenance to stay smooth and dust-free.

4. What equipment do I need for asphalt recycling?

You’ll need a milling machine, screener, and either a recycler or pugmill, depending on your mix type. For in-place or cold recycling, a reclaimer or stabilizer may also be used. Many contractors start by renting before committing to a full setup.

5. How much money can you save by using RAP?

Using RAP can cut material costs by 20–40%, depending on the mix and project size. You also save on asphalt disposal and hauling fees. Long term, RAP can improve bid competitiveness and margins.

6. What’s the difference between RAP and asphalt millings?

RAP refers to reclaimed asphalt that’s been processed and tested for reuse in new paving mixes. Asphalt millings are the raw, unprocessed chunks or granules from a milling job. All RAP starts as millings, but not all millings become usable RAP.

7. How long does recycled asphalt last?

Properly installed recycled asphalt can last 10 to 20 years, similar to traditional asphalt. Its longevity depends on binder quality, compaction, and traffic volume. Routine sealing and patching help extend its life.

8. Is RAP accepted in state or city contracts?

Yes, many state DOTs and municipalities allow or even require RAP in paving specs. The allowed percentage varies by jurisdiction and project type. Always check local guidelines and mix design requirements.

9. Can asphalt be recycled on-site?

Yes, on-site asphalt recycling lets you reuse existing pavement without hauling it off. It’s ideal for large lots or roads with base layers still intact. This method can greatly reduce time and cost.

10. What’s the best platform to manage RAP workflows?

OneCrew is the best platform for managing RAP workflows, especially for paving contractors. It lets you track RAP usage, update estimates, assign crews, and manage quotes in one place. Unlike general construction tools, it's built specifically for asphalt and concrete work.