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The recycled content percentage of mastic asphalt is typically 0–20% by mass. Higher recycle content percentages are possible where reclaimed mastic asphalt (RMA) or recycled aggregates are approved. Actual figures depend on application and specification: roofing and tanking mixes usually sit at the lower end to preserve finish and workability, while steps, walkways, and car parks can often accommodate 10–30%. In EPD terms this refers to pre- and post-consumer “secondary materials” actually blended into the product; high end-of-life recyclability doesn’t count unless it’s fed back into new mixes. Polymer-modified binders and tighter performance classes may cap recycled additions, so always confirm with the product’s EPD and project specifications.
Recycled content percentage is the share of a product’s mass that comes from recycled (secondary) materials, expressed as a percent by weight. It usually includes both pre-consumer inputs (reused process scrap) and post-consumer inputs (materials recovered after use), as defined by the relevant standard. The value is calculated for the declared unit on a mass basis: recycled mass ÷ total product mass × 100. Environmental Product Declarations (EPDs) report this, often separating pre- and post-consumer portions and stating whether the figures are verified. It is not the same as “recyclable” or “recycled at end of life”; future recyclability doesn’t count unless the material is actually re-incorporated into the product. Only secondary material physically blended into the product is counted; credits for what happens after the product’s life are handled separately under Module D. Module D (per EN 15804) reports “benefits and loads beyond the system boundary,” i.e., potential credits from reuse, recovery, or recycling of materials after end-of-life—these do not increase recycled content, they’re disclosed as separate downstream benefits. For construction products like mastic asphalt, recycled content commonly comes from reclaimed mastic/asphalt, recycled aggregates, and suitable mineral fillers; higher recycled content can cut embodied carbon and resource use, provided performance requirements are still met and supplier evidence supports the claim.
Mastic asphalt can be reclaimed during strip-out as reclaimed mastic asphalt (RMA), then crushed/screened, tested (binder content and contaminants), and fed back into new mixes at controlled percentages—typically ~0–20% for roofing/tanking and up to ~10–30% for steps/walkways. Clean offcuts and surplus can also be re-melted and blended hot with virgin material (closed-loop), adding make-up binder to restore target properties. Quality assurance is key: sieve analysis, binder-content testing, moisture limits, and checks for PAHs/asbestos, followed by verification of static indentation/creep at service temperatures.
Where closed-loop reuse isn’t suitable, RMA can be downcycled into non-critical bituminous applications—only with spec approval and performance testing.
Strip out mastic asphalt carefully and keep reclaimed mastic asphalt (RMA) separate from other demolition waste. Remove adhesives, screed residues, and debris so the stock stays clean and traceable. Store under cover, off the ground, and label by source/area to maintain a clear chain of custody. Dry, uncontaminated RMA is far easier to process and achieves higher reuse rates.
Crush and screen the RMA to a target grading envelope suitable for the intended mix. Test binder content, moisture, and contaminants (e.g., PAHs, tar/asbestos where relevant) and reject non-compliant batches. Verify cleanliness and particle shape; excessive dust or clay fines will upset rheology and density. Document results so the plant can adjust make-up binder/filler with confidence.
Dose the processed RMA back into fresh mastic at controlled percentages appropriate to the application (typically lower for roofs/tanking, higher for steps/walkways). Adjust make-up binder and filler to hit the target filler-to-binder ratio and workability. Mix hot enough for proper wetting, then verify performance with bulk density and static indentation at ~60 °C (add creep/wheel-tracking if applicable). Start with plant trials and small areas on site, scaling up once results are consistent.
Collect clean, uncontaminated offcuts and surplus during installation and keep them separate from general site waste. Re-melt within the supplier’s temperature window and blend with virgin mastic, avoiding over-heating or long hold times that oxidise the binder. Add make-up binder and filler as needed to restore the target filler-to-binder ratio and workable viscosity. Limit reheats and use first-in/first-out handling so material isn’t degraded. Record incorporation rates and locations to maintain traceability.
Sample the recycled blend and confirm bulk density against maximum theoretical density to ensure low voids and continuity. Check static indentation at about 60 °C against the project limit; add creep or wheel-tracking where sustained or rolling loads apply. Observe lay-down behaviour—flow, edge stability, and finish—at the specified temperature. Document results in a simple QA plan and adjust the recipe if values drift. Only scale up once repeatable compliance is demonstrated.
If grading, contamination, or performance tests fail, divert the material to non-critical bituminous applications permitted by local specifications. Typical outlets include bituminous mastics or screeds for non-traffic areas, damp-proofing compounds, or incorporation into composite bitumen-based products. Keep recycled content clearly labelled and declare end uses to avoid accidental reintroduction into high-duty work. Ensure environmental and waste regulations are met, including any required testing or declarations. Reserve closed-loop reuse for batches that meet the project’s performance criteria.
Recycled mastic asphalt (RMA) is most commonly used in steps, walkways, ramps, and access routes, where mixes can tolerate higher recycled proportions after QA. It’s also used in interior floors (plant rooms, service corridors) and on podium decks under paving pedestals, where point loads are known and detailing is robust. Where specified, car parks and bridge decks can incorporate RMA at controlled levels; roofs and below-grade tanking usually accept lower additions to protect finish and workability. Actual use always depends on project specs and testing (grading, contaminants, density, and static-indentation performance at service temperature).
Steps, walkways, ramps and access routres can use recycled mastic asphalt. These pedestrian zones can usually accept moderate recycled content (≈10–30% by mass) because loads are concentrated yet predictable and travel speeds are low. Map turning circles, nosings, and thresholds, then use local thickening and a tough wearing/sand-rub finish in those hotspots; add perimeter isolation strips to avoid hard bridges that promote rucking. Keep substrates stiff and fully supported; on softer insulation, add high-density boards to spread point loads from trolleys or sack trucks. QA should include grading and moisture checks, contaminant screening (e.g., PAHs/asbestos where relevant), bulk density close to MTD, and static-indentation at service temperature (~60 °C) within the project limit. Where summer heat is an issue, consider light-coloured chips/coatings to cut peak temperatures, and plan periodic renewal of the wearing finish in main footfall routes to maintain slip resistance and appearance.
Interior asphalt floor areas such as plant rooms and service corridors can use mastic asphalt. These areas see repeated but manageable point and rolling loads (castors, pallet jacks, equipment skids), making controlled RMA additions (≈10–25%) practical when supported by testing. Use load-spreading boards beneath stationary equipment and along manoeuvring paths; consider local thickening at turning bays and door thresholds. Verify performance with bulk-density checks (close to maximum theoretical), static-indentation at ~60 °C, and creep/wheel-tracking where long dwell or warm plant rooms are expected. Address service conditions: ensure falls to drains, chemical-compatible primers where oils may occur, and robust details around penetrations, plinths, and anchor points. Maintain a simple inspection and hot-patch plan so small marks are repaired promptly, preserving waterproofing and extending service life.
Recycled mastic asphalt can be used beneath pedestal-supported paving. High-density protection boards should be added over the asphalt to spread point loads away from pedestal feet. Specify boards with appropriate compressive strength and creep ratings for long-term service, and consider double-layering near perimeters and at cut tiles. Ensure good falls and drainage so heat and ponding don’t soften the surface, and keep upstands/penetrations perfectly sealed. Test recycled mixes for bulk density (near MTD) and static indentation at ~60 °C to maintain levelness and long-term support. Keep edge and corner support continuous to avoid localized cracking and rocking.
Car parks and bridge decks can use recycled mastic asphalt. These areas face heavy use, this includes; wheel loads, thermal cycling, and de-icing salts. Due to the demands on these areas recycled content must be tightly controlled and validated. Require test evidence for static indentation (~60 °C) and creep/wheel-tracking that matches the proposed build-up; polymer-modified binders are often warranted. Use conservative RMA percentages and increase thickness or reinforcement at ramps, tight turns, and wheel-stop zones. Detail joints and edges robustly and ensure effective drainage to manage salt ingress and shear. Implement a maintenance plan with regular inspections, prompt local repairs, and periodic refresh of protection finishes in high-stress areas.
Asphalt roofing and tanking applications are finish and waterproofing critical. This means for roofing and asphalt tanking you should limit RMA to lower percentages and insist on clean, dry, well-graded material. Verify workability/flow, bulk density, and static indentation to protect edge stability at upstands, outlets, and penetrations; trial panels help confirm lay-down behaviour before large areas. Ensure substrates are dry and fully supported, primers are compatible, and detailing prevents vapour or moisture entrapment that could cause blistering. In tanking, consider hydrostatic head and use only mixes proven for long-term immersion. Maintain strict QA on moisture and contaminants, and record batch/incorporation rates for clear traceability.