For many years, post-manufactured and post-consumer asphalt shingle waste was successfully recycled into asphalt paving, providing both a sustainable and cost-effective alternative to landfill disposal. At one time, asphalt paving companies even paid for post-manufacturing waste due to the value of the unaged asphalt.
As paving regulations evolved to become more sustainable, the industry prioritized the use of Recycled Asphalt Pavement (RAP), a proven and essential component in modern asphalt mix design. While RAP plays a critical role in sustainable paving, this shift has significantly reduced demand for Recycled Asphalt Shingles (RAS). The post-manufactured waste may still have options in paving due to the value of the unaged asphalt, but the roof tear-off shingles that are a large majority of the RAS will be used less in paving. At the same time, landfill restrictions on asphalt shingles continue to expand, creating additional pressure to find viable recycling solutions.
To ensure long-term sustainability, the industry must explore new ways to integrate RAS into both paving and roofing applications—maximizing its value across multiple sectors.
The Need for Industry Collaboration
Prior to joining Polyco, I worked in the asphalt shingle market for Elk and GAF for almost 23 years. This experience taught me that it’s crucial for manufacturers to collaborate in updating industry codes to expand opportunities for shingle recycling. If immediate and deliberate changes are not made, the ability to use asphalt shingles in the future could become problematic due to end-of-life limitations.
The Importance of Updating Industry Codes
It is clear that significant and rapid gains must be made in the use of RAS in the production of new asphalt shingles. However, this opportunity has its challenges.
There are two codes that provide criteria for evaluating asphalt shingle products. ASTM D3462 has been in place for many years and “is somewhat prescriptive and contains multiple weight measure requirements, which tends to limit future asphalt shingle innovation and product development.” In contrast, AC438, published in March 2012, “is largely testing- and performance-based with minimal prescriptive, weight and measure requirements.”
Despite the apparent advantage of adhering to AC438, the industry continues to give greater credence and weight to the ASTM D3462 code. To advance the asphalt shingle industry, we must phase out ASTM D3462, expand support for AC 438, and develop additional codes that allow for even more flexibility and creativity in asphalt shingle design—paving the way for increased use of recycled materials.
Processing Challenges for Recycled Asphalt Shingles
Depending on the method used to process RAS, separating and concentrating the shingle raw material components can lead to mass and/or energy balance challenges. Mechanical methods can remove most of the large headlap and butt (colored) granules, which can then be reused as headlap granules in new shingles. This is the easiest part of the process, with minimal impact on new shingle production, as long as any asphalt remaining on the recycled granules does not cause clumping in storage silos or interfere with application equipment.
The major challenge is separating the asphalt from the filler, fines, and fiberglass mat. Whether the process is solvent-based liquid, mechanical pulverization, or a combination of both, remnants of these raw materials will contribute to the total filler content of the new shingles. This can be detrimental to the shingle’s performance properties—such as tear strength—as the preferred filler is substituted by these other materials.
Overcoming Regulatory and Material Limitations
The prescriptive requirements of ASTM D3462 will quickly limit the amount of recycled shingle material because of filler limitations in the finished shingle. The issue of higher filler could possibly be overcome with asphalt improvements or additives, but this is not even an option if roofing stays focused on ASTM D3462.
Polyco has demonstrated that SigmaBond, an advanced asphalt rejuvenator, can help offset the effects of aged asphalt in post-consumer RAS while also addressing higher filler content. SigmaBond incorporates liquefied tire rubber, which enhances the durability and flexibility of asphalt, making it a valuable solution for increasing the use of recycled materials in roofing applications. However, ASTM D3462 remains a barrier, as its prescriptive requirements restrict certain components—such as carbon black and other non-asphaltic materials found in ground tires—limiting the full potential of innovative recycling solutions.
The quotes above are from an article by Mark S. Graham, NRCA’s Associate Executive Director of Technical Services, in Tech Today, July 2013, Alternative asphalt shingle products.
The second installment of Polyco’s Back to Black webinar series, A Producer’s Perspective of PGTR for a Sustainable Future, continued the conversation on the evolution of tire rubber asphalt, bringing together leading experts to explore innovations in sustainable pavement solutions. Hosted by Bob Rivers, this session revisited key takeaways from CalAPA’s 2021 discussion on recycling tire rubber for asphalt and examined new advancements in rubber-modified binder technologies.
Peter Sebaaly, Ph.D., Director of the Western Regional Superpave Center at the University of Nevada, Reno, spoke first on the performance of tire rubber modified mixtures, sharing groundbreaking research on pavement performance. His study demonstrated that asphalt concrete (AC) pavements incorporating tire rubber significantly outperformed unmodified AC pavements. His conclusion emphasized that utilizing tire rubber can extend pavement life and reduce tire waste, making it a win-win for infrastructure and the environment.
Then, Bob McGennis, who brings over four decades of experience in asphalt technology and currently serves as the Asphalt Technical Manager for HF Sinclair Corporation, delivered a presentation on the basics of performance graded terminal blended (PGTR) asphalt. He covered the fundamentals of crumb rubber asphalt and explained how specifications drive the manufacturing and engineering properties of PGTR systems. He also discussed the essential features of PGTR systems and their role in improving asphalt performance.
Drawing from his experience at Pacific Emulsions, Lance Allan discussed the benefits of modified slurry seals, highlighting how tire rubber modified slurry seals improve durability and visual appeal. He shared how projects like the City of Oceanside’s pavement treatments have successfully utilized this technology for almost two decades.
Finally, Skip Brown, a respected pavement consultant with over 60 years in the industry, shared his firsthand experience with Polyco’s Terminal Blend PG 64-16 TR 15% supplied by Pacific NorthWest Oil Company. His insights reinforced the importance of innovation in binder technology for achieving long-lasting, high-performance pavements.
The webinar concluded with an engaging Q&A session, where panelists discussed the practical applications of rubber-modified asphalt. They confirmed that tire rubber modified slurry seal can be applied using conventional slurry seal equipment, making it accessible for widespread use. The discussion also touched on legislative efforts to encourage the use of recycled rubber and reclaimed asphalt pavement (RAP), as well as the growing adoption of rubber-modified binders in western states. Experts highlighted the proven performance benefits of terminally blended asphalt with tire rubber, reinforcing its importance in advancing sustainable pavement solutions.
Looking ahead, the Back to Black series will continue to explore the latest advancements in asphalt technology, bringing together industry leaders to discuss emerging trends, best practices, and the future of sustainable infrastructure. Stay tuned for details on our next session.
If you missed this session, or want to rewatch the conversation, access the full recording to gain valuable insights.
The first installment of our Back to Black webinar series, Not Lost in Translation, brought together two distinguished experts from opposite sides of the Atlantic to discuss the latest advancements in rubberized asphalt performance.
Henrique Borges Miranda, Ph.D., a pavement engineer and assistant professor at Instituto Superior de Engenharia de Lisboa, shared insights from his groundbreaking work in Portugal, including research on incorporating crumb rubber tire waste into asphalt mixtures. Attendees were treated to an engaging presentation featuring a comparative analysis of dry and wet processing methods, as well as real-world case studies and a fascinating video demonstration of elastic recovery testing from Brisa laboratories in Portugal.
Joining Henrique was Robert Lee, P.E., Regional QC Director for Texas Materials. With nearly four decades of experience, Robert offered a U.S. perspective on sustainability in the asphalt industry. In a dynamic discussion with host Al Palmer, he highlighted innovative projects throughout Texas utilizing specialty mixes and shared how his team leverages Polyco’s SigmaBond to enhance asphalt performance. Missed the webinar? You can still explore these exciting discussions and gain valuable international perspectives. Watch the recording now and join us on the journey to redefine asphalt performance and sustainability.
FOR IMMEDIATE RELEASE
Ennis, Texas, November 21, 2024 – In its latest paving project, Polyco, manufacturer of high-performance, sustainable asphalt solutions for the roofing and paving industries, has solidified its partnership with All American Tire Recyclers (All American), affirming the collaboration required to achieve greener, more sustainable infrastructure.
All American, Polyco’s crumb rubber supplier, contracted Elite Asphalt to repave their high-traffic lot with a mix supplied by Austin Bridge and Road that included Polyco’s SigmaBond rubberized binder. The 2,200 tons of mix used on this three-acre lot contained 100 tons of PG70-22XR and approximately 18% tire rubber, which equates to roughly 18 tons of rubber and more than 2,000 recycled tires.
“I want to be able to sleep at night and make sure that we are making a difference,” said Tom Parker, CEO/owner of All American. “And this [rubberized asphalt] is by far, in my opinion, one of the best avenues out there. Rubberized asphalt lasts longer.”
As a 24/7 plant that processes 18,000 tires a day, 6.5 million tires a year, and 26% of all tire waste in Texas, All American’s lot is busy with heavy equipment. All American needed a solution that would be of minimal disruption to their operations (Austin Bridge and Road completed the paving project in just one day) and stand the test of time, stress, and volume. A product of Polyco’s patented Rapid Digestion Process™ (RDP), which completely liquefies tire rubber, SigmaBond is proven to increase fatigue resistance and thermal stability.
In addition to utilizing high percentages of waste tire rubber, SigmaBond is one of the only binders that allows tire rubber modified hot mix to incorporate RAP and RAS. Then there’s the eco-consciousness of neighboring businesses working together — SigmaBond is made right here in Texas, within 50 miles of All American.
About Polyco
Polyco is a leader in reducing environmental impact by repurposing waste tire rubber into high-performing, sustainable infrastructure solutions. Their flagship innovation, SigmaBond, enables asphalt products to be upcycled again and again. Click here to learn more.
At Polyco, we’re always pushing the boundaries of innovation in asphalt modification. One of our biggest breakthroughs is SigmaBond—a high-performance asphalt binder that includes recycled tire rubber that is liquefied through our unique chemical process (Rapid Digestion Process™). Unlike traditional methods that simply blend crumb rubber with asphalt, RDP harnesses the power of pyrolysis to chemically transform tire rubber, enhancing asphalt performance and sustainability.
The Science Behind SigmaBond: More Than Just Blending
When our chemists first began developing SigmaBond with RDP, the process started with a simple lab setup—heating asphalt to extreme temperatures and adding tire rubber to see what would happen. What we discovered was remarkable: at around 600°F, the rubber particles were no longer visible when passed through a sieve. At this temperature, the tire rubber breaks down into its base components, allowing it to homogeneously blend with asphalt mixtures.
This reaction, known as pyrolysis, is the key differentiator between SigmaBond and conventional rubberized asphalt. Instead of mixing rubber particles into asphalt (the “wet” or “dry” methods used by competitors), we use heat to break rubber’s long polymer chains into smaller molecules. This results in a stable, homogeneous blend of asphalt—a combination that enhances durability, elasticity, and overall pavement performance.
Why Pyrolysis Matters
Most rubberized asphalt technologies do not chemically alter the tire rubber; they merely suspend rubber particles in the asphalt, which can lead to separation, inconsistent performance, and processing challenges. With SigmaBond, the controlled pyrolysis process ensures a permanent chemical transformation, producing a smoother, longer-lasting asphalt blend.
Since tire rubber consists of several complex bonds—carbon-carbon, carbon-sulfur, and sulfur-sulfur—each requires different levels of energy to break. By carefully managing temperature and reaction time, RDP optimizes these chemical changes, ensuring the right balance of rubber integration without unwanted byproducts. This results in an asphalt modifier that retains the benefits of rubber without the downsides of high viscosity or poor mixability.
Performance & Sustainability Benefits
SigmaBond offers a range of advantages for pavement applications:
- Superior Durability: The enhanced elasticity and stability of SigmaBond-modified asphalt reduce cracking and extend pavement lifespan.
- Smoother, Darker Surfaces: The high carbon black content gives roads a deep black finish, which some customers have noted as a visual advantage.
- High Rubber Content: SigmaBond can incorporate up to 50% tire rubber by weight, making it one of the most sustainable asphalt solutions available.
- Better Workability: Despite its high rubber content, our proprietary process ensures that SigmaBond remains easy to transport, mix, and apply.
Setting a New Industry Standard
At Polyco, we’re not just modifying asphalt—we’re redefining how recycled materials can be used to build stronger, more sustainable roads. By introducing pyrolysis into the equation, SigmaBond represents a fundamental shift in asphalt technology, offering unmatched performance and environmental benefits.
As the industry moves toward more sustainable infrastructure solutions, SigmaBond stands at the forefront, proving that innovation and environmental responsibility can go hand in hand.
Recently, I joined industry leaders at the California Asphalt Pavement Association (CalAPA) Annual Awards Dinner, held at the historic Jonathan Club in downtown Los Angeles. This evening of camaraderie, celebration, and reflection showcased the achievements of key figures in the asphalt industry while also paying tribute to its storied past.
A Night of Recognition and Reflection
The night’s highlight was the induction of Skip Brown, a longtime paving contractor and dedicated advocate for the asphalt industry, into the CalAPA Hall of Fame. Skip, known for his innovation and leadership, delivered a memorable speech punctuated by his symbolic act of kicking an empty paint can across the stage. “This association,” he declared, “has nothing to do with kicking the can down the road. We’re going to make it better.” His gesture inspired keynote speaker Lori Wilson, Chair of the California Assembly Transportation Committee, who took the can to display in her Sacramento office as a reminder of the commitment to progress.
The evening also honored the legacy of Gerry Graham, inducted posthumously into the Hall of Fame. Gerry’s contributions to the industry were fondly remembered by his family, who shared touching stories of his dedication and passion for asphalt. The event also paid tribute to other legends the industry lost this year, including Bob Roth of World Oil, Bill Darnell with Valero, Gene Guido of Reed & Graham, and UC Berkeley Professor Emeritus Carl Monismith. Each of these individuals left an indelible mark on the industry, with Monismith’s pioneering work on long-life asphalt pavements being particularly celebrated.
A Bittersweet Celebration
While the evening was filled with joy and inspiration, it was also a time for reflection. Remembering those who have shaped the industry’s path underscored the importance of honoring their legacy by continuing to innovate and uphold the highest standards. We’re grateful to CalAPA for hosting such a meaningful event and for the chance to celebrate our shared commitment to excellence in asphalt.
Insights from Industry Leaders
Inspired by CalAPA’s thought leadership around PGTR, Polyco recently hosted a webinar featuring Skip Brown alongside other asphalt legends, including Dr. Peter Sebaaly, Bob McGennis of HF Sinclair, and Lance Allan of Pacific Emulsions (who was in attendance at the Awards Dinner as well). During the webinar, these esteemed professionals shared their insights and expertise about terminal blended tire rubber performance, providing a deeper understanding of the future of sustainable asphalt technology and innovation. It was an incredible opportunity to learn from some of the most respected voices in the field and explore the advancements shaping the industry.
Congratulations again to Skip Brown and all the CalAPA honorees. Thank you to everyone who joined the webinar and contributed to such an engaging and insightful conversation about the future of asphalt technology and innovation.
Read CalAPA’s report of the special night here.
Access a replay of Polyco’s past webinars and stay up to date on future ones here.
We experienced a full circle moment during one of our latest paving projects. All American Tire Recyclers (All American), our crumb rubber supplier, contracted Elite Asphalt and materials supplier Austin Bridge and Road to repave their high-traffic lot with a mix that included our SigmaBond rubberized binder! This unprecedented opportunity solidified our partnership as we move toward greener, more sustainable infrastructure.
The 2,200 tons of mix used on this three-acre lot contained 100 tons of PG70-22XR and approximately 18% tire rubber, which equates to roughly 18 tons of rubber and more than 2,000 recycled tires. As a 24/7 plant that processes 18,000 tires a day, 6.5 million tires a year, and 26% of all tire waste in Texas, All American’s lot is busy — and constantly bearing the weight of heavy equipment.
All American needed a solution that would not only be of minimal disruption to their operations, but also stand the test of time, stress, and volume. Thanks, in part, to the workability of SigmaBond, the paving contractor completed the job in just one day! Additionally, the carbon black found in All American’s tire rubber improves to the long-term performance of the pavement — retaining its dark color and resisting cracking for a longer period of time.
This performance comes with the added benefit of sustainability. SigmaBond is capable of including up to 40% tire rubber and more than 15% RAP and RAS without impacting performance. From cradle to gate — crumb rubber to liquefied tire rubber to a new pavement — Polyco and All American have brought the paving cycle full circle right in our own backyard.
FOR IMMEDIATE RELEASE
Reno, Nevada, October 14, 2024 – Polyco, manufacturer of high-performance, sustainable asphalt solutions for the roofing and paving industries, has named Dario Alvarez as its new Regional Sales Manager. Alvarez brings over 20 years of sales leadership experience in asphalt pavement solutions and highway safety technologies.
His strength lies in introducing customers to emerging, innovative product lines. Throughout his career, Alvarez has worked with several prominent companies in the industry, including Ingevity and Surface Tech, gaining critical experience with asphalt and pavement preservation technologies. These have included polymer modified asphalts, asphalt emulsion, fuel oils, surface sealers, refined products, and preformed thermoplastic pavement markings.
“What’s been fun for me is [that], in a lot of the jobs that I’ve taken on as a sales professional and as a sales leader, [the] product that I’m about to sell is brand new to the industry,” he said. “That’s something that’s really exciting to me. Polyco is offering the same type of adventure where this is a technology that we’ve had for a few years, but it’s still kind of burgeoning in the industry on the paving side.”
In his new position, Alvarez is tasked with developing relationships with specifiers and end users in the asphalt pavement market to promote SigmaBond, Polyco’s waste tire rubber asphalt modifier. “This role affords me a great opportunity to go out and introduce something that could really benefit the paving industry, that is proven to work really well and be sustainable. SigmaBond has got all of the characteristics and attributes that people are looking for.”
Alvarez has the personality, passion, self-motivation, and technical knowledge that compels companies to revolutionize how they do business. He showed this promise from the beginning when, in 2000, he launched his asphalt career selling liquid asphalt in Ogden, Utah, for Pioneer Oil Company.
“My boss [at the time] hired me because I had a really outgoing personality,” said Alvarez. “It was easy for me to talk to people and engage with people and get them to like me. So I got out there, started talking with contractors, getting involved in the industry.”
Polyco looks forward to advancing the asphalt industry with Alvarez on their team.
About Polyco
Polyco is a leader in reducing environmental impact by repurposing waste into high-performing, sustainable infrastructure solutions. Their flagship innovation, SigmaBond, enables asphalt products to be upcycled again and again. Click here to learn more.
At Polyco, we’ve successfully diverted over 1.5 million end-of-life rubber tires from landfills, transforming them into valuable resources for our roofing and paving projects. This innovative approach is driving widespread sustainability efforts. The use of rubberized asphalt helps contribute to a circular economy by continuously upcycling reclaimed asphalt pavement (RAP), reclaimed asphalt shingles (RAS), and recycled tire rubber (RTR).
While rubberized hot-mix asphalt solutions are always evolving, SigmaBond stands apart. Our flagship product reimagines the potential of tires by incorporating them into high-performance asphalt formulations. Our asphalt modifier shines for its ability to incorporate up to 40% scrap tire rubber, leveraging the resilient properties of carbon black. This innovative product demonstrates superior fatigue resistance and can significantly reduce construction costs compared to other rubber-modified asphalts.
If you would like to learn more about the benefits of SigmaBond, read our featured article in the Summer 2024 issue of Pavement Preservation Journal.
As many in asphalt know, we’re a community as much as we are an industry. That’s why Polyco’s latest hire, Dario Alvarez, our Regional Sales Manager, is a perfect fit – he’s about people.
In 2000, Dario launched his asphalt career selling liquid asphalt in Ogden, Utah, for Pioneer Oil Company. “My boss [at the time] hired me because I had a really outgoing personality,” he said. “It was easy for me to talk to people and engage with people and get them to like me. So I got out there, started talking with contractors, getting involved in the industry. For the next seven years, I worked in Idaho, Montana, Utah, and Wyoming, selling liquid asphalt to hot plants.”
From there, his sales career accelerated and he branched out into the highway safety industry, where his passion for people really began to shine. It was Dario’s job to engineer safe work zones that utilized smart work zone system technology and then sell that work zone configuration to contractors to implement. “We’ve got guys out there putting down the roads, putting down the asphalt, building bridges. And, as they are trying to create this infrastructure, they have to be kept safe from the traveling public,” he said.
Over the course of his career, Dario found his way back to asphalt sales. He worked with several prominent companies in the industry, including Ingevity and Surface Tech, gaining critical experience with asphalt and pavement preservation technologies. These have included polymer modified asphalts, asphalt emulsion, fuel oils, surface sealers, refined products, and preformed thermoplastic pavement markings.
Ultimately, asphalt is where he wants to be.
“What’s been fun for me is [that], in a lot of the jobs that I’ve taken on as a sales professional and as a sales leader, [the] product that I’m about to sell is brand new to the industry,” he said. “That’s something that’s really exciting to me. Polyco is offering the same type of adventure where this is a technology that we’ve had for a few years, but it’s still kind of burgeoning in the industry on the paving side.”
Dario has been tasked with developing relationships with specifiers and end users in the asphalt pavement market to promote SigmaBond, Polyco’s waste tire rubber asphalt modifier. “This role affords me a great opportunity to go out and introduce something that could really benefit the paving industry, that is proven to work really well and be sustainable. SigmaBond has got all of the characteristics and attributes that people are looking for.”
Outside of his profession, Dario makes sure to allocate time for personal pursuits, namely fly fishing and coaching judo. Alongside his coaching partner, he runs the largest judo program for juniors in Austin, Texas. It represents yet another way in which Dario connects well with people, who ultimately are what matters most.
