Erbil Construction LAB

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Recycled Asphalt Technology

Prepared By: Eng Twana Bajalan - ECL

OUTLINE

 Recycling benefits and polices.

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 Using of RAP in USA.

 Challenge faced in the using of RAP.

 Accounting of RAP in mix design and

selecting of binder grade.
 Additives for increasing the RAP %.

 Effect of RAP on the asphalt performance.

INITIATIVE TO IMPROVE SUSTAINABILITY
 Use Of Recycled Materials
- Recycled Asphalt

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- Recycled Tire
- Recycled Concrete
 Reduce Energy And Emission
- Warm Mix Asphalt
- Cold Mix And Emulsion
 Improved Service Life
- Modified bitumen and asphalt mixture
- Mechanistic Design
- More Advanced PG Grading And Balanced Mix Design
GROUPING METHODS OF BITUMEN:

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Clean
Fuels
Carbon Energy
Emission Consumption
Sustainability
Zone
Conserved Recycled
Air Resource Materials

Resource
Conservation
REASONS OF USING OF RAP:

1- Economic Benefit

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- Using RAP typically Lowers the unit cost of HMA in
terms of aggregate and binder re-use.

- The most economical use of RAP is in asphalt mixture

that go into the intermediate and surface layer of flexible
pavements, where the RAP actually replaces a portion of
the more expensive virgin binder.
RAP IN ASPHALT MIXTURE
FHWA-HRT-11-021 APR 2011

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Cost Of The Pavement Projects

80
70
60
50
40
30
20
10
0
Material Plant Production Trucking Lay Down
REASONS OF USING OF RAP:
2- Environmental benefits

- Conserves the non-renewable virgin binder and

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aggregates resources,
- Reduces the energy and transportation costs of
obtaining them.
- Reduces the amount of construction debris
going into landfills. Because RAP can be used
again and again,

* Using RAP creates a cycle of asphalt reuse that

optimizes use of natural resources and helps
sustain the asphalt pavement industry.
EMBODIED CARBON IN ASPHALT AND AGGREGATE

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8% 44%
36%

Source: Loveday2009
FHWA RECYCLING POLICY
(Wright, F.G., Jr., 2002)
https://www.fhwa.dot.gov/legsregs/directives/policy/recmatmemo.htm

• The policy acknowledges that recycling may not

be appropriate in all cases. The policy states:
 Recycling and re-use can offer

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engineering, economic, and
environmental benefits.
 Recycled materials should get first
consideration in materials selection.
• Restrictions that prohibit the use of recycled
materials without technical basis should be
removed from specifications.
 Any material used in highway or bridge
construction, be it virgin or recycled, shall not
adversely affect the performance, safety or the
environment of the highway system.
DEVELOPMENT OF GUID

- NCHRP Synthesis 495 (2016)

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- NAPA Quality and information series 2008-2017
- NCHRP Digest No 253
- NCHRP R-452
- NCHRP R-752
- National Standard :
AASHTO M323
AASHTO PP53
RAP USED BY SECTORS IN USA

 More than 75 Million Ton in 2017

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Source:JohnDavis andPhil Blankenship,Asphalt Institute, August2017
RAP USED IN THE USA BY STATE

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Source: NAPA Information Series 138
USE OF RECLAIMED ASPHALT MATERIAL IN THE EU

Other
Percentage of different
Recycling in unbound layers
end-of-life strategies
In Situ / Plant Recycling (half warm & cold)
for reclaimed asphalt
Plant Recycling in HMA Scource: EAPA 2008
100%
90%
Use of Reclaimed Asphalt [%]

80%
70%
60%
50%
40%
30%
20%
10%
0%
CAN RAP PRODUCE HIGH QUALITY HMA?
1. Need proper RAP processing,
2. Adjustment of Mix Design, and
3. Use of Chemicals (Recycling Agents)

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HMA RAP
SOURCE OF RAP

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VARAIABILITY OF RAP GRADATIONS

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PROCESSING RAP

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FRACTIONATION OF RAP BY SIZE

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PROCESSING OF RAP TO DEFINE QUALITY

SizeControl >> Binder &AggregateQuality

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Source: NAPA Quality Improvement Series 124
SUMMARY OF RAP USAGE IN THE USA

• The total estimated tons of RAP used in asphalt

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mixtures reached 76.2 million tons in 2017.
• The % of producers reporting use of RAP remained
constant at 98%for 2016 and 2017.
• The average % of RAP used in asphalt mixtures
increased from 15.6 % in 2009 to 20.1 % in 2017.
• The total estimated amount of RAP stockpiled
nationwide at the end of the 2017 construction
season was 102.1 million tons.
SUMMARY OF RAP USAGE IN THE USA

• Nationally, a reported 23 percent of RAP is

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fractionated.
• Producers from 31 states reported using softer binders
and 15 states reported using recycling agents in RAP
mixtures.
• When asked about limiting factors in the use of RAP,
the top-three responses were
– specification limits (38.5 percent),
– RAP availability (18.5 percent), and
– asphalt plant capabilities (15.4 percent).
QUALITY OF BINDER AND AGGREGATES IN
RAP

• Aggregates do not change with age. Since most are

from approved project, quality can be assumed high

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and acceptable.

• Binders oxidize and change

physically and chemically:
– Binders are stiffer and more brittle
RAP

– Chemicals are needed to rejuvenate/soften

them.
HOW BITUMEN AGES IN THE FIELD RAP BINDER

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PERFORMANCE GRADING – PG SYSTEM

Thermal Cracking Fatigue Cracking Rutting Production

Binder testing equipment and properties

BBR DSR DSR DSR RV
S (60) ≤ 300 MPa G*.sin Jnr- G*/sin G*/sin 
m (60)≥ 0.300 ≤ 5.0 MPa ≥ 2.2KPa ≥ 1.0 KPa 3.0 Pa-s

Low Temp. Intermediate Temp. High Temp. 135 oC

Pavement Temperature, ºC
CHANGE IN PERFORMANCE GRADE WHEN ADDING RAP
Thermal Cracking Fatigue Cracking Rutting Production

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BBR DSR DSR RV

S (60) increase G*.sin Jnr decrease 

m (60) decrease increase G*/sin increase increase

Red = negative effect

Green is positive effect

Low Temp. Intermediate Temp. High Temp. 135 oC

Pavement Temperature, ºC
 STIFFNESS CHANGE DUE TO FIELD AGING

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PG88-4 BinderB

G*,S, and  BinderA

PG82-4

PG70-10 recycling

Plantaging Fieldaging Time

ELASTICITY CHANGE DUE TO FIELD AGING

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PG70-10
m, Sin Jnr

PG88-4
BinderB

PG82+4
BinderA

Plantaging Fieldaging
 CHALLENGES FACED USING RAP
SOURCE: JOHN DAVIS AND PHIL BLANKENSHIP, ASPHALT INSTITUTE, AUGUST
2017

• “How much of the binder from the RAP is

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actually alive, working and effective?
– Aged binder could be very stiff and cannot
blend well.
• Long term durability is at risk if the binder is not
rejuvenated
• Right now, we are seeing the second and third
generation of RAP use. Is this a problem?
 THE RAP WITH NEW BINDER
‘DIRECT CONTACT’ BLENDING
What happens during mixing?
• Aggregates coated with aged binder (RAP) come

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into contact (mechanical) with fresh binder and
aggregates coated with fresh binder film(diffusion)
– This is a binder – binder film contact (diffusion)
– Some absorbed binder may not blend, or take
longer to diffuse

Binderfilms
incontact

Fresh bindercoated RAP

Fresh binder– RAP
Aggregate
coatedaggregate
 TEST METHODS & EXPERIMENTAL DESIGN
‘DIRECT CONTACT’ BLENDING
• Simulate field blending using binder ‘wafers’ with
known aging history and rheological properties

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‘FreshBinder Noaging
RAPBinder LaborFieldaged
RAPAgg
Factor Level Description
Conditioning 3 100, 120, 140 C
Temp.
Conditioning Time 4 5, 30, 60, 120 min
Binder 2 High(~16%)/Low
Compatibility (~9%)
Asphaltene
content
 TEST METHODS & EXPERIMENTAL DESIGN
‘DIRECT CONTACT’ BLENDING
Condition sandwiched wafers in forced draft
oven,removeandimmediately bringtotesting
temp...

‘Fresh’Binder
2 mm
‘RAP’ Binder

Also testconditioned ‘Fresh’and‘RAP’

binderalonetoaccount for aging
 ESTIMATING THE RATE OF DIFFUSION
BOUNDARY CONDITIONS

• Measure the fresh binder concentration, c,

with time, t , in the RAP material…

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‘Fresh’Binder
c(x,0) = 0
c(x,∞) = 0.5
‘RAP’ Binder x WemeasureG*composite in
theDSR
 TIME AND TEMPERATURE AFFECT BLENDING

• Blending will
12.00 0.65 occur butitis
11.80 y = 11.268x0.0248 0.64
sensitiveto time,
R² = 0.9904
temperature and

[Pa]
11.60
[Pa]

0.64
binder chemistry.

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11.40

11.20
y = 0.6254x0.0102
0.63
• Nearcomplete
11.00
R² = 0.9092 0.63 blendingis
possible andis

G*composite
G*composite

0.62
10.80
likelyat
Mortar

Binder
0.62
10.60
0.61
temperatures
10.40
above 100°C
0.61
withintwo hours.
10.20

10.00 0.60
0 1 2 3 4 5 6

Conditioning Time (hrs)

MixConditioningis veryimportant
PROCEDURE FOR USE OF RAP

1. Get a representative sample and check consistency.

– The use of material from an “anything goes”
RAP pile will produce an inconsistent,
unreliable mix.

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2.Calibrate asphalt contents with a solvent
extraction for RAP. At least use a better (less)
assumption than 100 percent.

3.Add softer liquid asphalt or recycling agent in order

to compensate for the stiffer RAP and RAS mixes.

4. Use more realistic RAP aggregate gravities

ANALYSIS OF RAP AND COMBINED PG BINDER
GRADE

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BINDER SELECTION GUIDELINES FOR RAP MIXTURES
(AASHTO M 323)

Recommended Virgin Asphalt RAP

Binder Performance Percentage

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Grade (PG)
No change in binder selection <15
Select virgin binder one grade
softer than normal (Select a PG 58- 15-25
28 if a PG 64-22 would normally
be used.)
Follow recommendations from
>25
blending
charts
RECYCLING AGENTS

• Recycling Agents Types:

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– Softer Grade Bitumen
– Petroleum
 Paraffinic Oil: PP-1, PP-2
 Aromatic Oil: PR-3
– Bio-based Oil:
 Wood Plant Liquid or Corn Oil: BO-1, BO-2
– Refined Used Oil:
 Re-refined Used Motor Oil: REOB (RW)
STANDARDIZATION

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RECYCLING AGENTS (RA) GRADES

• < 30%

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< 30% NewAggregates > 30%
EFFECT OF RECYCLING AGENTS ON HIGH
TEMPERATURE – PG (G*/SINΔ)

8
7 58 C
6 RTFO-aged
G*/sinδ (kPa)

5
4
3
2
1
0

 Oil modification softens asphalt binders at

high temperatures;
 Effects of oils vary between 5% to 10 % to achieve
same change in G*/sin

7
HMA PRODUCTION WITH RAP

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KEY ASPHALT PLANT PARAMETERS

- Aggregate gradation

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 Dust in RAP
 Surface area
- RAP pre-heating
- Moisture in RAP
- Storage time of produced mixture
MIX DESIGN PROCEDURE AND
PERFORMANCE TESTING

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AGGREGATE PROPERTIES MEASURED FOR RAP

 Gradations of the RAP are the most frequently

evaluated recycled material aggregate property

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after either ignition oven or solvent extraction.
 RAP source aggregate properties are
typically considered acceptable, usually
because RAP was obtained from state
projects.
 Only a limited number of agencies measure the
recycled material aggregate shape, clay-sized
particle content, soundness, and toughness.
FIELD PERFORMANCE OF PAVEMENTS WITH
RAP(LTPP PROGRAM)

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RESISTANCE TO FATIGUE CRACKING
MEASURED IN LAB (SEMI-CIRCULAR BEND- SCB
TEST)

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CONCLUDING REMARKS

• Recycling of asphalt pavement is widely used and is

considered a necessary practice.
• Performance of High RAP Mixes can be equal to virgin

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mixtures if done properly.
– Modulus of RAP Mixes
– Fatigue Concerns
– Moisture Damage Concerns
• How to Better Control RAP is very important.
– Processing (Fractionating)
• Binder Issues are very important
– Final Effective Binder Grade and recycling agents' selection
– True binder replacement ratio
RAP STOCKPILE

EXTRACTED GRINDED

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AGGREGATE APPEARANCE

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SECTION APPEARANCE

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Source: M.-C. Teguedi, E. Toussaint
PRACTICE STEPS
 Fractionation :
The variability of stockpile of RAP is important in
both mix design and quality control during

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production.
To effectively maximize the use of RAP in an asphalt
mixture, some important data is required for each
built stock like ( type of road extracted, gradation,
asphalt content..etc.)…..FRAP.

Fine FRAP & coarse FRAP.

passing #No.4 : Fine retained #No.4 : Coarse

 Fined Biner Content & Grade

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 By using on of the approved standard methods for binder
content to fined the binder content of the RAP.
 Using washing methods by solvent to separate the binder
form RAP Mix (save the aggregate to use it later for mix
design) and extract the binder for test it :
 - check viscosity - check rheology - cold strength …etc.

 Used trail and error or blending charts to fined the

required bitumen grade for mixing to get the region
required performance.
 MIX DESIGN

BWC -
Mix Design Page 5 of
XXXXXXX
Reference No. 13
X

Selection of DAS

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Aggregate Gradation
Sieve Percentage Passing
Size Sieve Size
Samples From the Hot Bins
raised to
0.45 mm in Agg. # 1 Agg. # 2 Agg. # 3 RAP1 RAP2
power
5.81 50.0 2 100.0 100.0 100.0 100.0 100.0
5.11 37.5 1.5 100.0 100.0 100.0 100.0 100.0
4.26 25 1 100.0 100.0 100.0 100.0 100.0
3.76 19.0 3/4 48.0 99.0 100.0 100.0 100.0
3.12 12.5 1/2 1.0 13.0 100.0 100.0 100.0
2.75 9.5 3/8 0.0 0.0 91.0 100.0 100.0
2.02 4.75 No.4 0.0 0.0 65.0 92.0 100.0
1.47 2.36 No 8 0.0 0.0 0.0 51.0 100.0
1.08 1.18 No 16 0.0 0.0 0.0 29.0 100.0
0.79 0.60 No 30 0.0 0.0 0.0 10.0 100.0
0.58 0.30 No 50 0.0 0.0 0.0 4.0 100.0
0.43 0.15 No 100 0.0 0.0 0.0 1.0 100.0
0.31 0.075 No. 200 0.0 0.0 0.0 0.4 94.0
Suggested Blending Percentages
Blend # Total Agg. # 1 Agg. # 2 Agg. # 3 Agg. # 4 Agg. # 5
Blend 1 100.0 10.0 25.0 40.0 25.0 0.0
Blend 2 0.0 0.0 0.0 0.0 0.0 0.0
Blend 3 0.0 0.0 0.0 0.0 0.0 0.0
DESIGN EVALUATIONS

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 Prepare Lab samples and trails as normal HMA
mix design procedure (or SP) .

CHECK :
 Voids , VMA, VFA, Kn, Rutt, Crack, TSR……etc.
STOCKPILE COMBINE AGGREGATE
 S-57 : 20 % 20.4%
 S-8 : 30 % Factory 30.6%

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 S-Fine : 25 % 25.5%
 RAP : 25 % 23.5%

 if 6% binder
 1000 kg sample :

 S-57: 20% x 1000= 200 kg S-57= 20.4% x 1000 = 204 kg

 RAP: 25% x 1000 = 250 kg RAP= 23.5% x 1000 = 235 kg
 Binder= 1000 x (Pbinder/Psolid) – (250-235)
 = 1000 x (5/95)-(250-235) = 37 kg instead of 50 kg.
SAVE COST

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 1 Ton Mixture = 4.0 m2

 1 kg bitumen = 0.3 $ : 15x0.3 = 4.5 $

 4.5$/4.0 m2 = 1.13 $/ m2 ***save in Binder***

 PLUS : save in Aggregate Cost

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Thank You For Listening

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