Geotechnical Special Publication No.

218 © ASCE 2011 26

Performance Evaluation of Recycled Asphalt Mixture Using Warm Mix

Asphalt Technology

Yingbiao Wu, Yanfang Guo, Xiuli Zhang

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Municipal Engineering Company of Cangzhou, #26 Huanghe East Road, Cangzhou City, Hebei, China;
061000; szgcgs-1@heinfo.net

ABSTRACT: As a means to optimize construction costs and in adherence to the Green

Revolution, many highway agencies are actively exploring the use of Warm Mix
Asphalt (WMA) technology and recycled materials. Based on the Evotherm® WMA
and hot-asphalt recycled technology, the feasible application of recycled WMA with
Reclaimed Asphalt Pavement (RAP) materials was investigated. In this study various
laboratory tests such as Marshall Stability and moisture susceptibility were conducted
to evaluate the effects of different RAP contents. The performances that include
dynamic stability of WMA with a certain proportion of RAP can be improved. WMA
technology can accommodate a higher percentage of RAP than hot recycled technology.

INTRODUCTION

To optimize construction costs and to adhere to the Green Revolution, many highway
agencies are actively exploring the use of Warm Mix Asphalt (WMA) technology and
recycled materials. Compared to conventional Hot Mix Asphalt (HMA), WMA
technology has the potential to reduce the mix and construction temperature
cost-effectively by about 20°C to 55°C (John et al. 2008). Additionally, WMA is
environmentally friendly and has less harmful gas emissions (Brian et al. 2007).
The feasibility of applying recycled WMA with Reclaimed Asphalt Pavement (RAP)
materials was investigated in this study based on the Evotherm® WMA (Hurley et al.
2006) and hot-asphalt recycled technology. Various laboratory tests such as ductility,
moisture susceptibility, and Marshall Stability were conducted to evaluate the effects of
different RAP contents. Results of the laboratory test evaluations including a field study
are presented in this paper.

LABORATORY TESTING

In both WMA and HMA mixes, different RAP contents, on the order of 20% to 45%,
were investigated. Evotherm was utilized as the additive for the WMA mixes. For
comparison purposes, similar tests were also conducted on virgin WMA and HMA
materials without RAP ( i.e., 0% RAP). The laboratory test plan is shown in Table 1.

Emerging Technologies for Material, Design, Rehabilitation, and Inspection of Roadway Pavements
 Geotechnical Special Publication No. 218 © ASCE 2011 27

Table 1 Laboratory Test Plan

RAP Mixing Molding

Type Mix Type Additive
(%) Temperature Temperature
AC-16 0, 35, 40, 45
HMA 150～160 °C ≥ 145 °C None
AC-10 0, 20
AC-16 0, 35, 40, 45 Evotherm™
WMA 125～130 °C ≥ 115 °C
AC-10 0, 20 DAT
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For both the HMA and WMA mixes, Marshall Stability tests were conducted to
determine the optimum asphalt binder content (OAC). Thereafter, dynamic stability at
60°C, freeze-thaw splitting strength and immersion Marshall Stability tests were
conducted at OAC. Air void measurements were also conducted.

Properties of Raw Materials

Fractionated coarse and fine RAP, with 10mm to 20mm and less than 10mm nominal
maximum aggregate size (NMAS), respectively, was utilized after a screening process.
The asphalt to aggregate ratio was 3% in the coarse RAP and 5% in the fine RAP. The
properties of the recycled asphalt binder in the RAP are summarized in Table 2.

Table 2 Properties of Recycled Asphalt-Binder in RAP

Density Penetration Softening Point Ductility

(g/cm3) (25°C, 0.1mm) (°C) (5cm/min, 15°C)
1.034 36.8 59 11

The other raw materials and additives that were used are summarized below:
Aggregates: Limestone
Asphalt-Binder: A-90
WMA additive: Evotherm™ DAT
Evotherm™ DAT is a WMA liquid additive that is brownish to orange in color with a
pH of 7.5±1.

Presentation and Discussion of Lab Test Results

In general, the test results indicated that the properties of the recycled WMA were
equivalent to that of ordinary HMA, albeit their Marshall Stability and dynamic stability
were even better than that of WMA with virgin aggregates. These results are presented
and discussed below.

z Marshall Stability (MS) Test

For both the WMA and HMA mixes, the Marshall Stability test results are shown in
Fig. 1, as a function of the RAP content. The threshold for the Marshall Stability
indicates a good mix is no less than 8KN (JTG F40-2004).

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 Geotechnical Special Publication No. 218 © ASCE 2011 28

14
Marshall stability (KN)
12

10 HMA AC-16
WMA AC-16
8
HMA AC-10
6 WMA AC-10
4
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0
0 20 35 40 45
RAP content (%)

FIG. 1 Marshall Stability of Different Mixes

From Fig. 1, the following observations can be made: (1) for the same RAP content,
the Marshall Stability of the WMA mix is slightly lower than that of the HMA mix; (2)
the Marshall Stability of the recycled WMA with RAP is significantly higher than that
of WMA with no RAP (but with virgin aggregates); and (3) the Marshall Stability of the
recycled WMA with RAP is almost equivalent to that of conventional HMA without
RAP. For the test conditions considered and the materials evaluated, this means that
adding RAP is helpful in improving the Marshall Stability of WMA.

z Stability at High Temperature

Dynamic Stability (DS) is a rutting resistance index of asphalt mix from a Wheel
Tracking Test. A higher DS number means a higher temperature stability of an asphalt
mix. The test is based on Standard Test Methods of Bitumen and Bituminous Mixtures
for Highway Engineering (JTJ 052-2000) T0719. The wheel load with a solid rubber
wheel contact pressure was 0.7MPa. The number of cycles of the wheel was 42
cycle/min; the total testing time was 60min, with a testing temperature of 60°C. Figure 2
is a bar-chart plot of the Dynamic Stability (DS) results as a function of the RAP
content. From the bar-chart, the following observations can be made:
- Similar to HMA, the DS of the recycled WMA increased significantly with an
increase in the RAP content. This result suggests that adding RAP can improve the
high temperature stability of WMA.
- The DS of the recycled WMA is slightly lower than that of recycled HMA, but
higher than that of conventional HMA without RAP. Therefore, adding a certain
percentage of RAP can improve the DS of WMA above that of conventional HMA,
and subsequently improve the rutting resistance of WMA.

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 Geotechnical Special Publication No. 218 © ASCE 2011 29

dynamic stability (Cycle/mm)

3000

2500
HMA AC-16
2000 WMA AC-16
HMA AC-10
1500
WMA AC-10
1000
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500

0
0 20 35 40 45
RAP content (%)

FIG. 2 Dynamic Stability of Different Mixes

100
Retained stability (%)

90

HMA AC-16
80
WMA AC-16
70 HMA AC-10
WMA AC-10
60

50
0 20 35 40 45
RAP content (%)

FIG. 3 The Retained Marshall Stability of Different Mixes

Retained freeze-thaw splitting

100

90
strength ratio (%)

HMA AC-16
80 WMA AC-16
HMA AC-10
70
WMA AC-10

60

50
0 20 35 40 45
RAP content (%)

FIG. 4 The Retained Freeze-Thaw Splitting Strength Ratio of Different Mixes

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 Geotechnical Special Publication No. 218 © ASCE 2011 30

z Moisture Susceptibility
The retained stability (JTJ 052-2000 T0709) and freeze-thaw splitting strength ratio
(JTJ 052-2000 T0729) reflects the mix’s resistance to water damage. As shown in Fig. 3
and Fig. 4, all the mixes (both WMA and HMA) satisfactorily met the retained stability
and retained freeze-thaw splitting strength ratios of above 80% and 75%, respectively.
Figure 3 further shows that the retained stability ratio of the WMA mix did not decline
but increased slightly with the addition of RAP. This observation suggests that the
addition of RAP has no significant adverse effects on the moisture susceptibility of
WMA mixes.
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Based on the above lab test results, it can be concluded that adding a certain
percentage of RAP into Evotherm® WMA can improve the bearing capacity, dynamic
stability, and rutting resistance of the WMA mix. Furthermore, the recycled WMA did
not exhibit any moisture susceptibility problems and indicated that the addition of RAP
did not have any adverse effects on this property.

FIELD TESTING

To produce recycled WMA mix, one of the critical additions to the conventional plant
operation was WMA additive equipment. The recycled WMA was used on the Yellow
River Road project in Cangzhou, China. Two types of recycled WMA mixes were used:
35% RAP content with AC-16 (base layer) and 20% RAP content with AC-10
(surfacing upper layer), respectively.

Recycled WMA Technology – More RAP

With 35% RAP content in the warm recycled production process, the heating
temperature of the new aggregates was reduced by about 20°C when compared to
recycled HMA, and decreased by about 20°C to 30°C compared to that of virgin HMA.
These results are summarized in Table 3. Based on these results, recycled WMA
technology can potentially solve the problems of using more recycled materials.
Compared to hot recycled HMA, the ratio of RAP will improve significantly under the
same heating temperature of new aggregates and reduce the costs of recycled surface
courses in WMA.

Table 3 Comparison of Mix Temperatures

Mix Process HMA Production WMA Production

AC-16 with AC-16 with
Mix type Virgin mix Virgin mix
35% RAP 35% RAP
Heating temperature of
— 90～110 — 90～100
RAP (°C)
Heating temperature of the
160～170 180～200 135～145 160～180
new aggregates（°C）
Discharge temperature of
150～155 150～160 125～135 125～135
mixture（°C）

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 Geotechnical Special Publication No. 218 © ASCE 2011 31

Workability – Ease to Mix at Low Temperature

When the recycled WMA with 35% RAP was produced, the electric current in the
motor cylinder was 103A to 105A and was uniformly mixed. However, the electric
current in the motor cylinder for the hot recycled HMA production was 95A to 110A.
Although the mixing temperature of the recycled WMA decreased by 20 to 30°C, no
major difficulties were encountered with regards to the uniformity of the mixing
process. Results indicate that recycled WMA based on the Evotherm® WMA
technology has satisfactory workability properties and is fairly easy to mix.
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Gas Emission Reduction - Better Air Quality

During production of recycled WMA, it was observed that the air quality was much
better than air quality from the production of HMA. There was no pitch smoke or
simulative odor during WMA production. As shown in Fig. 5, the emissions of asphalt
smoke, CO2, CO, NOX, SO2, and dust are greatly reduced. Therefore, recycled WMA
technology has the potential benefit of not being a health hazard to workers during
WMA production. Also, it minimizes environmental pollution.

a） Recycled WMA b）HMA

FIG. 5 Comparison of Gaseous Emission during Production

Effect of Recycled WMA on Fuel Consumption

Based on the field experimentation study, it was observed that recycled WMA mix
reduced the mixing temperature and fuel consumption. On this basis, it was calculated
from the amount of production and natural gas consumption that:
- The average natural gas consumption of AC-16 recycled WMA mix with 35%
RAP was 5.2m3/ton.
- The average natural gas consumption of AC-10 recycled WMA mix with 20%
RAP was 5.9m3/ton.
3
- The average natural gas consumption of 35% recycled HMA mix was 9m /ton.
3
- The average natural gas consumption of ordinary HMA without RAP was 8m /ton.

Emerging Technologies for Material, Design, Rehabilitation, and Inspection of Roadway Pavements
 Geotechnical Special Publication No. 218 © ASCE 2011 32

Therefore, recycled WMA leads to about a 30% reduction in fuel consumption

compared to HMA production. Also, recycled WMA reduces the emission of
greenhouse gases as it is a low-carbon mix and thus, is environmentally friendly.
Effect on Compactability

The rolling temperature was rigorously controlled during the placement of recycled
WMA mix surface courses. Based on the Chinese specifications, the beginning rolling
temperature must not be less than 120°C and the end rolling temperature should be
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greater than 75°C. For effective compaction of the WMA, a vibratory steel wheel and a
rub (pneumatic) tire roller were used. An example of the paving and rolling process is
shown in Fig. 6.

FIG. 6 Paving and Rolling Compaction on the Test Road

The temperature of the recycled WMA was 20°C to 30°C lower than that of HMA
during the paving and compaction process, but still rolled and compacted satisfactorily.
The test section has been used for one year and the road surface is still in good condition
without any visible distresses. This practical application shows that recycled WMA
technology would not only promote the recycling of old materials (i.e., RAP), but would
also decrease the consumption of fossil fuel. This technology also decreases the
emission of asphalt fumes, greenhouse gases, and other harmful gases, also resulting in
the improvement of work environment, particularly in terms of the air quality.
Therefore, recycled WMA technology supports the Green Revolution and can be
regarded as a Green Technology.

CONCLUSIONS AND RECOMMENDATIONS

Based on laboratory and field experimentations presented above, the following

conclusions can be drawn about recycled WMA technology:
- The laboratory performance properties indicated that recycled WMA can achieve
the same quality and technical standards as that of conventional HMA. To date, the
performance of the recycled WMA pavement remains satisfactory after more than
a year of service.

Emerging Technologies for Material, Design, Rehabilitation, and Inspection of Roadway Pavements
 Geotechnical Special Publication No. 218 © ASCE 2011 33

®
- Adding a certain percentage of RAP into Evotherm WMA can effectively
improve the bearing capacity and high temperature stability of the WMA mix.
Adding a certain percentage of RAP can improve the Dynamic Stability of WMA
above that of conventional HMA.
- The recycled WMA did not exhibit any moisture susceptibility problems and
indicated that the addition of RAP did not have any adverse effects on this
property.
- Recycled WMA technology offers the opportunity to use more recycled materials
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in the mix. Thus, the amount of RAP additive can be further increased in WMA
mix.
- Under reduced temperature about 20°C to 30°C lower than that of HMA, recycled
WMA is still easy to mix and roll. Also, constructability is good.
- Recycled WMA technology has various advantages such as energy savings, fuel
consumption reduction, and gas emission reduction. In support of the Green
Revolution, recycled WMA technology has potential to become the asphalt paving
technology of the future.
Lastly, the oxidative-aging rate of new and old asphalt-binders is theoretically
expected to be lower when the production temperature of recycled WMA drops by
about 20 to 30°C. Accordingly, WMA’s resistance to age-related distresses is
theoretically expected to be better. However, further studies are warranted to
substantiate these assumptions with a focus on crack resistance, fatigue cracking, and
long-time durability evaluation.

REFERENCES

John D’Angelo, Eric Harm, John Bartoszek, Gaylon Baumgardner, Mattew Corrigan,
Jack Cowsert, Thomas Harman, Mostafa Jamshidi, Wayne Jones, Dave Newcomb,
Brian Prowell, Ron Sines, and Bruce Yeaton (2008). “Warm Mix Asphalt:
European Practice.” Publication No. FHWA-PL-08-007, U.S. Department of
Transportation, Federal Highway Administration.
Brian D Prowell. (2007). The International Technology Scanning Program Warm Mix
Asphalt Scan Summary Report [R]. Washington DC: Federal Highway
Administration, US Department of Transportation.
Hurley, Graham C. and Brian D. Prowell. (2006).“Evaluation of Evotherm® for Use in
Warm Mix Asphalt,” NCAT Report No.06-02, Auburn, AL 36830.
The Ministry of Communication of the People’s Republic of China. (2004). “Technical
Specifications for construction of Highway Asphalt Pavements”, JTG F40, MOC
Publishing House. Beijing.
The Ministry of Communication of the People’s Republic of China. (2000). “Standard
Test Methods of Bitumen and Bituminous Mixtures for Highway Engineering”, JTJ
052, MOC Publishing House. Beijing.
Mallick, Rajib B, Prithvi S.Kandhal and Richard L.Bradbury. (2008).“Using Warm Mix
Asphalt Technology to Incorporate High Percentage of Reclaimed Asphalt
Pavement (RAP) Material in Asphalt Mixtures.” Presented at the 87th Annual
Meeting of the Transportation Research Board, Washington, DC.

Emerging Technologies for Material, Design, Rehabilitation, and Inspection of Roadway Pavements
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Van de Ven, M.F.C., Jenkins, K.J.,Voskuilen, J.L.M. and Beemt, R. Van den.
(2007).“Development of (half-) warm foamed bitumen mixes: state of the art”,
International Journal of Pavement Engineering, Vol. 8, No. 2, pp 163–175.
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Emerging Technologies for Material, Design, Rehabilitation, and Inspection of Roadway Pavements