Foam Bitumen Mixes for Base Layers-Laboratory and Field Study

Dr. Sunil Bose, Head Flexible Pavements Division, CRRI-New Delhi

Shri Arun Gaur, Lecturer Civil Engineering Deportment, MNIT-Jaipur
G Narendra Goud, Student M.Tech Transportation Engineering MNIT-Jaipur

Abstract
In the dense populated cities like Delhi, where environmental pollution and Land fill
problems are of prime concerns in the recent years. In rapid developing countries like India,
where conservation and optimum utilization of the road building materials specially petroleum
and mineral products are an important issue. There is an immediate attention requirement
towards the development and implementation of Eco-friendly and cost effective pavement
construction technologies. Through application of these technologies the efficient use of existing
and waste materials can be made with out creating problems to the environment and at the same
time meeting the quality requirements of the pavements.
Advances in technology and techniques in the in recent years have made cold recycling an
increasingly popular and cost-effective pavement construction and maintenance technique. In the
present study an effort is made to study the laboratory and field behavior of recycled cold mixes
with binder as foamed bitumen. The Marshall specimens were cast using foamed bitumen in
combination with cement. The specimens were tested for Density, Indirect Tensile Strength,
Resilient modulus and dynamic creep. Benkelman Beam deflection study was carried out on the
pavement constructed with recycled foamed bituminous mix after a period of three months from
construction and field cores were cut from the pavement and were investigated in the Laboratory.
It was found that the pavement constructed with foamed bitumen treated RAP was structurally
sound and cores cut from that pavement have shown higher ITS and MR values when compared
with Laboratory cast cores but they shown less creep stiffness and densities.
1.0 Introduction
In the dense populated cities like Delhi, where environmental pollution and Land fill
problems are of prime concerns in the recent years. In rapid developing countries like India,
where conservation and optimum utilization of the road building materials specially petroleum
and mineral products and energy are an important issues. The rehabilitation and up gradation of
existing badly distressed Pavements due to rapidly growing heavy vehicular traffic are attracting
the concentration. There is an immediate attention requirement towards the development and
implementation of Eco-friendly pavement construction technologies. Through application of
these technologies the efficient use of existing and waste materials can be made with out creating
problems to the environment and at the same time meeting the quality requirements of the
pavements.
Advances in technology and techniques in the in recent years have made cold recycling an
increasingly popular and cost-effective pavement construction and maintenance technique. It has
been proved in abroad that cold recycling with foamed bitumen is one of the best alternatives to
be considered as a rehabilitation option. Cold recycling technology can be an option which has
the potential to address the above mentioned issues.
In the present study an effort is made to study the laboratory and field behaviour of
recycled cold mixes with binder as foamed bitumen. The Marshall specimens were cast using
foamed bitumen in combination with cement. The specimens were tested for density, Indirect
Tensile Strength, Resilient modulus and dynamic creep. Benkelman Beam deflection study was
carried out on the pavement constructed with recycled foamed bituminous mix after a period of
three months from construction and field cores were cut from the pavement and were investigated
in the Laboratory.
2.0 Literature review
2.1 Foam bitumen
In order to mix bitumen with road-building aggregates, you first need to considerably
reduce the viscosity of the cold hard binder. Traditionally, this was done by heating the bitumen
and mixing it with heated aggregates to produce hot mix asphalt. Other methods of reducing the
bitumen viscosity include dissolving the bitumen in solvents and emulsification. Prof. Csanyi
came up with the idea of introducing moisture into a stream of hot bitumen, which effects a
spontaneous foaming of the bitumen (similar to spilling water into hot oil). The potential of
foamed bitumen for use as a binder was first realised in 1956 by Dr. Ladis H. Csanyi, at the
Engineering Experiment Station in Iowa State University. Since then, foamed asphalt technology
has been used successfully in many countries, with corresponding evolution of the original
bitumen foaming process as experience was gained in its use.

Figure 1: schematic diagram of foamed bitumen production

The foamed bitumen, or expanded bitumen, is produced by a process in which pressurized water
and compressed air is injected into the hot bitumen (155-180 0c), resulting in spontaneous
foaming. The physical properties of the bitumen are temporarily altered when the injected water,
on contact with the hot bitumen, is turned into vapour which is trapped in thousands of tiny
bitumen bubbles. In the foam state the bitumen has a very large surface area and extremely low
viscosity making it ideal for mixing with aggregates however the foam dissipates in less than a
minute and the bitumen resumes its original properties. In order to produce foamed asphalt mix,
the bitumen has to be incorporated into the aggregates while still in its foamed state. A distinct
difference between foamed asphalt mixes and conventional asphalt stabilised mixes is the way in
which the bitumen is dispersed through the aggregate. In the later case the bitumen tends to coat
all particles whilst in the foamed mixes the larger particles are not fully coated. The foamed
bitumen disperses itself among the finer particles forming a mortar which binds the mix together.
2.2 Characterization of Foam bitumen
Foamed bitumen is characterized by two primary properties:
 1. Expansion Ratio that is a measure of the viscosity of the foam and will determine how
well it will disperse in the mix. It is calculated as the ratio of the maximum volume of
foam relative to its original volume
2. Half-Life is a measure of the stability of the foam and provides an indication of the rate
of collapse of the foam. It is calculated as the time taken in seconds for the foam to
collapse to half of its maximum volume.
The “best” foam is generally considered to be the one that optimizes both expansion and half-life.

Figure 2: Bitumen Foam characterization

2.3 Action of Foamix
Unlike hot-mix asphalt, material stabilised with foamed bitumen does not appear black.
This result from the coarser particles of aggregate not was being coated with bitumen. When
foamed bitumen comes into contact with aggregate, the bitumen bubbles burst into millions of
tiny bitumen droplets that seek out and adhere to the fine particles, specifically the fraction
smaller than 0.075 mm. The bitumen droplets can exchange heat only with the filler fraction and
still have sufficiently low viscosity to coat the particles. The foamed mix results in a bitumen-
bound filler that acts as a mortar between the coarse particles, as shown in Figure 3. There is
therefore only a slight darkening in the color of the material after treatment. The addition of
cement, lime or other such fine cementitious material (100 % passing the 0.075 mm sieve) assists
the bitumen to disperse, in particular where the recycled material is deficient in fines.
 Figure 3: Foamed bitumen dispersion and binding in the treated mix

2.4 Material suitability for foamed bitumen treatment

The foamed bitumen process is suitable for treating a wide range of materials, ranging
from sands, through weathered gravels to crushed stone and RAP. Aggregates of sound and
marginal quality, from both virgin and recycled sources have been successfully utilized in the
process in the past. As depicted in Figure 4, the minimum requirement is 5% passing the 0.075
mm (No. 200) sieve. When a material has insufficient fines, the foamed bitumen does not
disperse properly and tends to form what are known as “stringers” (bitumen rich agglomerations
of fine material) throughout the recycled material. These stringers vary in size according to the
fines deficiency, a large deficiency will result in many large stringers which will tend to act as a
lubricant in the mix and lead to a reduction in strength and stability.

Figure 4: Material gradation envelops

Material that is deficient in fines can be improved by the addition of cement, lime or other such
material with 100 % passing the 0.075 mm sieve. However, the use of cement in excess of 1.5 %
by mass should be avoided due to the negative effect on the flexibility of the stabilised layer. The
envelopes provided in Figure 4 are broad and can be refined by targeting a grading that provides
the lowest voids in the mineral aggregate. This produces foamed bitumen mixes with the most
desirable mix properties. A unique relationship for achieving the minimum voids, with an
allowance for variation in the filler content, is shown in equation. This relationship is useful as it
provides flexibility with the filler content of a mixture. A value of n = 0.45 is utilised to achieve
the minimum voids.

Where: d = selected sieve size (mm)

P = percentage by mass passing a sieve of size d (mm)
D = maximum aggregate size (mm)
 F = percentage filler content (inert and active)
n = variable dependent on aggregate packing characteristics (0.45)
Achieving a continuous grading on the fraction less than 2 mm is important for the proper
dispersion of the foamed bitumen and easier compaction, thereby reducing voids and the
material’s susceptibility to water ingress. Where necessary, therefore, consideration should be
given to blending two materials to improve the critical grading characteristics.
Moisture Conditions: The moisture content during mixing and compaction is considered by many
researchers to be the most important mix design criteria for foamed asphalt mixes. Moisture is
required to soften and breakdown agglomerations in the aggregates, to aid in bitumen dispersion
during mixing and for field compaction. Insufficient water reduces the workability of the mix and
results in inadequate dispersion of the binder, while too much water lengthens the curing time,
reduces the strength and density of the compacted mix and may reduce the coating of the
aggregates. The optimum moisture content (OMC) varies, depending on the mix property that is
being optimized (strength, density, water absorption, swelling). However, since moisture is
critical for mixing and compaction, these operations should be considered when optimizing the
moisture content. The optimum mixing moisture content occurs in the range of 65 - 85 per cent of
the modified AASHTO OMC for the aggregates.
Curing Conditions: Studies have shown that foamed asphalt mixes do not develop their full
strength after compaction until a large percentage of the mixing moisture is lost. This process is
termed curing. Curing is the process whereby the foamed asphalt gradually gains strength over
time accompanied by a reduction in the moisture content. A laboratory mix design procedure
would need to simulate the field curing process in order to correlate the properties of laboratory-
prepared mixes with those of field mixes. Since the curing of foamed asphalt mixes in the field
occurs over several months, it is impractical to reproduce actual field curing conditions in the
laboratory. Most of the previous investigations have adopted the laboratory curing procedure
proposed by Bowering (1970), i.e. 3 days oven curing at a temperature of 60° C. This procedure
results in the moisture content stabilizing at about 0 to 4 per cent, which represents the driest state
achievable in the field. In the present study the specimen are cured for 72 hours at 40 0C
temperature only.
3.0 Laboratory and Field studies
3.1 Material evaluation
Representative sample of pulverized and air dried Reclaimed Asphalt Product (RAP)
and Crusher stone dust were collected from stock piles and then sieved through a set of sieves for
gradation. The details of sieve analysis are presented in tables 1 and 2. Bitumen content and
moisture content of air dried RAP found to be 5.2% and 0.12% respectively. Moisture content
and specific gravity of air dried Stone Dust found to be 0.40% and 2.68 respectively. Based on
pulverized RAP and stone dust gradation their proportions were fixed (RAP:Stone
dust::55%:45%) to meet the gradation requirements for Foamed bitumen treatment. Figure 5
shows the gradation envelops.
 0
lowerlimit

10
upperlimit
combined achieved

6 passing
0 8
RAP
stone dust

0
Percentage
4 20 00

0.01 0.1sieve size, mm

1 (log scale) 10 100

Figure 5: Gradation envelops

Table 1: Sieve analysis of pulverized and air-dried RAP
sieve size, mm 37.5 26.5 19 13.2 9.5 6.7 4.75 2.36 1.18 0.6 0.425 0.3 0.075 pan
cumulative % passing 100.0 99.2 95.0 74.7 52.1 39.1 29.1 16.6 7.5 5.3 3.4 2.0 0.2 0.0

Table 2: Sieve analysis of Stone Dust

sieve size, mm 6.7 4.75 2.36 1.18 0.6 0.425 0.3 0.075 pan
cumulative % passing 100.00 93.40 72.00 50.60 43.60 35.80 26.20 9.00 0.00

OMC Determination for Foamed Bitumen Treatment: The pulverized and air dried RAP is
separated in to three different fractions (i.e. P-19mm & R-13.2mm, P-13.2mm & R4.75mm and
P-4.75). The proportioned and un-treated material was used to find Optimum Moisture Content
with modified Proctor compaction effort for foamed bitumen treatment. The Optimum Moisture
Content found to be 8.75% with a Maximum Dry Density of 2.09 g/cc. The mixing moisture
content of proportioned material was decided based on optimum moisture content and air dried
field sample moisture content to prepare foamix.
Foamed Bitumen Characterization: The Study of foamed bitumen and its characterization wais
carried out using Wirtgen Foam bitumen Laboratory plant, WLB-10. The Foamability and the
variation of foam characteristics viz. expansion ratio and half life time were observed at different
air pressures, temperatures and Bitumen water contents. The bitumen used was of 80/100
penetration grade. The figure xx shows variation of Half life time and Expansion ratio with
Bitumen water at 4.5 bars air pressure and 165 oC bitumen temperature. Optimum foam
producing bitumen water found to be 3.3% by weight of bitumen.
12 9
11 8
Half life, seconds
Expansion ratio

10 7
9 6
8 5
7 4
6 3
5 exp ratio 2
4 half life
1
3 0
2.0 2.5 3.0 3.5 4.0 4.5
Bitumen water content, %

Figure 5: Bitumen water content Influence on expansion ratio and half life time of Foamed
bitumen
3.2 Foamix preparation and specimens casting
The graded material and filler cement was mixed using pug-mill type mixer Initially dry mixing of
proportioned material was carried out for 10 to 15 seconds then additional water was added and then in to
that mix foamed bitumen was sprayed using WLB-10, after setting the calculated and determined
parameters on the laboratory plant. Foam bitumen quantity varied from 2 to 5% with 1% interval and
cement varied from 0 to 3% with 1% interval. The Marshall Specimens were cast with the mixture,
the number of blows applied were 75 on each side.
3.3 Specimens conditioning and testing
The Marshall specimen prepared with formulated material have been tested for Bulk
Density, Resilient modulus (MR) and Indirect Tensile Strength (ITS) after a curing period of 24
hours at room temperature in mold and 72 hours at 40 0C after taken out of mold. And testing was
carried out at room temperature only. Duplicate samples were tested for soaked Indirect Tensile
Strength after a soaking period of 24 hours in water bath at ambient temperature. Indirect Tension
Test for Resilient Modulus was carried out at a repetitive load 100 N, frequency 0.1 Hertz and at
a temperature of 25 0C. The test results of bulk density, indirect tensile strength and Indirect
Tension test for Resilient Modulus are presented in table 3. Field cores cut from the Foamed
bitumen treated recycled pavement layer were tested for Bulk Density, Resilient modulus (MR),
Indirect Tensile Strength (soaked and un-soaked) and dynamic creep resistance. Some Laboratory
cast specimens were also tested for dynamic creep resistance since the uniaxial unconfined creep
test is effective in identifying the sensitivity of asphalt mixtures to permanent deformation or
rutting. Dynamic creep test was conducted under unconfined conditions at a temperature of 40
0
C. The Specimens were placed in the temperature control cabinet for a minimum period of two
hours for conditioning the specimen to achieve test temperature before testing. The contact stress
of 3 kPa was applied for 0.1 second and rest period of 0.9 second at a frequency of 1 Hz. The
load was applied for a maximum of 3600 cycles. The results of Dynamic creep test on lab and
field cores presented below in table 4.
The values of Resilient modulus were plotted in graphs (Figure 6) and then linear trend
lines were drawn to observe the variation in MR with foam bitumen and active filler. It was
observed from the graphs that the increase in foam bitumen and increase in cement increased the
MR but at higher cement contents and at higher foam bitumen contents increase in MR was not
much significant. The optimum cement content ranges from 1 to 2% and optimum foam bitumen
content ranges from 3 to 4%. The maximum MR values observed was 2372 MPa at 1% cement
and 5% foam bitumen and 2350 MPa at 3% cement and 3% foam bitumen.
The ITS values were increased and then decreased with increase in foam bitumen. The
addition of cement increased the ITS values significantly. Maximum ITS observed was 510 kPa
at 3% cement and 4% foam bitumen (Figure 7). The specimens with cement were observed to be
very less susceptible to moisture as it was observed from soaked ITS of the specimens.

Table 3: Test results of Marshall Specimens of Foamix

Bulk Average Resilient ITS, kPa
Mold Filler Filler, Foamed Mean Resilient TSR,
Density, Bulk Modulus,
ID type % Bitumen, % Modulus, MPa %
g/cc Density, g/cc MPa Dry Soaked

0/2/1 0% 2.107 1211 316.74

2 2.085 1318 58
0/2/2 2.063 1425 183.41
0/3/1 2.114 2090 353.89
3 2.148 1445 73
0/3/2 2.182 800 259.87
0/4/1 2.134 1845 372.66
4 2.133 1687 87
0/4/2 2.132 1528 322.41
0/5/1 2.129 2544 402.01
5 2.130 2155 79
0/5/2 2.131 1765 318.31
1c/2/1 Cement 2.340 2519 329.83
2 2.152 2018 89
1c/2/2 Cement 1.964 1517 292.94
1c/3/1 Cement 2.188 2585 390.23
3 2.158 2417 104
1c/3/2 Cement 2.127 2250 405.37
1%
1c/4/1 Cement 2.126 2132 437.23
4 2.125 2247 89
1c/4/2 Cement 2.125 2362 387.04
1c/5/1 Cement 2.148 2335 450.46
5 2.111 2399 76
1c/5/2 Cement 2.074 2464 343.44
2c/2/1 Cement 2.144 2094 435.79
2 2.142 2169 70
2c/2/2 Cement 2.140 2244 305.23
2c/3/1 Cement 2.161 2188 448.34
3 2.150 2195 90
2c/3/2 Cement 2.139 2201 403.76
2%
2c/4/1 Cement 2.152 2278 519.35
4 2.153 2282 72
2c/4/2 Cement 2.155 2286 376.00
2c/5/1 Cement 2.126 2300 359.33
5 2.101 2277 84
2c/5/2 Cement 2.077 2253 301.16
3c/2/1 Cement 2.163 1957 484.19
2 2.141 1993 90
3c/2/2 Cement 2.120 2028 433.83
3c/3/1 Cement 2.117 2494 494.21
3 2.119 2148 86
3c/3/2 Cement 2.121 1802 426.57
3%
3c/4/1 Cement 2.114 2058 512.92
4 2.116 2173 79
3c/4/2 Cement 2.118 2287 402.82
3c/5/1 Cement 2.110 2258 500.38
5 2.102 2324 76
3c/5/2 Cement 2.095 2390 382.34
Field cores
1 Cement 1.5% 3.5% 2.110 3350 525.8072
2 Cement 1.5% 3.5% 2.090 2374 403.3839
2.090 2861 155
3 Cement 1.5% 3.5% 2.108 3416 342.1538
4 Cement 1.5% 3.5% 2.035 2302 258.0461

Table 4: Dynamic creep Test results of Foamix

Creep Total accumulated axial
S.NO Mold description stiffness, strain at 1 hour of Remarks
MPa loading, %
1 1.5% Cement, 3.5% Foamed bitumen 464.7 0.015 No failure
Field core of 1.5% cement, 3.5% Foamed No failure
2 30.5 0.222
bitumen
 Variation of MR w ith Foam ed Bitum en and Cem ent
3500
3250
3000

Resilient modulus, MPa

2750
2500
2250
2000
1750
1500 0% Filler
1250 1% Cement
1000 2% Cement
750
3% Cement
500
1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5
Foam ed bitumen, %

Figure 6: variation of Resilient modulus with foamed bitumen and cement

Variation of Dry ITS with Foamed bitumen and cement
550
500
450
400
Dry ITS, KPa

350
300
250
200
0% Filler
150
1% Cement
100
2% Cement
50
3% Cement
0
1.5 2 2.5 3 3.5 4 4.5 5 5.5
Foam ed bitum en, %

Figure 7: variation of ITS with foamed bitumen and cement

3.4 BBD study on RAP Foamix pavement
Benkelman beam deflection study has been carried out on the pavement constructed with
Recycled mix of Foamed bitumen in Kumbalgodu industrial area, Bangalore after three months
of construction i.e. in the month of March 2006. The interval of deflection measurement points
was selected as 30 meters and initial point was marked at a distance of 10 meters from the zero
Chainage of the Road (i.e. SH-17 Junction). The pavement temperature observed was 37 0 C, The
PI value and moisture content of sub-grade soil found to be 14% and 17% respectively. The
temperature correction factor and moisture correction factor applied were -0.02 and 1.1
respectively. The average characteristic rebound deflection of the pavement found to be 1.17mm.
Table 5: Deflection data (LHS, towards Karnataka cold Storage Pvt. ltd)
Chainage, km & m 00+010 00+040 00+070 00+100 00+130 00+160 00+190 00+220 00+250 00+280 00+310
Distance, m 10 40 70 100 130 160 190 220 250 280 310
Corrected Rebound
0.89 0.66 1.18 0.37 0.62 0.65 0.31 0.62 0.37 1.03 1.31
Deflection, mm

Table 6: Deflection data (RHS, towards Karnataka cold Storage Pvt. ltd)
Chainage, km & m 00+010 00+040 00+070 00+100 00+130 00+160 00+190 00+220 00+250 00+280 00+310
Distance, m 10 40 70 100 130 160 190 220 250 280 310
Corrected Rebound
1.2 0.99 1.01 1.16 0.33 0.62 1.06 1.32 1.23 1.14 0.57
Deflection, mm
4.0 Conclusions
The following conclusions were drawn based on the studies performed on foamed
bitumen treated RAP in laboratory and Field.

When recycling with foam bitumen mixing moisture content should be around
60% of OMC as per Wirtgen Cold Recycling Manual, however observing the material
it can be varied from 50 to 65% to reduce problems in compacting the mix
Loss of strength on soaking is very less with foamed bitumen and cement treated
material, in most of the cases the tensile strength ratio ranges from 70 to 100% and it
is 155% in case of field cores
Cores cut from the foamed bitumen treated pavement have shown higher ITS and MR
values in comparison with laboratory cast cores
Dynamic creep stiffness of Cores from the field was very less in comparison with
laboratory cast cores but they were comparable to HMA cores, which needs to be
further examined before any conclusions are drawn.
Benkelman beam deflection study on foamed bitumen treated pavement shows that it
was structurally sound with an average characteristic rebound deflection of 1.17mm
and no functional failure was observed even in the absence of surface course
Foam bitumen treated mixes can be one of the considerable options for base courses
in a flexible pavement structure since it requires a surface course

Acknowledgements
The authors are grateful to the director for granting permission to publish this paper. Thanks are
also due to M/S Wirtgen India Pvt. Ltd. For supporting during foamix study and Nagarjuna
Construction Company for the help rendered during field study.

References
Websites
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• www.arra.org
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• www.wirtgen.com
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• www.asphaltwa.com/wapa
• www.trb.org
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