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THE MAGAZINE OF THE ASPHALT INSTITUTE | SUMMER 2021 | VOL. 36, NO.

PAVEMENT
CONVERSION
A JOHN DEERE COMPANY

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PRESIDENT’S MESSAGE CONTENTS S U M M E R 2 0 21

E
arlier this year, on February 1 ............... President’s Message
15th to be precise, the Asphalt 4 ................ Asphalt News
Institute launched our online 36 .............. Asphalt binders added to audit program
Pavement Inspector Certification 41 .............. Asphalt Academic
course – known as PIC for short. Several 42 .............. Lab Corner
years in the making, this training 44 .............. Calendar of Events
and certification tool addresses a
critical need in our industry – teaching
‘what right looks like’ to our pavement inspectors.
If you proudly carry this position title, how much education
did you get in school that applies to your role as an inspector? FEATURES
Probably not a lot. How much on the job training did you

7
get with your employer before heading out to fulfill the
requirements as inspector? Hopefully, you were able to “learn
the ropes” from a veteran inspector who knew their stuff. But
the reality for many new inspectors is being handed a set of
plans and specs and being told your job is to enforce them.
Do you remember the pit in your stomach which comes Nashville interstate is converted to asphalt
directly from not being sure if what you were looking at was The Tennessee Department of Transportation rebuilt
being done correctly, if it met spec or what to do if it didn’t? the I-440 by converting a deteriorated concrete
pavement to new asphalt pavement.
Watching isn’t inspecting. And specifications are not written in a
way to educate the inspector. This is exactly why we created PIC.
PIC is designed for the busy pavement inspector who
has neither the time nor travel budget to go somewhere
to learn the nuances of this important job. It is fully online
instruction, allowing students to proceed through the course
at their own pace. With eight modules, we cover everything
17
from inspector authority and responsibility to acceptance
and testing with all the details in between. Each module Pyrophoric material formation in tanks
ranges between 60 and 135 minutes of instruction by A new paper released by the Asphalt Institute
Asphalt Institute Regional Engineers who have a tremendous provides information on pyrophoric material
amount of experience in this area. Completing the course formation in heated asphalt storage tanks.
and passing each module exam nets the student not only
the PIC certification but 16 professional development
hours. Better yet, it is priced for any agency’s budget.

21
Fundamentals of an inspector’s work are the same
regardless of the project or the employer – city to federal
jobs and agency staff or hired guns doing the same. If
you or someone in your circle is headed into this role
or was recently assigned to it, this is for them. Curtailing oxidation with warm mix asphalt
We’re working on complementing PIC with in-person There are compounding benefits of WMA that limit the rate
training to address the U.S. Department of Defense’s of oxidation during asphalt mix production and placement.
needs for their specifications on airfield paving. A
face-to-face session for these inspectors should be
available later this year. Have a similar need for your

28
agency to address your specifications? We can help.
If you are a veteran inspector, you know how long it
took you to gain the experience to not only be confident in
what you were doing but to be truly competent. Help the
next generation of pavement inspectors by giving them
the tools they need to succeed. Tell them about PIC. 50 years of asphalt advancement
If you are an owner and want to ensure your asphalt inspection Advancements over time have been relatively steady – much
staff has a level of competence necessary to be truly effective, has changed while much has also stayed the same.
consider adopting PIC into your training requirements.

1
There are
partners.
Then there
is Russell
Standard.
Rest assured, when it comes to a partner you can trust
in asphalt materials and pavement preservation, look
no further than Russell Standard. Visit RussellStandard.com
and find out how we are truly unmatched all the way around.
ASPHALT INSTITUTE® MEMBERS as of June 1, 2021
Summer 2021 Vol. 36, No. 2

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3
ASPHALT NEWS SUMMER 2021

ASPHALT PAVEMENT ALLIANCE ANNOUNCES


2020 PERPETUAL PAVEMENT AWARDS

Mississippi State Route 63

T
welve departments of transportation (DOTs) in the U.S. The 2020 winners are:
were named winners of the 2020 Perpetual Pavement
Award (PPA) by the Asphalt Pavement Alliance (APA). Alabama Department of Transportation (ALDOT), North
Region, for a two-mile section of a four-lane highway with
This number ties last year’s record of awards in a a center turn lane on U.S. Highway 411 (State Route 25) in
single year since the awards were first presented in 2001. Etowah County. The original construction of this roadway
The award celebrates long-life asphalt pavements that was completed in 1979. This is the twelfth PPA for ALDOT.
reflect the characteristics of a perpetual pavement design.
Arizona Department of Transportation (ADOT) for
The award is presented to state DOTs and local agency a 2.46-mile segment of a four-lane divided highway
road owners for well-performing asphalt pavements that on Interstate 40 in Mohave County originally opened
are at least 35 years old with proven high-quality structural to traffic in 1976. This is ADOT’s second PPA.
design. To earn the award, the pavement must have not
suffered a structural failure and it should have an average Arkansas Department of Transportation (ARDOT)
interval between resurfacing of no less than 13 years. for a 2.85-mile section of two-lane State Highway 1
(Section 17) in Craighead County. This roadway is
The pavement must demonstrate the over 44 years old. ARDOT has earned 11 PPAs.
characteristics expected from long-life, perpetual
pavement design: excellence in design, quality Florida Department of Transportation (FDOT) for
in construction and value to taxpayers. a 3.012-mile section of a two-lane roadway on State
Road 40 in Marion County. This road was originally
Engineers at the National Center for Asphalt constructed in 1954. This is the eleventh PPA for FDOT.
Technology (NCAT) at Auburn University evaluated the
nominations and validated the results for the 12 winners Maryland Department of Transportation (MDOT)
for 2020. Since the PPA was first presented in 2001, State Highway Administration for a 66-year-old
156 pavements in 31 U.S. states and one Canadian 8.89-mile section of four-lane Interstate 270 NB in
province have been honored with the award. Frederick County. MDOT has earned six PPAs.

4
Mississippi Department of Transportation (MDOT) for
a 5.8-mile section of a divided four-lane state route, MS
63, in Jackson County. The original construction of this
roadway was completed in 1977. This is MDOT’s fifth PPA.

Ohio Department of Transportation (ODOT),


District 2, for a 3.66-mile section of two-lane State
Route 199 in Wood County. At 91-years-old, this
is the oldest road at the time of the award to
earn a PPA. This is the fifth PPA for ODOT. Pennsylvania State Route 0096

Pennsylvania Department of Transportation


(PennDOT), Engineering District 9-0 for a 10.16- Washington State Department of Transportation
mile section of two-lane State Route 0096 in Bedford (WSDOT) for a 6.9-mile section of two-lane State
County. This project was originally constructed Route 395 in Franklin County. This project is over
in 1958. PennDOT has earned 10 PPAs. 40 years old. WSDOT has earned seven PPAs.

South Carolina Department of Transportation Winning agencies are honored by their local
(SCDOT) for a 6-mile section of four-lane Interstate state asphaltpavement association and are
26 in Berkeley County. This roadway is over 58 presented with an engraved crystal obelisk.
years old. SCDOT has earned nine PPAs.
“One key indicator of quality in construction is a
Tennessee Department of Transportation (TDOT) for smooth, long-life pavement,” said Amy Miller, P.E.,
a 2.93-mile section of two-lane State Route 72 in Loudon National Director of the APA. “Long-life asphalt
County. The original construction of this roadway was pavements serve the community, reduce the
completed in 1962. This is TDOT’s sixteenth PPA. money needed for maintenance and conserve raw
materials, ultimately leading to a truly sustainable
Virginia Department of Transportation (VDOT) structure that exemplifies the triple bottom line."
for a 2.51-mile section of Interstate 81 SB in
Roanoke County. This road was originally opened Learn more about the awards at driveasphalt.
to traffic in 1964. This is VDOT’s second PPA. org/awards/perpetual-by-performance.

KIRK SCHOLARS ANNOUNCED This year’s Kirk Scholars are:

• Madeline Blair, University of Maine


The Asphalt Institute • Rachel Cousins, Auburn University
Foundation (AIF) • Tanner Keen, Virginia Tech
announced the recipients • Tyler Kleinsasser, South Dakota School of Mines & Technology
of scholarships from • Richard Lee, University of Texas at Austin
the Bill and Shireen Kirk Scholarship Fund. • Helmut Leodarta, University of Missouri-Columbia
• Jessica Lewis, Mississippi State University
The scholarships are awarded annually to • Ady Tibrewal, Drexel University
third- or fourth-year undergraduate, master’s
or doctoral students studying business, Interested students can go to asphaltfoundation.org
chemistry, civil engineering, construction to learn more about the program.
management, marketing or sales. Scholarship The Asphalt Institute Foundation was incorporated in
recipients are referred to as “Kirk Scholars.” 2014 and is a 501(c)3 non-profit public charity.
ROADS
LEAD TO
WHAT’S
IMPORTANT.
It’s not just about getting from Point A to Point B.
It’s about having the freedom to get out there, live
your life, and make memories happen.

At Ergon, we’re proud to deliver the right paving,


preservation, and maintenance and solutions
designed to keep your road networks safe and
strong. Because you have places to go and people
to see. Don’t let inferior road conditions get in the
way of life’s adventures.
Tennessee DOT
uses innovation to
rebuild Nashville’s

I-440
Historic project converted concrete
pavements to asphalt
By Bob Horan, P.E.

7
A reconstructed section of the
I-440 corridor which is part
of the loop around Nashville,
Tennessee from I-40 to I-24
was opened in July 2020 –
a full month ahead of schedule.

That was very good news for the approximately


110,000 drivers that use this roadway daily as it is now
safer and less congested than the old roadway. The
cost of the design-build project was $154 million which
made it the largest reconstruction project ever by the
Tennessee Department of Transportation (TDOT).

The project successfully converted a deteriorated


concrete pavement to new asphalt pavement and
was completed in one year and nine months.

According to Clayton Markham of TDOT’s


Region 3 Innovative Delivery Division, the
goals of the I-440 project were to:

• Address the deteriorated concrete pavements


• Improve safety
• Address congestion

This section of the I-440 corridor was originally built in


the 1980s and therefore the concrete pavement was over
30 years old. The original structural section consisted
of 10 inches of plain jointed concrete pavement on 5
inches of cement treated base (CTB). The pavement was
badly deteriorated and needed major rehabilitation. The contract required the contractor to both design the
pavement section to meet TDOT structural requirements
From a safety standpoint, the corridor was and to construct the project in a limited amount of time.
experiencing roughly 1.8 times the state crash
rate standards. The project included provisions to TDOT selected Kiewit Infrastructure South (KIS) as the
dramatically improve safety for the traveling public. general contractor for the project. Based on Kiewit’s
proposal, the project would be completed no later than 708
As for congestion, the project was originally designed calendar days after the project started in August of 2018.
to carry 64,000 vehicles per day. With the current
traffic volumes exceeding 100,000 vehicles per day, Jordan Gregg of Kiewit Infrastructure South described the
there was a need to increase capacity by adding lanes design-build approach like this: “This was an A (cost) plus B
to mitigate traffic congestion. This project added two (time) design-build project with the B component equal to
new traffic lanes and an occasional accessory lane. $100,000/day which means that both the project cost and
schedule were critical factors in the selection process. This
The project was a design-build and the winning contractor type of contract allows the contractor to consider innovative
was the one that offered the best value based on the approaches to both accelerate construction as well to
total cost of the project and the target completion date. provide the most cost-effective way to accomplish the work.”

8
The project successfully
converted a deteriorated
concrete pavement to
new asphalt pavement.
Structural sections the contractor settled on the following structural
After looking at several options, the contractor design for mainline and shoulder sections:
decided on a pavement reconstruction approach that
consisted of rubblizing the old concrete pavement • Mainline over rubblized concrete – a total
and constructing a new asphalt pavement on top thickness of 8.75 inches of asphalt pavement
of the rubblized material on the existing lanes. To • Right shoulder over rubblized concrete – 3.5 inches of
construct the new lanes, KIS placed an aggregate base asphalt pavement over 5.25 inches of aggregate base
layer topped with a cement treated aggregate base • Mainline over widening (new lanes) – 8.75 inches
underneath multiple layers of asphalt pavement. of asphalt pavement over a 3-inch asphalt treated
drainage layer over an aggregate base (with
TDOT provided a minimum structural number that variable depths of the base being cement treated)
the contractor could use to design the pavement
materials and thicknesses to be used on the The mainline asphalt pavement section consisted of 4
projects. They also provided structural numbers inches compacted thickness, 3.5 inches of intermediate
for each of the paving layers (including rubblized of asphalt binder mix and 1.25 inches of asphalt
concrete – 0.22 and existing cement treated surface mix. All three layers of asphalt pavement were
base materials – 0.14). Using that information, constructed using a polymer-modified PG 76-22 binder.

9
One Hundred Years of

1921 • 2021

Innovation & Excellence

www.suit-kote.com (800) 622-5636


The rubblization process
Rubblization (also known as fractured slab An estimated 215,000 tons of
crushed concrete aggregate
technology) is the process of fracturing an existing
portland cement concrete pavement (PCCP) into
small, interconnected pieces that serve as a base
course for a new hot mix asphalt (HMA) overlay.
was produced and used as an
The rubblization subcontractor, Antigo, used their
multi-head breaker (MHB) equipment to rubblize the untreated aggregate base layer.
concrete that stayed in place as a pavement base
material and also to break up the existing concrete
for removal. From March 2019 through March 2020, particle size on top and 12-inch maximum particle size
158,000 square yards were rubblized, while 265,000 throughout the existing concrete pavement. After some
square yards were broken for removal and crushing adjustments, Antigo was able to demonstrate that they
to create aggregate materials used on the project. could consistently meet the test strip requirements
and were allowed to start the rubblization process.
Antigo used a combination of Badger Breakers
and a vibratory “Z”-grid roller to perform the As is typical in rubblization projects, the contractor
concrete rubblization. The project phasing required was required to install edge drains to drain water from
Antigo to mobilize equipment operators and/or the existing pavement section before rubblization. In
equipment to the job site twenty-three times. addition, an asphalt treated drainage layer was added
under the new lanes in mainline pavement sections.
TDOT’s rubblization specification required a test The drainage layer and underdrains will facilitate
section and test pit be constructed before beginning the drainage of water that entered the pavement
work to ensure the requirement for 3-inch maximum either from the bottom or top of the pavement.

11
TDOT wanted
th public
the bli to
k
know h they
that h
w being
were b
environmentallyll
r bl
responsible.
Removal and processing of at a central crushing location within the project footprint.
broken concrete pavement The broken concrete was then crushed to meet the size
By design, the contractor had to maintain a strict specifications for aggregate base materials. An estimated
pavement elevation throughout the project to tie into 215,000 tons of crushed concrete aggregate was produced
existing structures on I-440 and also to maintain proper and used as an untreated aggregate base layer and as a
clearances under bridges going over the interstate. So, cement treated base material in construction of the new
simply placing the new asphalt pavement on top of the lanes where full-depth asphalt pavement sections were built.
rubblized concrete was not an option on much of the
project. In those locations, the broken-up concrete would be There were many benefits in keeping the crushing
removed from the roadway so a new full-depth pavement operation within the confines of where the entire pavement
section could be built. This created a large amount of structure needed to be removed. Kiewit estimates that
broken concrete that had to be dealt with. The question this eliminated the need for approximately 24,000 heavily
then was: “What to do with all of that concrete rubble?” loaded trucks (over 300,000 tons of aggregate base
materials) to import and export materials on to and
KIS solved the problem with an innovative solution of off the project. This also reduced the wear and tear on
reprocessing and reusing the concrete rubble within the surrounding roads and bridges and also offered significant
limits of the project. Where the elevation of the pavement safety benefits by eliminating the need for trucks to merge
needed to be adjusted, the broken concrete already fractured and exit from live traffic lanes. This also allowed for faster
by the rubblization process was removed and stockpiled completion of the project and significant cost reductions.

12
During preparation for paving, mixture placement
and compaction, quality control and quality assurance
procedures were in place to monitor the quality
of the asphalt materials being placed. Substantial
amounts of quality control testing were performed
by the prime contractor and their subcontractors
and quality assurance testing and inspection were
performed by TDOT’s subcontractor HDR.

From a compacted density standpoint, over 2,500


cores were taken throughout the project to determine
density for both the travel lanes and the longitudinal
joints. An incentive/disincentive specification was
used on the project to encourage the contractor
to compact the asphalt mat to meet or exceed
specified density in a consistent manner for both
the mainline paving and along the longitudinal
joints. One interesting aspect of the specification
was that the measured density of both the joint
and mainline density had to meet minimum density
requirements to obtain an incentive for a given lot.

To expedite the completion of the project, the contractor


submitted a cold weather paving and compaction
plan and was allowed (in some cases) to pave outside
of TDOT’s seasonal and temperature restrictions.
Greenhouse gas emissions were reduced This applied to base and binder layers only. TDOT
due to less truck travel and reduced need closely monitored paving during cold weather and the
for the production of new aggregates. contractor made good decisions on when (and when not)
to pave in less-than-ideal situations without adversely
Paving operations impacting the quality of the in-place asphalt pavement.
Kiewit worked with their subcontractor Vulcan Materials
to produce all 290,000 tons needed on the project. The Public relations
bulk of the mixture came from two plants, with third Anyone that has been around the rubblization of
plant being pressed into service when the accelerated concrete pavements or aggregate crushing knows that
project schedule called for more production. Overall, these processes can be loud…very loud. And, because
Vulcan’s two crews laid a total of 170,000 tons and the location of the project is in an urban setting, TDOT
KSI’s crew placed the remaining 120,000 tons. knew that educating the public was essential. Almost
all of I-440 is in a highly populated area consisting
Actual constructed thicknesses of mainline mostly of single-family homes, this was especially
paving varied from a total thickness of 9.75” to true of the western portion of the project. With many
10.75” on rubblized concrete base and 12.25” homes only separated from the roadway by relatively
to 13.25” on a crushed concrete base (with low walls, TDOT decided paving operations could be
various depths at the top of the aggregate being conducted both day and night, but rubblization and
cement treated) in new lane construction. crushing operations were only allowed during the day.

13
TDOT also implemented a public relations effort to ensure Conclusion
that the public knew what to expect related to construction The I-440 reconstruction project demonstrated
noise. They wanted to let them know what was causing using the benefits of the design-build approach to
the noise, how loud the noise would be and when they contracting as well as the advantage of using well-proven
could expect to hear it. The effort included information on fractured slab technology to convert a worn concrete
social media, radio, TV and even door-to-door activities. pavement to a high-quality asphalt pavement. The
completion of the I-440 project was a big win for both
This effort was effective and helpful in keeping the the Tennessee DOT as they were able to reconstruct
complaints to a minimum. By emphasizing the green I-440 in a cost-effective and efficient manner and
aspects of the project that reused the existing pavement the traveling public as they can now enjoy a safer,
materials either in-place through rubblization or by smoother and long-lasting asphalt pavement.
reprocessing concrete rubble as an aggregate base within
the confines of the project, TDOT wanted the public to know
that they were being environmentally responsible. TDOT
also was able to communicate the expected improvements Horan is an Asphalt Institute Senior
in safety and traffic congestion with the new project. The Regional Engineer based in Virginia.

message from TDOT was: “It is going to be noisy and


will take some time, but it definitely will be worth it!”

RUBBLIZING IN NASHVILLE
Antigo Construction performed 60 lane miles of
concrete pavement rubblization in 2019 and 2020
on the I-440 Reconstruction Project in Nashville.
Antigo worked with the D-B contractor, Kiewit,
and Tennessee DOT to incorporate rubblization
into the project to save cost, time and natural
resources while producing an excellent base for
a smooth and durable asphalt pavement.

Antigo is proud of its contribution to the success


of TDOT’s largest ever construction contract.

Antigo Construction has 50 Badger Breakers® ready


to rubblize, crack & seat, break & seat and break for
removal concrete pavements worldwide.

Contact us +1 715-627-2222

WORLDWIDE
www.antigoconstruction.com ac@antigoconstruction.com

14
BUILT TO
CONNECT

It’s more than a piece of equipment.


Astec helps build the infrastructure that connects the world. Our
Heatec thermal products are used to make asphalt, store asphalt,
modify asphalt, transport asphalt, and so much more. But beyond
equipment, the connections we build with people are what make us a
true partner in the industry. We’re not really in the business of building
equipment. We’re in the business of building connections.

astecindustries.com/asphalt
New paper released on pyrophoric
material formation in tanks
By Paul Sohi

PYROPHORIC
MATERIAL
FORMATION
IN HEATED
ASPHALT
STORAGE
TANKS

17
he Asphalt Institute
(AI) developed a white
paper titled “Pyrophoric
Material Formation
HEAT
in Heated Asphalt
Storage Tanks” Chemical Chain
Reaction
O2
The purpose of this document
is to provide information on OXYGEN FUEL
pyrophoric material formation
in heated asphalt storage Fire Tetrahedron
tanks. The document provides
a summary of published information on this topic as a
starting point for the owner/operator and other users headspace blanketing, etc. There is a stressed
to evaluate potential pyrophoric material formation importance of routine inspections and cleaning.
and prevention. It is not an attempt by the Asphalt
Institute to establish guidelines or recommendations This document was developed by a task force
related to heated asphalt storage tank management. consisting of members of the AI Health, Safety
and Environment committee and the AI Technical
The paper includes references so readers can Advisory committee. The idea behind the document
perform a more detailed evaluation if desired. It arose as a result of a presentation by staff from the
presents two heated asphalt storage tank accidents National Fire Protection Association. During that
that identified pyrophoric material ignition as the presentation, it became apparent that the asphalt
cause. Other topics include background information industry lacked information on pyrophoric material
on pyrophoric material, potential sources and formation in heated asphalt storage tanks.
formation causes in heated asphalt storage tanks.
Kevin Hardin of Vecenergy headed the task force,
The document highlights how fires in heated other members include Bob Hockman from Tamko
asphalt storage tanks can be prevented by Building Products, Linda Osborn of Heritage Research,
implementing methods such as an air sweep, Eileen Dutton and Tony Silva from Malarkey Roofing,

pyrophoric material:
any material igniting spontaneously or
burning spontaneously in the air when rubbed,
scratched or struck

18
Andrew Cascione from Flint Hills Resources, Tom Lonyo
and Brian Wilt from Marathon Petroleum, Jay Keating
Tips for preventing formation
from IKO Industries, Tom Hecker of Vecenergy, Michael
Foster of BP and Mike Southern from Eurobitume.
in asphalt tanks
“I wish this information had been available
• Air sweep
to me 20 years ago,” said Hardin. • Headspace blanketing
The document is available as a free download
• Storing asphalt at lower temps
at asphaltinstitute.org. Paper copies are available • Keep asphalt at proper tank levels
for purchase at the AI online store.
• Low-placed fill pipes
• Routine inspections
Sohi is the Asphalt Institute Director of • Proper cleaning
Health, Safety and Environment.
• Reduce reactive surface area
• Minimize air introduction

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19


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20
Effectively curtail oxidation
with warm mix asphalt By Amma Wakefield, P.Eng.

HMA WMA

A
couple of years ago, I was asphalt molecules, often termed “volatiles” and changes
the structure and composition of the asphalt molecules
preparing a talk on “What – it becomes stiffer and more brittle. These changes
happened to warm mix make asphalt pavements more susceptible to cracking.
asphalt?” and I remember
Even though apples turning brown is inevitable,
getting stuck on the we often use a few old-fashioned tricks to help slow
presentation outline in a daydream… down this process, and the most important thing is to
reduce the apple’s exposure to air. The same principle
Once upon a time, technical asphalt conferences can be applied, keeping in mind that an asphalt
showcased countless WMA research findings from binder’s rate of oxidation depends on temperature
the lab and field. I happily added my master’s thesis and how much oxygen is available to react with
to the knowledge pool when I researched material the individual asphalt modules. As a rough rule of
properties of HMA and chemically-modified WMA. thumb for very thin films of asphalt, the rate at which
oxidation occurs doubles for every 10oC increase in
It is no surprise that there was so much excitement temperature. This increase is compounded, meaning
about WMA then, because there are many that the rate quadruples for a 20oC increase in
demonstrated benefits of using WMA including the temperature. This behavior is illustrated in Figure 1.
potential to lower energy demand during production
and construction, reduce emissions at the plant
160
and the paver, increase allowable haul distances,
reduce thermal segregation, use as a substitute for 140 Rate doubles every 10°C
anti-striping additives, lower production and paving 120 Rate increases in simple
temperatures, improve compaction and the list goes on. proportion to temperature
100
Property

Two of these benefits of WMA that have long fascinated 80


me are the lower production and paving temperatures of 60
asphalt mix and improved compaction because of their 40
potential impact on the performance and service life of our
asphalt pavements. This goes back to our understanding 20
of how asphalt binders age with time in the environment. 0
100 110 120 130 140 150 160
Asphalt binders are composed of organic molecules, Temperature, °C
so they react with oxygen from the environment. This
reaction is called oxidation and it is as natural as the
Figure 1: Effect of temperature on property change
browning of an apple or banana when exposed to the air. (Source: AI MS-26)
Oxidation causes the asphalt binder to lose the smaller

21
This tells us two important things: (1) oxidation temperature, hours of exposure to sunlight and moisture.
rate is highly dependent on a combination Laboratory tools used to simulate the short-term aging
of temperature and time; and (2) oxidation is and long-term aging are respectively the rolling thin
reduced if the access to oxygen is limited. film oven (RTFO) and pressure aging vessel (PAV).

To discuss what we can use to reduce asphalt binder How well the asphalt binder performs depends on
aging, we have to remember that there are two both its short-term and long-term aging conditions.
types of asphalt binder aging, the first is short-term What can we control from the short-term aging side
aging, which occurs when the binder is heated to the during asphalt mix production and placement?
temperatures used in the laboratory for asphalt mix
designs and in the mixing plant during asphalt mix Short-term: Reducing production
production, up to 350oF (177oC). During mix production, and placement temperatures
the asphalt binder has the most exposure to oxygen Laboratory testing of asphalt binder blends of PG
and high temperatures, with asphalt film thicknesses 64-22 has shown that a reduction in short-term aging
of just a few microns coating heated aggregates. The temperature of 50oF (10oC), reduces asphalt binder mass
rate of aging is significantly faster at this stage. loss (loss of volatiles) by approximately 40 percent and
asphalt binder aging rate by approximately 30 percent
The second type of aging occurs in-service. This is a (Figure 2). If production and paving temperatures
slower rate of aging and varies depending on the asphalt can be reduced, what would be the impact on the
pavement density, environmental conditions such as long-term performance of that asphalt pavement?

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 Enhance mix failure, fatigue, cracking & rutting resistance  Improve compound tack, adhesion & cold ductility
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22
Figure 2:
Example of
asphalt binder
hardening rate
with time and
temperature for
PG 64-22
(Source: Ingevity)

23
To answer that question, we need to consider testing HMA vs WMA: Rutting performance
that estimates the performance of appropriately The Hamburg Wheel Tracking device was used to
conditioned asphalt mix samples. Ingevity recently evaluate the rutting performance of the HMA and
shared performance testing data from TSIT Engineering WMA mixes and showed no significant change in
that compares the rutting (permanent deformation) and the WMA rutting performance as compared to the
cracking performance of dense graded asphalt mixes HMA. Interestingly, the 0.2 percent increase in AC
that addresses this. The various asphalt mixes, listed in for the HMA showed more potential for rutting than
Table 1, were produced at the conventional production the control HMA and WMA mixes (Figure 3).
temperatures (i.e., HMA) and at lower temperatures
(i.e., WMA) using two chemical warm mix additives. HMA vs WMA: Cracking Performance
From a cracking standpoint, TSIT used the Indirect
Table 1: Asphalt mix parameter used in Tensile Cracking Test (IDEAL CT) to determine the cracking
TSIT testing of HMA and WMA tolerance index of the asphalt mixes at intermediate
temperatures. IDEAL-CT results have been correlated
Description Mix (oF) Compaction (oF) AC % WMA Rate % with field performance in terms of fatigue, reflective and
HMA Ctrl 300 275 5.2 None thermal cracking with field data collected from the Federal
Highway Administration’s accelerated load facility (ALF).
HMA Ctrl
+0.2% 300 275 5.4 None The test results from TSIT Engineering showed better
more AC
cracking performance when the mixes were produced as
WMA 1 265 240 5.2 Additive 1, 0.5 WMA, and when 0.2 percent more AC was added to the HMA
(Figure 4). Statistically though, the HMA with 0.2 percent
WMA 2 265 240 5.2 Additive 2, 0.5
more AC was equivalent in cracking performance compared

Figure 3: Hamburg Wheel Tracking


Performance of HMA and WMA

24
CT Index - Normalized to 7.0% Air Voids

300

250

200
CT Index

150

227 238
100 220
192

50

0
HMA HMA + 0.2% AC WMA 1 WMA 2

Figure 4: Cracking Tolerance (CT) Index of HMA


(Orange) and WMA (Blue) mixes. (Source: Ingevity)

to the control HMA, and on the average WMA mixes showed These performance test results show overall improved
better cracking performance by having a higher CT index. performance when the asphalt mix is produced
warm versus hot. Additionally, increasing the binder
HMA vs. WMA: Low-temperature evaluation content in HMA by 0.2 percent compared to the
To evaluate the low-temperature performance of the HMA control did not provide a statistically significant
HMA and the chemically modified WMA mixes, the difference in the cracking performance, however,
asphalt binders were extracted and recovered from the the WMA provided better cracking performance
mixtures after short-term aging, to determine their PG and equal or better rutting resistance than the
high and low failing temperatures (i.e., the PG true grade). HMA with 0.2 percent more asphalt binder.
The PG low temperatures result in Table 1 show better low-
temperature performance for the WMA mixes compared Long-Term: Limit access to oxygen
to both HMA mixes. The high-temperature impact is Now let’s consider what can be controlled in-
minimal and confirmed by the HWT rutting results. service to limit asphalt binder aging and improve
mix performance. Since the majority of the in-service
Table 2: Mixture Extraction and Recovery aging is in the hands of Mother Nature, we can’t
Binder Evaluation of HMA and WMA easily control things like environmental conditions,
hours of sunlight, moisture exposure, effects of
Description PG High Temp (oC) PG Low Temp (oC) ultraviolet radiation, etc. What can be controlled
HMA Ctrl 79.7 -23.3 is the access to oxygen, by reducing the amount
HMA Ctrl +0.2% 77.2 -23.8 of air in the in-place mat. This can be achieved
more AC during the final step in the construction of asphalt
WMA 1 76.7 -25.6 pavement – the compaction process – where the
freshly placed asphalt mat is compressed (or
WMA 2 76.9 -25.2
densified) to reduce the in-place air voids in the mat.

25
Chemically-modified WMA mixes have been shown to
provide better and more consistent compaction than
HMA. The WMA additives enhance the lubricating
properties of the asphalt binder and allow the mixes
Visit www.pavaeon.com to test to remain workable at even lower temperatures. WMA
drive our free online paving calculator. also remains workable for a longer period than HMA
because it doesn’t lose heat as quickly to the environment
since there isn’t as big a difference between the
TM WMA temperature and the ambient temperature.

A Technology Driven Product of


New Brunswick Department of Transportation
WWW.PAVAEON.COM and Infrastructure (NBDTI) recently compared
INFO@USPOLYCO.COM core compaction results for HMA and chemically
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Typical Pavements

Figure 5: Relationships between field


compaction and pavement service life

26
All States
Materials Group
®

Chemically-modified
WMA mixes have been
shown to provide
better and more
consistent compaction
than HMA.
SERVING THE
NORTHEAST FOR
modified WMA projects completed between 2017
and 2019 with PG 58-28 and PG 58-34 asphalt OVER 60 YEARS
binders. The core compaction results for the HMA
projects ranged from 92.5 to 93.0 percent and the
WMA project ranged from 93.5 to 94.5 percent.

There are many other studies that show the direct


relationship between compaction and pavement
performance and confirm that obtaining optimum Asphalt Supply Point
density through the compaction process is essential to Other ASMG Operation

long-term pavement performance. Two such studies


conducted by Washington and Colorado DOTs have are
highlighted in Figure 5, where both conclude a reduced with over 60 years in the asphalt
service life when compaction levels drop below 93 industry and facilities strategically
percent (7 percent in-place air voids). The presence of located throughout the northeast ,
air will prematurely oxidize and age the asphalt binder. we continue to grow and expand our
liquid asphalt capabilities. we offer
These compounding benefits of WMA to effectively
limit the rate of oxidation during asphalt mix production a full suite of pg asphalts , polymer
and placement and increasing in-place density to modified asphalt , and pre - blended
limit long-term access to oxygen, has government warm mix asphalt to meet the needs
agencies looking for ways to specify WMA for all of customers throughout the region .
contractors to use it. New Brunswick Department
of Transportation and Infrastructure adopted WMA
we have also continued to expand
for 100 percent of their asphalt paving projects in
2019 after almost 20 years of successful usage. our product offering to include
liquid asphalt additive options for
customers across the country .

Wakefield in Asphalt Institute Regional


Engineer based in Canada.
(800) 343-9620 | WWW.ASMG.COM

27
The advancement of asphalt pavements
over the last 50 years
Dr. Jon A. Epps, Ph.D., P.E. and Dave Johnson, P.E.

A
sphalt pavements are the surfacing choice Motivation for improving
for about 94 percent of the roughly 2.75 asphalt pavements
million miles of paved roads in the United A substantial amount of the innovation associated
States. Asphalt is used to construct sub- with asphalt pavements has been stimulated by global
base, base course and surface layers. and national events. Product availability, environmental
movements and political interests have all influenced
The largest consumption of asphalt binders the advancement of asphalt materials. The in-place
in paving applications is for hot mix asphalt (HMA) and price of asphalt mixtures is significantly driven by the
warm mix asphalt (WMA). WMA makes up 40 percent of cost of the asphalt binder, fuel for heating materials,
the production of asphalt paving mixtures. For simplicity, transportation costs and construction equipment fuel.
HMA is used to imply either HMA or WMA herein.
Availability of fuels and asphalt binders was also of
According to the National Asphalt Pavement great concern in the mid-1970s. Energy conservation
Association (NAPA), HMA production in 2017 was and its availability were national and international
about 375 million tons. State highway agencies and concerns. Environmental concerns were also being
other public agencies including cities and counties use addressed globally during this period for the first
about two-thirds of the total production of HMA. Private time. Inflation was significant. Price controls were
work (commercial and residential) accounts for the implemented on several products. As a result of
remaining one-third of the production. State highway these driving factors, the 1970s and early 1980s
agencies utilize about 45 percent of HMA production. witnessed a period of rapid technology development
and deployment in the asphalt paving industry.
Incremental increases in pavement life or a
reduction in the first cost for materials or pavement The first decade in the 2000s also witnessed significant
structural sections can result in substantial cost crude oil and asphalt binder price increases. During
savings. For example, HMA production in the United this decade global warming became an additional
States has historically ranged between about item of concern throughout the world. The rapid
350 million and 500 million tons on an annual inflation of goods and services has not followed the
basis. If pavement life can be increased by one rapid increase in crude oil price during this decade,
year, an annual saving of billions will result. as occurred during the mid-1970s and early 1980s.

28
Horizontal Tensile
HMA
Strain
Figure 1.
Failure Stress Vertical Compressive Base course
and Strains in Stress and Strain
Pavements

Subgrade soil

The Strategic Highway Asphalt pavement technology changes


Research Program The technology associated with the use of asphalt
Accompanying technology development was a binders in roadways has changed over the decades. While
general reduction in available funding for highway change in the asphalt paving industry is relatively slow,
construction and rehabilitation and maintenance. Thus, it has nevertheless been significant from an economic as
the condition of the nation’s highways deteriorated. well as environmental, health and safety points of view.
The primary performance problems documented in the
early 1980s were rutting, water sensitivity of asphalt Asphalt pavement thickness design
mixtures, transverse cracking and aging. These problems Pavement thickness design concepts were developed
were recognized by agency and industry leaders. based on soil mechanics principles in the 1930s. Two-
and three-layer elastic solutions became available to
This led to the formation of the Strategic Transportation predict deflections and stress and strains in pavement
Research Study (STRS) Committee in 1983. A variety of layers by the late 1950s. A linear elastic multilayered
activities followed culminating in the Strategic Highway pavement analysis computer program was developed
Research Program (SHRP) that defined the research in the mid-1960s, first by Chevron Asphalt and then by
program in 1986. A $50 million research and development Shell Oil shortly thereafter. Layered elastic programs
program was developed with key research directed have been utilized as a research tool since the
towards asphalt binders, asphalt mixtures, pavement 1960s and have been incorporated into mechanistic-
performance and performance-based specifications. empirical pavement design procedures (Figure 1).

Research results were available in the early 1990s and In the late 1970s and early 1980s linear viscoelastic
included the performance-graded (PG) asphalt binder and nonlinear viscoelastic methods were introduced.
specification, a new method for asphalt mixture laboratory Finite element approaches to pavement design were also
compaction, as well as new test methods for mixture developed during this period. The engineer’s ability to
design. The effort associated with the implementation predict rutting in pavements and cracking has improved
of SHRP was extensive and continues today. from these more advanced mechanistic methods.

29
Stresses, strains and deflections in pavements under Asphalt binder technology has moved from the
a variety of loading and environmental conditions “chew” test in the early 1900s to advanced rheological
can be calculated by layered elastic, viscoelastic techniques used by the polymer industry today. Key
and other solid mechanics approaches. Fracture properties of asphalt binders include the health and
mechanics has been used to predict various forms of safety aspects of the material as well as consistency over
cracking based on calculated stresses and strains. a range of temperatures, loading rates and durabilities.
Various types of rheological, mechanical or physical
Layered elastic and finite element models to calculate tests are primarily used to characterize the viscoelastic
stress, strain, deflection and permanent deformation properties of asphalt binders. Asphalt binders are
require complex material characterization. For example, liquids at elevated construction temperatures and
unstabilized subgrade, subbase and base material brittle solids at temperatures common in the winter.
properties are stress-dependent and moisture content-
dependent. Loading time and temperature are factors The needle penetration test was utilized to describe
for asphalt-bound material properties. Asphalt-bound the consistency or stiffness of asphalt binders until
materials also change with aging time and with the about 1962 when many agencies progressed to
presence of moisture. Proper characterization of viscosity-based systems. The PG system was developed
pavement materials is time-consuming and has been in the Strategic Highway Research Program (SHRP)
a major issue associated with the implementation during the late 1980s and early 1990s and is used
of more advanced methods of pavement design. in the United States and other countries. Many
agencies are now including the Multiple-Stress Creep
The theory available to calculate stress, strain and Recovery system to classify asphalt binders.
deformation is far more accurate than our ability to
characterize materials. In addition, the correlation The SHRP-developed PG specification system for asphalt
of these calculated parameters and their associated binders was a significant advancement in the technology,
materials inputs with field performance needs to be although quality relationships between asphalt binder
further developed to determine robust failure criteria. properties and pavement performance are elusive.
This has been a difficult and challenging task.
Asphalt binder manufacturing practices have
The perpetual pavement concept developed in the 2000s fundamentally not changed over the years. However,
is based on limiting the stresses and strains in pavement fewer asphalt binders are produced directly during the
layers below critical threshold values. The use of engineering refining process today. Today a significant number of
mechanics to predict these stresses and strains is a critical asphalt binders are blends of refined asphalt binders
part of the development of this concept. Commonly accepted and any number of materials or modifiers. These
failure criteria for pavement rutting, based on maximum combinations of materials are used to economically
vertical compressive strain on the subgrade, and for adjust low-temperature and high-temperature properties
pavement fatigue cracking, based on maximum horizontal of asphalt binders to meet the PG specification as well
tensile strains in the asphalt bound layers, are used to as to potentially improve the overall performance.
design perpetual pavements, in which, theoretically, an This blending is more likely performed in terminals
extremely large number of traffic loads can be carried by the rather than in large crude oil refineries.
pavement without rutting or fatigue cracking. In a perpetual
pavement, the impact of the environment, loss of friction One of the most widely used groups of additives is
and the aging of the pavement are addressed by removing polymers. Natural rubbers saw limited usage in the
and replacing a thin layer of asphalt surface mixture every 1950s and styrene-butadiene random copolymers
10 to 20 years as distresses become evident at the surface. were utilized regionally in the 1960s for chip seals and
for some asphalt mixtures. Styrene-butadiene-styrene
Asphalt binders (SBS) polymers introduced in the late 1970s and early
Asphalt binders are complex materials of which 1980s are in relatively widespread use in many areas
mechanical properties are difficult to define and of the world. Chemical additives that improve the water
the chemical properties are extremely complex. sensitivity of the asphalt mixture were developed as well.

30
Asphalt mixture design
Asphalt mixtures contain both asphalt binders and
graded aggregates with or without other additives and
modifiers. These mixtures are designed and constructed
to minimize distresses. Asphalt mixtures harden with
age and may be sensitive to the presence of moisture.

Asphalt mixture properties change dramatically with test


temperature and rate of loading. Thus, materials should
ideally be characterized over a temperature range and
loading rate that simulates the asphalt mixture in service.

Mixture design methods


Mixture design methods are used to establish optimum
combinations of asphalt binder and aggregate. The Hveem
and Marshall methods were primarily developed in the 1930s
and 1940s and were named after public agency pioneer
engineer/technologists from California and Mississippi,
respectively. These test methods continue in use today.

The Hveem and Marshall approaches to asphalt mixture


design allow the asphalt mixture to be designed to resist
permanent deformation or rutting while providing some
consideration for durability of the mixture. Volumetric
design parameters were also part of the design for both
methods. Mixture design parameters include asphalt binder
content, aggregate gradation and air void contents.

SHRP developed more fundamental mixture property


tests in the late 1980s and early 1990s to address
rutting, cracking, aging and water sensitivity. This
mix design system became known as Superpave.

A significant number of cracking tests have also been


developed over the years. These tests include the repeated
load beam tests (fatigue) developed in the late 1950s
and the “overlay tests” first developed in the 1970s for
several forms of indirect tension, direct tension, flexural
tests and several notched beam types of samples.

The asphalt mixture performance tester (AMPT) was


developed in the last decade and is now associated with the
American Association of State Highway and Transportation
Officials (AASHTO) mechanistic-empirical pavement design
method. This test provides parameters to predict rutting
and cracking as well as provide stiffness information for
pavement thickness design purposes. The equipment was
developed to be a compact and user-friendly test method
based on lessons learned from the SHRP program.

31
Asphalt binder technology has
Balanced mix design concepts, while not new, wisely
promote various means to design mixtures that

moved from the “chew” test in


perform better. They attempt to design mixtures that
will both resist rutting and cracking distresses.

Mixture types
Dense-graded mixtures are the most widely used asphalt the early 1900s to advanced
rheological techniques used by
mixture today. A gap-graded mixture, stone mastic
asphalt or stone matrix asphalt (SMA), was developed in

the polymer industry today.


Germany. Today it is used in several U.S. states. Improved
resistance to rutting and cracking as well improved
durability and friction can be achieved with SMA mixtures.

Open-graded or porous friction courses have gained


widespread acceptance in some states. These types of for asphalt mixtures which affords a variety of benefits.
mixtures reduce “splash and spray” from traffic, reduce Known benefits of WMA include reduced emissions,
tire-pavement noise, reduce the potential for hydroplaning improved worker conditions, reduced fuel usage for mix
and can be designed to provide excellent friction. production and benefits to the construction operations.
The construction operations benefit from improved
Several concepts have been developed to reduce, slow compaction, extending the construction season,
down or eliminate reflection cracking from an old asphalt increasing the paving day and longer haul distances.
or portland cement concrete (PCC) pavement after
treated with a new asphalt mixture overlay. A satisfactory Asphalt mixtures and pavement
“interlayer” to reduce, slow down or eliminate reflection thickness design
cracking in most climates has not been developed. The perpetual pavement concept mentioned previously
is an extension of the “full-depth” concept promoted by
Additives and modifiers for mixtures the Asphalt Institute in the 1960s. Properly designed
Much like how asphalt binders have benefited via perpetual pavements design their respective layer’s
modification, asphalt mixtures have also utilized several mixtures to address their specific and unique requirements.
additives to assist mixture performance. These include The bottom layer’s mixture will have high asphalt
hydrated lime, portland cement and liquid anti-strip binder content, smaller maximum size aggregate and
agents to improve the water sensitivity of the material. By low air void content to provide good fatigue resistance
the early 1990s, hydrated lime was widely used following and resistance to the presence of moisture.
slow growth in the 1980s. Portland cement has been used
as an antistrip agent in a few states since the 1980s. As the intermediate or middle layer requires
Another additive now found in some mixtures is fibers. relatively high stiffness values, it can be a lower-
They have been used in a few specialty patching mixtures, cost asphalt mixture with high percentages of RAP
for some types of open-graded mixtures and stone mastic or RAS, having a lower asphalt binder content.
asphalt mixtures and dense-graded mixture as well.
The surface course materials should be resistant to rutting
Warm mix additives were introduced to the United and the presence of water, have good friction properties
States paving industry in the early 2000s, having and be resistant to thermal or low temperature cracking.
been developed in Europe the previous decade. NAPA An optimum asphalt binder content and a binder that is not
and the Federal Highway Administration are largely too soft or hard is important for this mixture. A relatively
responsible for advancing the technology stateside. thin layer (1-inch plus or minus) of an open-graded or
porous friction course can be used to obtain high friction,
Warm mix technologies include wax-based products, reduce hydroplaning and reduce traffic tire-pavement
chemical systems and foaming techniques. Warm mix contact noise. Dense-graded or SMA mixtures are other
allows for reduced mixing and compaction temperatures appropriate options depending on circumstances.

32
Asphalt pavement recycling
For over 70 years the asphalt paving industry has
proudly recycled existing pavement materials for pavement
rehabilitation, reconstruction and maintenance. The most
common form of recycling is hot central plant recycling,
with nearly 80 million tons of RAP used on an annual basis.
Significant national research and implementation efforts
advanced by the state departments of transportation and
the Federal Highway Administration resulted in recycling
technology development and deployment in the mid-1970s
when all forms of recycling grew in popularity following the
oil embargo. As a result, substantial savings in pavement
construction, rehabilitation and maintenance have
resulted from recycling asphalt pavements. Refinement
and improvement to these technologies continue today.

Preventive maintenance and


management systems
Optimization of the type and timing of rehabilitation and
maintenance operations has saved significant amounts
of money associated with providing safe and efficient
transportation on the nation’s highways. This is best done
with maintenance management and pavement management
systems developed in the 1960s. These systems have become
increasingly more sophisticated and can provide forecasts
of funding needs through optimization techniques.

Today’s sophisticated management systems provide


predictions of future pavement conditions based on design,
construction, current conditions and maintenance data.
Moreover, they incorporate funding parameters in association
with other economic factors to allow engineers to better
optimize their roadway systems. This tool allows them to plan
both current and future activities to accomplish the optimization.

Accelerated pavement testing


Several full-scale test roads have been constructed over
the years in the United States to improve the future of
pavements. The 1950s saw regional test roads in Maryland
and Idaho and it culminated with the AASHO Road Test
constructed and operated in the late1950s and early 1960s
for both asphalt and portland cement bound pavements in
Illinois. Flexible and rigid pavements continue to be tested on
the MnRoad facility as they have been since the early 1990s
in Minnesota. WesTrack was constructed in Nevada in the
early 1990s for asphalt bound pavements, and the National
Center for Asphalt Technology (NCAT) Test Track was
constructed in Alabama in the 2000s, also for asphalt bound
pavements. The NCAT Test Track remains in service today.

33
Other forms of accelerated pavement testing have been Vibratory compactors were developed in the late
used throughout the world. Large-scale equipment has 1970s and became common for asphalt paving in
been developed to test small pavement sections placed the 1980s. These compactors or rollers allowed for
under field construction conditions. This equipment has more efficient compaction of asphalt paving mixtures.
been utilized in several countries including France, Spain, In addition, the roller widths became greater, which
China, Japan, South Africa and the United States. contributed to the improved efficiency of the compaction
operation. Intelligent compaction systems are now the
Construction equipment for next step in the evolution of compaction equipment.
asphalt pavements
Equipment manufacturers have also advanced the The materials transfer device was developed in 1989
asphalt paving industry with major innovations in the and affected the market in the 1990s. These devices
1970s. At the hot plant, the introduction of drum plants allow for storage of the asphalt mixture (about 25
for the production of hot mix began. Drum plants have tons) at the laydown site, remixing, which reduces
continued to be refined, now being offered in various aggregate segregation and promotes temperature
configurations including parallel flow, counter flow and uniformity. Nonstop movement of the paving machine,
double drum options. Today’s drum plants are also which improves the smoothness of the riding surface,
very capable of handling large quantities of RAP. is more easily accomplished with this tool as well.

The Clean Air Act of 1970 stimulated the use Wrap up


of baghouse and wet washer systems on HMA Flexible asphalt pavements have been serving the driving
plants to improve air quality. The baghouse is public for well over 100 years. Advancements over time
now the primary tool used to meet air quality have been relatively steady. During the past 50 years,
standards in the developed countries. much has changed while much has also stayed the same.

To take advantage of the high production of drum Asphalt binders have gone from being mostly a product
mix plants, mixture storage silos were developed and from their respective refineries without modification, to
attached to these plants. These storage silos allowed now being blends of materials from various refineries,
mixture to be produced at high production rates, commonly with different modifiers within them to
stored and loaded into trucks at a different rate. enhance performance and meet today’s more robust
specifications. These specifications have changed too.
The first cold milling machine was developed in 1974 Going from very empirical grading methods to more
and demonstrated to a Federal Highway Administration fundamental processes which also attempt to take
Expert Task Group meeting on recycling in Las Vegas into consideration local environmental conditions.
that year. This equipment allowed for the economic
removal of asphalt mixtures from the roadway The mix design process has taken a leap forward with
and quickly became a must-have tool for roadway the advent of Superpave supplanting older methods
rehabilitation. It is one of the most useful equipment which were developed generations before. Today
pieces for pavement rehabilitation and recycling. they are moving even further as balanced mix design
concepts are potentially better engineering mix design
The 1970s witnessed a significant development properties beyond traditional volumetric data.
in equipment for both cold in-place and hot in-
place recycling. Improved pulverization equipment, Recycling technologies grew in popularity in the 1970s
portable crushing and mixing equipment were and 1980s. While their usage decreased for some
developed during this period for cold in-place years, they are again growing in popularity once more.
recycling (CIR). Improved heating, mixing, laydown Moreover, additional products from outside the paving
and air quality control equipment was developed industry have been and are being incorporated into
for hot in-place recycling during the 1970s and mixtures. Crumb rubber from waste tires and asphalt
early 1980s. These complemented the improved shingle waste are two prime examples of materials
engineering of asphalt emulsions used with CIR. that can be used successfully in asphalt pavements.

34
:Ƞ(Ȧ,Ȭ&ȧ0ȝ6
Equipment manufacturers have and continue to
7ȧ3ș9ȝ0ȝ1Ȭ
develop better options for the production, construction
and maintenance of asphalt pavements. Continuous
0ș,Ȧ7ȝ1ș1ț(Ȅ
flow drum plants, vibratory rollers and cold milling
machines are three major examples on the equipment
side. Advanced automation continues to be developed
:ȝoȮ(*ȧ7<ȧ8
and implemented. Higher and more consistent quality
pavements are the end goal of these advancements. &ȧ9ȝ5ȝ'
The engineering of pavement structures has
also advanced from relatively simple empirical
design procedures to more advanced mechanistic
approaches. Advanced computer programs are now
commonplace, and designs are further optimized via
the incorporation of layer-specific design parameters.

The future for asphalt pavements continues to be bright.


Evidence of asphalt’s ability to provide tremendous
long-lasting service is seen in the 156 perpetual
pavement awards issued by the Asphalt Pavement
Alliance to date. But more can and should be done.

Much more can be said about where challenges are seen


for our industry’s future, but that is a discussion for another
day. To quote an ad campaign from 1968, “You’ve come
a long way baby!” While certainly true that asphalt has
come a long way, it is readily capable of meeting future
challenges with the gusto and success it has enjoyed
in propelling our country and the world forward.

Dr. Jon A. Epps completed his Ph.D. from the


University of California at Berkley in 1968. Generally
speaking, asphalt mixtures were designed, produced
and constructed with means and methods that
were then decades old. Asphalt binders were rarely
modified and largely single-sourced, unblended
products in 1968. Construction equipment was still
much like it had been at the end of World War II.

Dave Johnson was introduced to asphalt materials


in 1990 when dramatic changes were being
developed and implemented due to the Strategic
Highway Research Program. The modification
of binders was increasingly common. New
laboratory tools for both binders and mixtures
were being adopted across the nation.

Much of this article is an adaptation of Dr. Epps’ 2019 TRB


Thomas B. Deen Distinguished Leadership and 2020 AMAP Hall
of Fame presentations, coupled with Johnson’s perspective.

35
Asphalt binders added to
U.S. national audit program
Will it be a success?
By Greg Harder, P.E.

S
o, what is NTPEP? NTPEP stands for National Transportation
Product Evaluation Program. NTPEP is part of AASHTO
(American Association of State Highway and Transportation
Officials) and each state department of transportation
(DOT) contributes $20,000 annually to NTPEP.

36
How it works
NTPEP operates two different programs – a product has reviewed both documents for completeness, they
evaluation program and a manufacturing audit program. will then schedule an on-site audit to go through the
manufacturer’s facility and observe their manufacturing
The product evaluation program provides single- process to ensure the manufacturer is following their
source testing of common products used by DOTs QSM. A complete review of the manufacturer’s records
that are manufactured to AASHTO standards. as they relate to the QSM is part of the on-site audit. The
auditor will identify a random lot of the product and the
The manufacturing audit program provides quality traceability of the materials used in the manufacture
management system reviews and on-site inspection of that lot will be investigated by the auditor.
of plants that manufacture many of these same
products used in highway and bridge construction. The Once the audit is complete, NTPEP
primary goal of these two programs is to provide cost- will post the audit report for the
effective evaluations for the state DOTs by eliminating DOTs to review. The manufacturer
duplication of testing and auditing by states as well as
eliminating the duplication of effort by manufacturers
will receive an NTPEP certificate of
compliance if they meet all of the
State agencies
that provide products to the DOTs for evaluation. manufacturing audit standards. can then review
the test results
Again, NTPEP does not approve
Product evaluation program any product or manufacturer and
To participate in the product evaluation program, a
manufacturer must apply to NTPEP along with a sample
actual approval to supply products
is left up to each individual state
and decide
of their product that will be sent to an independent
third-party lab. Depending on the product, there is a
DOT. The manufacturing audits are
required to take place annually.
whether or not
renewal period of every 3-5 years. Once the application they will allow
Evaluating binders
that product
has been reviewed and the product has been tested,
the test results are posted on an online repository of The NTPEP Committee on
data and audit reports for the NTPEP programs. Asphalt Binders recently
completed the development
for use in
State agencies can then review the test results and decide
whether or not they will allow that product for use in their
of the work plan that covers
the requirements and auditing
their state.
state. NTPEP coordinates and posts test results for the criteria for the NTPEP evaluation
DOTs to review while not endorsing or approving products. of asphalt binder suppliers.

Warm mix asphalt (WMA) technologies/additives and The purpose of the program is to provide audit information
anti-strip additives (ASA) are a few of the products in from supplier facilities that comply with the quality control
NTPEP’s product evaluation program. The cost for WMA and product testing requirements of the program. AASHTO
manufacturers to participate in the product evaluation member departments can use this information in their
program begins at $9,275 per WMA product and quality assurance program for supplier qualification.
according to the NTPEP website, only five state DOTs
currently require WMA providers to participate in the By participating in this program, the supplier
NTPEP program. The ASA/WMA committee has begun the agrees to produce product(s) that meet or exceed
effort to add asphalt rejuvenators to their list of products. the requirements in applicable AASHTO/ASTM
designation standard(s) and follow the minimum
Manufacturing audit program quality control provisions of their quality program.
To participate in the manufacturing audit program, a
manufacturer must develop and submit a quality system Initial estimates of cost provided by NTPEP for the
manual (QSM) along with an application for what is binder supplier program are a one-time fee of $500 for
considered to be a desktop audit. The QSM is a written the initial application/desktop audit and then annually
document that describes the overall quality control between $7,000-$8,000 per audit per facility. In the
operating procedures of the manufacturer. Once NTPEP northeast U.S. alone there are 76 binder facilities.

37
State DOT Utilization of NTPEP Audit Program
Corrugated Elastomeric Guard HDPE Polypropylene Rebar & Welded Wire
Geotextiles PVC Pipe
Metal Pipe Bridge Bearings Rail Pipe Pipe Reinforcement
Required 8 7 9 28 28 17 12 19
In Lieu of 1 1 2 7 3 3 6 5
Something Else
Not Used 42 43 40 16 19 31 33 27
Source: ntpep.transportation.org

DOTs often accept The question


It all sounds good, right? Well, not so fast.

these products Unlike asphalt binders, many of the construction products currently

based solely on
in the NTPEP manufacturing audit program are not routinely
sampled and tested by the DOTs. The DOTs often accept these

the manufacturer’s
products based solely on the manufacturer’s certification. With this
in mind, one might think that the states would embrace the on-site
audits and either require or accept participation by the manufacturer

certification. in the NTPEP audit program in lieu of some other requirements.

But according to the state DOT usage of NTPEP, most states


do not utilize the audit program. Along with the annual on-site

New
MODULE DESCRIPTIONS

On Demand
Module 1: Asphalt Inspector Responsibilities
Module 2: Materials
Module 3: Asphalt Mixes and Mix Design

Paving Inspector Module 4: Mix Production


Module 5: Transportation, Preparation

Certification Program for Paving and Tack Coats


Module 6: Placement
Module 7: Compaction
Module 8: Quality Assurance
The Asphalt Institute’s Paving Inspector
course covers information essential for Entire course (all 8 modules) $495
inspection and project management personnel Individual modules $85
each

to ensure asphalt pavements reach their Please visit asphaltinstitute.org


intended service life. This course allows to learn more and register.

users to progress at their own pace.

38
Benefits and Costs of the NTPEP Asphalt Binder Audit Program
Intended Benefits Associated Costs
For Agency
No QC Plans Reviews
None
Audits by Others
For Industry
$7-$8K Per Facility Per Year
No Multiple QC Plan Submittals Development & Maintenance of QSM
Privacy of Proprietary Information

audit cost, participation in the audit program is labor While there are a number of benefits to this program,
intensive with the development and maintenance of the hurdles – universal acceptance by the states,
the QSM. So, lack of widespread use by the DOTs could cost to industry and the protection of proprietary
make participation by binder suppliers less attractive. information – may be difficult to overcome.

Binder suppliers may also have concerns about the


privacy of proprietary process and manufacturing Harder is an Asphalt Institute Senior
Regional Engineer based in New York.
information which may be scrutinized during these audits.
Non-disclosure agreements will likely need to be signed by
NTPEP auditors prior to admittance into the binder facility.

Long-Life asphalt emulsion


technology available for licensing
Developed under Government contract
15-year lab-retain still stable

There are four generally-accepted failure


mechanisms of emulsions. We discovered a
fifth, and were thereby able to formulate
exceptionally stable asphalt emulsions.

Interested parties may contact Steve Smith


steve@consultingscientist.us to discuss
technology licensing.

39
We talk with leading
educators and researchers
to learn more about the
people and topics of
asphalt technology.

Dr. Cassie Castorena is an Associate Professor in the Department of Civil, Construction,


and Environmental Engineering at North Carolina State University.

What drew tablish a national calibrated and validated ing protocols and pavement aging models.
you to PG specification for asphalt emulsions. In NCHRP Project 09-54, we field-calibrated
transportation a loose mixture laboratory aging proce-
engineering? What research is needed when dure that prescribes the duration of oven
it comes to engineering asphalt conditioning at 95ºC required to represent
My dad is a surveying engineering mixtures with high recycled the long-term aged state of the asphalt
professor and encouraged me to fol- binder replacement (RBR) mixture in a pavement as a function of
low a similar career path. I was very percentages for peak asphalt climate and depth. The field-calibration of
fortunate to obtain a research assistant pavement performance? this procedure demonstrates that it requires
position in Professor Hussain Bahia’s two to four days of oven conditioning at
asphalt laboratory while I was a civil A significant area of uncertainty in the 95ºC to simulate eight years of field aging
engineering undergraduate student at engineering of asphalt mixtures with near the pavement surface in much of the
the University of Wisconsin-Madison. recycled materials is the recycled binder northern U.S. but eight to 10 days of oven
I enjoyed working with both asphalt availability, that is, the percentage of total conditioning to simulate the same extent
and Professor Bahia and therefore, recycled binder that is available to blend of field aging in much of the southern U.S.
pursued a Ph.D. under his guidance. with the virgin asphalt. It is generally
accepted that complete availability is not In what area should
What is an advancement achieved in practice, which we and several today’s students focus
you are seeing in chip other groups have recently confirmed us- their asphalt research?
seal quality measures? ing advanced microscopy investigations of
asphalt mixtures. Despite this, the majority There are many important and exciting
Research is underway to develop a of current mixture design procedures as- asphalt research topics for students to
performance-related specification for as- sume complete recycled binder availabil- explore. Asphalt binders and mixtures are
phalt emulsions used in chip seals. Current ity. Research is needed to develop a practi- inherently very complicated materials.
emulsion specifications rely on traditional cal method to quantify binder availability Increased variability in crude sources,
residual binder viscosity, penetration and within mixture design procedures. The the increased use of recycled materials
ductility measurements that do not relate erroneous assumption of complete blend- in asphalt mixtures and the use of a wide
directly to chip seal distress mechanisms. ing may lead to an underestimation of the range of additives have added to this com-
The future emulsion specifications will ad- required virgin asphalt binder during volu- plexity in recent years. Therefore, research
dress bleeding and raveling with the incor- metric mixture design and consequently is needed to support the development of
poration of traffic and climate conditions, may yield mixtures with poor durability. more robust asphalt binder and mixture
similar to the current Superpave perfor- design specifications that accurately re-
mance-graded (PG) specifications (i.e., How important are thermal flect performance. Specifications that ac-
AASHTO M 320 and M 332). The Emulsion conditions when evaluating curately reflect performance can support
Task Force developed a draft emulsified as- the effects of aging on material and recycling innovation without
phalt PG specification based on two initial asphalt pavements? inadvertently compromising the long-term
frameworks proposed by the Texas A&M durability of asphalt mixtures. To explore
Transportation Institute and North Caro- Asphalt binder oxidative aging rates vary these topics, it is important that students
lina State University. NCHRP Project 09-63, exponentially with temperature and thus, develop a fundamental understanding
led by the Asphalt Institute, is currently considering thermal conditions is critically of asphalt binder and mixture composi-
building on this draft specification to es- important when establishing laboratory ag- tion as well as mechanical behavior.

41
LAB CORNER

Sci-fi and
french fries

By Mike Anderson,
Anderso , P.E.

P
robably not a surprise given that I’m an french fries? Why would you consider leaving them? For me,
engineer, but I have always loved science it’s because leftover, reheated fries never taste like fresh
fiction. When I was younger, I remember french fries. I’ll pause briefly for alliteration appreciation.
reading a book by Robert Heinlein called [pause]. I can easily make them hot again, but what I
“Time Enough for Love.” Despite it sounding really want is for them to be hot, crispy and salty – the
more like a non-fiction relationship book way they were. Barbra Streisand fries, if you will.
instead of a science fiction book I dove in anyway. By contrast,
“Men Are from Mars, Women Are from Venus” sounds like it We have the same issue with using reclaimed asphalt
could be a sci-fi book instead of a non-fiction relationship book. materials. We can add lower viscosity asphalt binders and
In the words of Captain Jack Sparrow, “Funny ole world, innit?” additives or modifiers to get a softer blended asphalt binder
in the mixture but are we restoring the viscous/elastic
Anyway... “Time Enough for Love” was the tale of Lazarus relationship that was present in the original asphalt binder
Long, a person who was blessed with extraordinary before aging? For that, I turn to Black Space diagrams,
longevity. His own natural genetics were then enhanced which are a way for us to look at modulus and viscoelastic
periodically by undergoing rejuvenation at a clinic where behavior on the same graph, and the figures below.
the doctors literally replaced almost every part of his
body until he looked and felt like a person who was much Shown in Figure 1 are two data points (represented by circles)
younger. I was fascinated by the idea of rejuvenation when representing equal testing conditions (temperature, applied
I was younger. I’m even more fascinated now...for obvious strain and loading frequency) of an unmodified asphalt binder.
reasons. Being able to take my body back to a state that As can be seen, the process of aging results in a movement
it once was before the ravages of time has its appeal. from A to B up and to the right, increasing stiffness and
decreasing phase angle. It may be an oversimplification
In the asphalt world, the concept of rejuvenation is also but think of a decrease in phase angle with an increase in
appealing for older reclaimed asphalt products, providing an stiffness as increasing brittleness.* In Figure 2 we see two
opportunity to recycle old asphalt materials with new, virgin possible paths that can happen when we try to bring an
asphalt mixtures. But what is real rejuvenation? For that, I turn older asphalt back to a newer state. Point C represents a
to another love from my youth – french fries – and an analogy softening. We have returned the asphalt binder to the same
to asphalt rejuvenation which I call “The French Fry Analogy.” modulus (or stiffness or viscosity) as the original asphalt
binder, but the phase angle remains lower – meaning its
Have you ever wanted to bring home leftovers from viscoelastic properties are not the same as the original. It
dinner and had to decide whether to include the remaining will behave more like a brittle material as it further ages

42
Figure 1:
Aging of
Asphalt
Represented
in Black
Space

Figure 2:
Softening and
Rejuvenating
Represented
in Black Space

than the original asphalt binder. In other words, this is So, whenever you think about how you design your
the result when we heat our fries in the microwave – hot, asphalt mixtures using recycled materials think
but not crispy. If we really want rejuvenation, we need about how you like your leftover french fries. Hot is
the path to follow from B back to A, restoring the original better than cold, but hot and crispy are best.
modulus, but also restoring the phase angle. This is
what we want from our leftover fries - hot and crispy. For information on Asphalt Institute's laboratory training,
research, and testing services please contact Mike Anderson
In our testing, it is easy to see the rejuvenation path in (manderson@asphaltinstitute.org) or Gary Irvine (girvine@
Black Space diagrams, but other parameters can give us asphaltinstitute.org). A new kind of testing. A new kind of fries.
similar indications as long as they capture that balance
between modulus and phase angle as an asphalt binder
ages. The Glover-Rowe Parameter is one; Delta Tc is another. Mike Anderson is the Director of Research and Laboratory Services at the Asphalt Institute.
If you haven’t heard of these yet you probably will soon.

43
CALENDAR OF EVENTS AD INDEX
The dates below are subject to change. Please check the All States Materials Group ............................................ 27
websites for possible postponements and cancellations. Antigo Construction ....................................................... 14
Applied Test Systems ......................................................39

2021
Astec ..................................................................................16
Cannon Instrument Co. ................................................. 31
Consulting Scientist ........................................................39
July 9 – 12 • Prince George’s County, Maryland ECF, Inc. ............................................................................20
Ergon Asphalt & Emulsions ............................................. 6
2021 NACo Annual Conference Etnyre ................................................................................35
naco.org/events/2021-naco-annual-conference Ingevity .......................................................................... IBC
International Roofing Expo ............................................40
International Tank Service, Inc...................................... 19
Kokosing Materials Inc. ..................................................23
July 31 – August 3 • Orlando, Florida
PRI Technologies ..............................................................20
2021 SASHTO Annual Meeting Russell Standard ................................................................ 2
sashto2021.com Shanley Pump & Equipment, Inc...................................33
Soprema............................................................................15
Sripath Technologies.......................................................22
Suit-Kote Corporation .....................................................10
August 10 – 12 • Las Vegas, Nevada U.S. Polyco .......................................................................26
International Roofing Expo Wirtgen ............................................................................IFC
theroofingexpo.com

August 30 – September 1 • Chicago, Illinois


2021 MAASTO Annual Meeting
maasto.net/2021maastoannualmeeting
Quality Management System

A new way to manage your laboratory


August 30 – September 2 • Nashville, Tennessee accreditation with AASHTO
AAPT 2021 Annual Meeting and Technical Sessions
asphalttechnology.org
Ditch the
paper
September 21 – 23 • Las Vegas, Nevada and view
Western Roofing Expo your QMS
wsrca.com in a simple,
web-based
portal.
September 21 – 24 • San Antonio, Texas
TXAPA 46th Annual Meeting
texasasphalt.org www.r18labqms.com
toll free 1-855-328-7623

44
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