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j o u r n a l o f t r a f fi c a n d t r a n s p o r t a t i o n e n g i n e e r i n g ( e n g l i s h e d i t i o n ) 2 0 1 9 ; 6 ( 4 ) : 3 5 9 e3 6 5

Available online at www.sciencedirect.com

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Original Research Paper

Emulsion cold mix asphalt in the UK: A decade of site


and laboratory experience

Dennis Day a,*, Ian Michael Lancaster a, Dougie McKay b


a
Nynas UK AB, Ellesmere Port CH651AJ, UK
b
Tayside Contracts, Dundee DD38SS, UK

highlights

 Cold mix asphalt successfully laid on the UK trunk road network.


 Laboratory testing used to validate the design.
 Continued specification development in place for widespread cold mix adoption.

article info abstract

Article history: Cold mix asphalt manufactured using bitumen emulsion, by its very nature, has struggled
Received 17 November 2018 to gain market penetration in the UK due to lack of design guidance and specifications and
Received in revised form the need to comply with prevailing hot mix asphalt specification requirements. Despite
3 March 2019 this, a number of contractors have successfully utilized emulsion cold mix asphalt mate-
Accepted 23 March 2019 rials containing recycled asphalt planings on various categories of road. Whilst the ma-
Available online 1 June 2019 jority of schemes in the UK have been on lower category traffic roads, in this paper we
discuss the use of one material which has been used on a strategic highway (trunk road) in
Keywords: 2008 which saved 43 t of CO2 during construction and is still performing well in situ to this
Cold mix day. Site construction details along with an analysis of traffic loading are presented. Lab-
Bitumen emulsion oratory simulations of in-situ curing of material supplied to site demonstrated an indirect
Specifications tensile stiffness modulus at 10  C of 5 GPa was achieved within 6 months. Binder recovered
Carbon savings from site cores was found to be in line with comparable hot mix materials, whilst wheel
tracking of site cores demonstrated excellent deformation resistance which has been borne
out by site performance over the last decade. The continued development of standards
enabling engineers to design and specify cold mix asphalt in the UK is also reviewed.
© 2019 Periodical Offices of Chang'an University. Publishing services by Elsevier B.V. on
behalf of Owner. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).

* Corresponding author. Tel.: þ44 151 327 3171.


E-mail addresses: dennis.day@nynas.com (D. Day), mike.lancaster@nynas.com (I.M. Lancaster), dougie.mckay@tayside-contracts.co.
uk (D. McKay).
Peer review under responsibility of Periodical Offices of Chang'an University.
https://doi.org/10.1016/j.jtte.2019.05.002
2095-7564/© 2019 Periodical Offices of Chang'an University. Publishing services by Elsevier B.V. on behalf of Owner. This is an open
access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
360 J. Traffic Transp. Eng. (Engl. Ed.) 2019; 6 (4): 359e365

CMA adopted more widely. Hveem and Marshall design


1. Introduction methods for both in-situ and plant mixed materials have been
published by the Asphalt Institute in MS-14 (Asphalt Institute,
The majority of asphalt produced worldwide is manufactured 1989).
at elevated temperatures, typically mixed in excess of 140  C, However, widespread adoption of CMA in the UK has been
and is commonly known as hot mix asphalt (HMA). Whilst the slow to develop despite numerous efforts. The Highway Au-
production and laying procedures for HMA are well-estab- thorities and Utilities Committee (HAUC) published a docu-
lished, it is clear that HMA is a highly energy intensive pro- ment “New Roads and Street Works Act” (1991) on the
cess. Alternative technologies have been developed over specification for the reinstatement of openings in highways
recent decades with the aim of reducing the mixing temper- which included an appendix A10 which called for the use of
atures for asphalt as shown schematically in Fig. 1. storable cold mixes with in-situ performance equivalent to
Warm mix asphalt (WMA) technologies include viscosity hot mix asphalt after installation. The national joint utilities
reducing additives and chemical additives which lead to 20  C group were responsible for the certification of what were
e 40  C reductions in temperature. Asphalt produced below called permanent cold lay surfacing materials (PCSMs). This
100  C, but still at elevated temperatures, is often referred to as certification responsibility was later overseen by the British
semi-warm or half-warm mix asphalt and includes foaming Board of Agre ment Specialist Group 8. The Transport
technologies. Research Laboratory (TRL) published a report on the use of
However, to minimize the energy required during asphalt cold bituminous materials by Leech (1994). The first
production cold mix asphalt (CMA) may be manufactured at accreditation of PCSMs was achieved in 1996 and
ambient temperatures using bitumen emulsion instead of hot performance studies on one of these materials was reported
bitumen. Le Bouteiller (2010) reported that emulsion based by Phillips (1998) along with field studies of Phillips (1997).
cold mixed asphalt consumed only 13% of the energy The publication of a patent on bituminous coated materials
required to produce equivalent hot mixed asphalt at 160  C. by Robinson (1996) was followed by the development and
trials of a cold lay asphalt thin surfacing which was reported
1.1. Worldwide adoption of cold mix asphalt by ETSU (1997) and further reported by Day and Robinson
(2002). A guide to the use and specification of cold recycled
Despite its significant energy savings the quantity of CMA materials for the maintenance of road pavements TRL
produced remains relatively small compared to the total Project Report 611 (Merrill et al., 2004) provided additional
worldwide asphalt production. This is partly due to the guidance on the use of cold recycled materials using mainly
different behavior of CMA and HMA as CMA is tender imme- foam bitumen which was later introduced as a clause in the
diately after laying and requires a curing period to achieve full manual of contract documents for highway works volume 1
stiffness. However, the lack of standardization for CMA has specifications for highway works series 900 (clause 948)
also delayed its progress, although there are some notable (Highways Agency, 2018) which included the option to use
examples of its wider adoption. emulsions. However the volume of CMA remained low.
In 1950's France a cold reprofiling asphalt was developed In the absence of established design protocols and speci-
known as Grave emulsion. This class of CMA was formally fications the University of Dundee, a local authority organi-
standardized by SETRA (1974) and continues to be updated as zation called Tayside Contracts and Nynas Bitumen developed
TF-P-98-121 (Association Francaise De Normalisation, 2014). a CMA via a Knowledge Transfer Partnership on a project
Whilst the majority of grave emulsion applications have entitled “adding value to recycling of construction aggregates,
historically taken place in southern France, where the warm by developing and implementing a cold mix bituminous
dry climate facilitates curing of the emulsion, the technology recycling technology”. The product was a 20 mm CMA for
has also gained acceptance in Spain (Bardesi, 1994) and structural layers and was called Tayset, described as a greener
Ireland (Bullen et al., 1994; Killeen et al., 1993). shade of black it was estimated adoption could save 17,160 t of
In the USA the large haulage distances from hot-mix plants CO2 in Scotland (University of Dundee, 2008). The 3-year
to job sites combined with a favorable climate has also seen project involved numerous installation trials on both urban
and industrial sites within Tayside Contracts local authority
region including one where the early life stiffness
development was compared to that of AC20 dense bin100/
150 hot mix asphalt using a light weight deflectometer on a
street within the city of Dundee. The site plan is shown in
Fig. 2 and the results demonstrated that the CMA was
comparable in stiffness to the hot mix during the first 24 h
prior to overlaying with surface course.
During the spring of 2008 material was supplied for a new
park and ride construction scheme within another client au-
thority where two of the objectives were to demonstrate speed
of laying and the CMAs ability to resist sideways forces from
buses using a turning circle. The materials ability to be stable
Fig. 1 e Schematic of nomenclature used to classify asphalt to site traffic enabling the construction of a second layer much
types by temperature. sooner than for hotmix was seen as a major benefit. The
J. Traffic Transp. Eng. (Engl. Ed.) 2019; 6 (4): 359e365 361

Fig. 4 e Installation of Tayset on the bus turning circle for a


park and ride scheme.

Fig. 2 e Schematic plan monitoring stiffness development


using a lightweight deflectometer on CMA and hot mix. to the RA/aggregate blend and the overall moisture content of
the mixture controlled to be within 3%e6% by mass. The
mixing was performed in advance on a hotmix asphalt plant
at Collace quarry whilst the plant was cold. Tayset has the
installation of the material is shown in Fig. 3 whilst Figs. 4 and
added property of being storable for up to 3 weeks which
5 show the turning circle during construction and after 3
enabled the contractor to manufacture the CMA in advance of
years.
the contract enabling the production plant to focus on hotmix
The culmination of the project included a product launch
during construction without having to suffer time constraints
of Tayset supported by the MSP and cabinet minister for
waiting for the plant to cool to produce CMA.
finance and sustainable growth in Scotland. Transport Scot-
land gave permission to trial the CMA on the A90 a trunk road
2.1. A90 site trials
on the Scottish network. Full scale paving trials on the A90
were performed during November 2008 with extensive site
Notwithstanding skepticism from some quarters the devel-
and laboratory testing undertaken as detailed below.
opment work and small scale proving trials enabled Transport
Scotland to give permission to trial the material on the A90,
which was the first known use of CMA on a UK trunk road
2. Materials and methods where traffic counts of 19,500 vehicles per day were measured
of which 15% were multi-axle HGV vehicles.
The precise composition of the CMA design remains pro- The 800 m long section of the A90 to be reconstructed had
prietary information, but in general terms employed approx- previously been designed with 260 mm of HMA base course.
imately 70% screened recycled asphalt (RA) planings with the This was replaced with 300 mm of CMA as shown in Fig. 6, laid
remaining 30% made of virgin coarse and fine aggregate to in two 150 mm lifts on top of the existing 200 mm granular
achieve a target gradation. A C60B5 emulsion, produced by sub-base, and surfaced with 100 mm of HMA. The CMA
Nynas UK using a 40/60 penetration grade bitumen, was added layers were installed using a Bitelli BB670 wheel driven

Fig. 3 e Installation of Tayset on a bus park and ride depot. Fig. 5 e Bus turning circle 3 years after construction.
362 J. Traffic Transp. Eng. (Engl. Ed.) 2019; 6 (4): 359e365

damp and cold. CMA remains workable so long as it is not


allowed to dry out by evaporation or the moisture is extruded
during compaction, therefore the CMA was able to be manu-
factured in advance of the works whilst the hot mix plant was
cold thereby freeing the plant to manufacture standard hot
mix during the installation.

2.1.1. A90 site trials e site testing


During the site construction, the surface modulus of each
layer was determined immediately after completion of
compaction by a light weight deflectometer using an applied
stress of 100 MPa. Typical results are detailed below in Table 1
with a typical deflectometer response pulse during testing of
the CMA shown in Fig. 7.
A90 trunk road site paved cold mix asphalt after compac-
Fig. 6 e A90 trunk road site paved cold mix asphalt prior to tion is shown in Fig. 8. The surface modulus of each layer of
compaction. the construction is consistent with the one below suggesting
that the CMA does not improve on the substrate surface
paver at a nominal width of 3.5 m and compacted using a 10 t modulus. However, it is expected that the values for the
steel drum Bomag 161 and a pneumatic tyred roller. The first CMA will evolve over time as the asphalt stiffness develops
layer of 150 mm was compacted with the Bomag 161 which as had been demonstrated during earlier work although this
involved passes without vibration followed by vibration until was not measured as part of this trial.
substantially compacted and finishing off once more A total of 1600 t of CMA was laid on the site and a CO2
without vibration. The second CMA layer was installed saving of 43 t calculated using the Asphalt Pavement
immediately after completing the first layer and no major Embodied Carbon Toll (asPECT, 2009), which had been jointly
tracking or marking of the first layer was visible from site developed by the UK Highways Agency, Mineral Products
vehicles. Compaction of the second layer was identical to Association, Refined Bitumen Association and the UK
the first but was finished with a pneumatic tyred roller. The Transport Research Laboratory.
HMA surfacing was overlaid 6 h after completion of the CMA
base course layer. 2.1.2. A90 site trials e laboratory testing
The site work was undertaken in November 2008 and, as is Plant mixed material was stored in sealed plastic containers
typical for Scotland at that time of year, the weather was and used to produce specimens for subsequent laboratory

Table 1 e Site light weight deflectometer results.


Chainage Testing location nearside Surface modulus (MPa)
(N/S) or offside (O/S)
Formation layer Sub-base layer Lower base Upper base
(sandy clay soil) (Blend of Type 1 & 1R) layer (CMA) layer (CMA)
280 N/S 97 89 130 121
280 O/S 80 97 108 120
330 N/S 60 84 105 108
330 O/S 66 102 115 110
380 N/S 50 801 95 140
380 O/S 55 851 110 135
430 N/S 78 92 90 165
430 O/S 50 82 90 110
480 N/S 501 801 80 125
480 O/S 55 82 93 135
530 N/S 130 60 108 130
530 O/S 80 96 81 104
580 N/S 78 88 90 115
580 O/S 67 96 87 121
630 N/S 76 92 120 105
630 O/S 70 80 81 145
680 N/S 50 2002 1073 1753
680 O/S 57 801 112 120
730 N/S 97 80 106 125
730 O/S 60 80 80 138
780 N/S 120 85 100 112
780 O/S 106 82 114 125

Note: 1. Re-test; 2. Type 1 replacement; 3. Effect of improved sub-base.


J. Traffic Transp. Eng. (Engl. Ed.) 2019; 6 (4): 359e365 363

to ensure that stiffness results could be obtained during the


early curing period whilst the asphalt was relatively weak. As
can be seen the initial stiffness build-up was more rapid in the
unsealed specimens due to the higher rate of moisture loss.
However, the moduli of the two sets of specimens began to
stabilize after approximately 100 days, reached 5 GPa within 6
months and finally converged and stabilized to around 6 GPa.
This is consistent with previous studies assessing in-situ CMA
curing rates (Leech, 1994; Santucci, 1977).
Fig. 7 e Typical light weight deflectometer output.

2.2. Riverside avenue site trials

It was not possible to obtain site cores from the A90 trial.
However, in March 2009 a slip road onto the A90 at a nearby
site, Riverside Avenue, Dundee, was also constructed from
which permission to remove cores was obtained. This site
used the developed CMA as a lower layer, overlaid with
150e200 mm total thickness of dense asphaltic concrete and
30/14 Hot Rolled Asphalt surfacing paved in two layers.
150 mm diameter cores were extracted in November 2012,
with an example core shown in Fig. 10.
Each core was trimmed using a diamond tipped slab saw to
remove the hot mix asphalt and produce an even surface top
and bottom of the core. The trimmed core specimens were
maintained at 20  C and periodically their ITSM determined,
also at 20  C as the usual laboratory test temperature in the
Fig. 8 e A90 trunk road site paved cold mix asphalt after UK, as shown in Fig. 11 below.
compaction. Initially the ITSM results were relatively low which 3 years
after paving and with no signs of distress on site was
testing. Specimens were prepared to assess the CMA curing
rate in the laboratory. Each 150 mm diameter specimen used
2800 g of CMA and was compacted at ambient temperature by
gyratory compaction to 120 gyrations.
Pairs of specimens were produced from each container of
stored uncompacted asphalt. From each pair one specimen
was partially wrapped in cling film, leaving the bottom surface
exposed, to simulate the asphalt in situ where the bottom of
the layer would be in contact with the subbase, whilst the
other was left unwrapped. These specimens were then
allowed to cure at 5  C e 10  C. The specimens’ indirect tensile
stiffness modulus (ITSM) was determined at 10  C after 1, 4, 7,
17, 28, 56, 100, 112, 146, 230, 341 and 508 days to assess stiff-
ness development as shown in Fig. 9. This required the
wrapped specimens to be unwrapped during testing but
immediately re-sealed to prevent excessive moisture loss.
Fig. 10 e 150 mm diameter riverside drive site core.
The low temperature for curing and testing was chosen to
simulate the likely conditions of the material on site and also

Fig. 9 e A90 CMA stiffness development of specimens Fig. 11 e Stiffness development of riverside drive site cores
stored at low temperature. at 20  C.
364 J. Traffic Transp. Eng. (Engl. Ed.) 2019; 6 (4): 359e365

unexpected, and may have been a consequence of the coring Thanaya et al., 2009) whilst to enable industrial implementa-
or the laboratory specimen trimming processes. However, tion there has been considerable progress on specification
over the course of approximately one month the specimens development, with the experiences from the Tayset site trials
regained their expected modulus values albeit with a rather providing a significant contribution. For instance, the UK
large degree of scatter in the results. Specification for Highways Works now includes clauses 947
Once stable ITSM values were obtained two of the speci- and 948 for in-situ and ex-situ cold recycled bound material.
mens were selected with moduli close to the average of the These clauses include the option for bitumen emulsion based
full set. The wheel tracking performance of these cores was materials and give guidance on mix designs, testing fre-
then determined using the small device and procedure B from quencies and expected pavement stiffness modulus values.
the British Standard Institute (BS EN 12697-22) (2003) under European standard EN 13108 part 8 enabling the classifi-
the standard UK test conditions temperature of 60  C and cation of RA was published in 2005, and new EN standards are
10,000 cycles with the results shown in Table 2 below. currently under development to cover WMA and CMA. As an
As can be seen very low levels of rut depth and rate were interim measure in the UK a guidance document PPR666 was
obtained from both cores. This indicates a good aggregate published in 2013 by Nicholls et al. (2013) as a culmination
skeleton but may also have been due to excessive hardening from the carbon trust sponsored project mentioned
of the binder. To assess this the binder from the core 3A was previously to further encourage the adoption of these
recovered and analyzed as shown below in Table 3. technologies.
The results are in line with those expected from a blend of
50 dmm bitumen from the emulsion and a harder binder,
typically 10e20 dmm, from the RA, therefore indicating that 4. Conclusions
the wheel tracking results are a valid site performance indi-
cator and that CMA can provide a high level of deformation The A90 site trials of CMA have a theoretical traffic count of
resistance. over 10 million equivalent standard (80 kN) axel loads since
construction and show no signs of distress after nearly 10
years service. They have clearly demonstrated that the ma-
3. Cold mix asphalt standards development terial can be successfully utilized as part of a heavily trafficked
in the UK highway pavement design. The long term stiffness develop-
ment was assessed in the laboratory at typical site tempera-
Cold mix asphalt standards in the UK have mainly covered tures (Worldweatheronline, 2018) and found to stabilize at
their use in reinstatements and for structural layers using 6 GPa at 10  C. Site CMA cores were also shown to exhibit
mainly foam bitumen. Numerous trials have been undertaken excellent deformation resistance by wheel tracking tests at
to demonstrate the potential of CMA (Day et al., 2010). In 2008 60  C. The stiffness results obtained from laboratory cores
the Carbon Trust funded a project called “Market cured at 10  C demonstrate good correlation to site cores
Development of Low Carbon Asphalt” to encourage the use tested at 20  C.
low carbon technologies to reduce CO2 from asphalt The success of these and similar site trials along with
production in the UK. This culminated in a full scale continued specification development has laid the foundations
demonstration trial to confirm the potential for CMA to be for more widespread adoption of CMA as part standard
used as a standard material in pavement construction. The pavement design procedures in the UK.
UK government funded site trial in 2011 (The Carbon Trust,
2014) compared and verified the performance of HMA, WMA
and CMA. Conflict of interest
Fundamental research into CMA continues to refine the
design procedure (Arimilli et al., 2015; Cheng and Bahia, 2018; The authors do not have any conflict of interest with other
Lee et al., 2016; Nassar et al., 2016; Tabakovic  et al., 2016; entities or researchers.

Table 2 e Small device wheel tracking results for cured Acknowledgments


Riverside Drive CMA cores.
Core 1B Core 3B The design work carried out by the University of Dundee as
part of the Knowledge Transfer Partnership is acknowledged.
Rut depth (mm) 0.9 0.9
Rut rate (mm/1000 cycles) 0.010 0.018

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