Mix Design

Hot Mix Asphalt Recycling (Materials and Mix Design)

(This set of slides come from Pavement Recycling Guidelines for State and Local Governments by NCAT.)

Material Evaluation
Sampling Reclaimed Asphalt Pavement (RAP) Recycling Agents

Mix Design Procedures

Conventional (Marshall/Hveem) Superpave

Sampling

Sampling from Pavements

Sampling from Pavements for Preliminary Analysis Sampling from Trucks Sampling from Stockpiles

Divide Pavement into Sections of Equal Length Conduct Random Sampling Perform Tests

If Pavement is One Lane Wide

Divide Pavement into 12 to 16 Sections of Equal Length Obtain One Random Sample Per Section

If Pavement is Two Lane Wide

Divide Pavement into 6 to 8 Sections of Equal Length, 2 Lanes Wide

Obtain One Random Sample Per Section, Per Lane

Perform Tests Determine Mean, Standard Deviation

Milling Machine Loading a Truck

Sampling from Trucks

Divide Production into 12 to 16 One Day Period

Randomly Select Two Trucks per time Period for Sampling

Divide Production into one or two day periods Randomly Select Two Trucks Per Sampling Period Conduct Random Sampling Perform Tests

Obtain One Random Sample Per Truck Perform Tests Determine Mean, Standard Deviation

RAP Stockpile

Sampling from Stockpiles

Divide Stockpile into Grid of Blocks

Conduct Random Sampling from Each Block Obtain Samples from Top and Bottom Portion of Pile Perform Tests

Divide Stockpile into a Grid of 12 to 16 Blocks

Select One Random Sampling Point in Each Block

Conduct Sampling

With Power Equipment, Obtain One Sample from Upper Third and One from Lower Third of Pile at Each Sampling Point

Without Power Equipment, Obtain One Sample from top of Pile at Each Sampling Point and One from Lower Half of Pile at Sides of Adjacent Blocks

Perform Tests

Determine Mean, Standard Deviation

Evaluation of RAP

Recycling Agents
Restore Aged Asphalt Binder to Desired Consistency Restore Aged Asphalt Binder to Optimum Properties for Durability Provide Sufficient Additional Binder for Coating Added Virgin Aggregate Provide Sufficient Additional Binder to Satisfy Mix Design

RAP Mix Composition Asphalt Content Gradation Asphalt Binder Recovery (More than 15-20% RAP) Viscosity at 60oC or Rutting Factor (G*/Sin delta)

Types of Recycling Agents

Recycling Agents (ASTM D4552)

RA1 Viscosity @ 60C (cSt) RA5 RA25 RA75
450112500

Soft Asphalt Cements

AASHTO M226 (Viscosity Graded Asphalt Cements) AASHTO MP1 (PG Asphalt Binders)

RA250 RA500
12501- 3750137500 60,000

50-175 176-900 9014500

Flash Point, C, 218 Minimum Saturates, %, Minimum 30

218 30 3

218 30 3

218 30 3

218 30 3

218 30 3

Commercial Recycling Agents

ASTM D4552 (Classifying Hot-Mix Recycling Agents)

Viscosity Ratio 3 (RTFO or TFO)

Steps in Conventional Mix Design

Aggregate Gradation, Asphalt Content, and viscosity of Extracted Binder from RAP

Steps in Conventional Mix Design (continued)

Determine Approximate Asphalt Demand of Combined Aggregate

Gradation of New Aggregate

Estimate Percent of New Asphalt Binder in Mix

Determine Combined Gradation in Recycled Mix

Select Grade of New Asphalt Binder (from Viscosity Chart)

Steps in Conventional Mix Design (continued)

Select Grade of New Asphalt Binder

Example 1
Viscosity of Aged Binder in RAP: 46,000 Poise Target Viscosity: 2,000 Poise

Run Trial Mix Designs by Marshall or Hveem Method

Percentage of Recycling Agent in Total Binder: 69 Viscosity of Recycling Agent ?

Select Job Mix Formula

700 Poise

108 107 106 105 104 103 102 10

Viscosity, Poise, 60C

Example 2
700

Viscosity of Aged Binder in RAP: 100,000 Poise Target Viscosity: 2,000 Poise

1

Percentage of Recycling Agent in Total Binder: 57 Viscosity of Recycling Agent ? 180 Poise

0 10 20 30 40 50 60 70 80 90 100

New Asphalt or Recycling Agent, R, Percent by Weight

108 107 106 105 104 103 102 10 1

Viscosity, Poise, 60C

Example 2 (continued)
180

Let us Use AC 20 Viscosity of Available Recycling Agent: 1 Poise Percentage of Recycling Agent Required to Blend with AC 20 to Produce a Viscosity of 180 Poise? 22 %

0 10 20 30 40 50 60 70 80 90 100

New Asphalt or Recycling Agent, R, Percent by Weight

108 107 106 105 104 103 102 10 1

Viscosity, Poise, 60C

180

Steps 5 and 6 Trial Mix Design and Job Mix Formula

5 Asphalt Contents (2 Above and 2 Below Estimated AC) Heat RAP to Mixing Temperature (Not More Than 1 Hour) Heat New Aggregate 10oC Above Mixing Temperature Marshall or Hveem Mix Design Procedures

22 %
0 10 20 30 40 50 60 70 80 90 100

New Asphalt or Recycling Agent, R, Percent by Weight

Marshall Hammer

Marshall Stability Machine

Kneading Compactor

Stabilometer

Steps in Superpave Mix Design

Aggregate Gradation, Asphalt Content, and viscosity of Extracted Binder from RAP

Gradation of New Aggregate

Determine Combined Gradation in Recycled Mix

Steps in Superpave Mix Design (continued)

Determine Approximate Asphalt Demand of Combined Aggregate

Steps in Superpave Mix Design (continued)

Compact Trial Mixes with Superpave Gyratory Compactor

Determine G*/sin of Proposed Recycling Agent Select Job Mix Formula Determine Amount of Recycling Agent (Use G*/sin Blending Chart)

Step 4 Selection of PG Grade for New Binder

Up to 15% RAP: Use Same PG Grade 16-25% RAP: Select One Grade Below (Both high and low temperatures) For Example: PG 58-28 in Lieu of 64-22, Blending Chart Optional 25% or More RAP: Use Blending Chart

G*/Sin Blending Chart

Uses 1.0 kPa and 2.0 kPa Stiffness Lines Determines Minimum and Maximum Percentages of New Binder Determines Maximum and Minimum Amounts of RAP

Data Needed for Blending Chart

Target PG Grade G*/Sin of Aged Asphalt Binder from RAP Determined at High Temperature of Target PG Grade G*/Sin of New (Virgin) Binder Also Determined at High Temperature of Target PG Grade % New Binder in Total Binder

Example 1
Binder Specified: PG 64-28 G*/sin of Aged Binder, at 64C: 100 kPa G*/sin a of Virgin Binder, at 64C : 1.13 kPa Amount of Virgin Binder to be Added to RAP: 85 - 100 %

100 10

G*/Sin(delta), kPa, 64C

Example 2
Binder Specified: PG 64-28 Binder to be Used: PG58-34 G*/sin delta of Aged Binder, at 64C: 100 kPa G*/sin delta of Virgin Binder, at 64C : 0.65 kPa Amount of Virgin Binder to be Added to RAP: 72 - 89 %

2 1

0.1

0 10 20 30 40 50 60 70 80 90 100

New Asphalt or Recycling Agent, R, Percent by Weight

100 10 2 1

G*/Sin(delta), kPa, 64C

Steps 5 and 6 Trial Mix Design and Job Mix Formula

0.65 kPa

0.1

72

89

0 10 20 30 40 50 60 70 80 90 100

New Asphalt or Recycling Agent, R, Percent by Weight

5 Asphalt Contents (Bracket the Estimated Asphalt Content Heat RAP to Mixing Temperature (Not More Than 1 Hour) Heat New Aggregate 10oC Above Mixing Temperature Compact Specimens in Superpave Gyratory Compactor (SGC)

% Gmm

Binder Content

Summary

Material Evaluation
Sampling of RAP Evaluation of RAP Recycling Agents

Mix Design
Selection of New Binder

Viscosity Grade Superpave PG Grade Marshall/Hveem Procedures Superpave Volumetric Procedure

Trial Mix Design and JMF

10

Log Gyrations

100

1000