Alabama Dept.

of Transportation ALDOT Procedures

Bureau of Materials and Tests ALDOT-388
Testing Manual Revision: 5/8/96
Page 1 of 9

ALDOT-388
SUPERPAVE VOLUMETRIC MIX DESIGN PROCEDURE USING RECLAIMED ASPHALT
PAVEMENT

1. Scope

1.1. This procedure covers designing hot mix asphalt paving mixtures using reclaimed asphalt
pavement (RAP) and should be used in conjunction with ALDOT-384. This method is for
use with mixtures with a gradation such that one hundred percent of the aggregate passes the
2.5 in (63.0 mm) sieve and one hundred percent of the RAP passes the 2.0 in (50.0 mm)
sieve.

2. Referenced Documents

2.1. AASHTO Standards

2.1.1. AASHTO T-49, Penetration of Bituminous Materials

2.1.2. AASHTO T-164, Quantitative Extraction of Bitumen from Bituminous Paving

Mixtures

2.1.3. AASHTO T-170, Recovery of Asphalt from Solution by Abson Method

2.1.4. AASHTO T-201, Kinematic Viscosity of Asphalts

2.1.5. AASHTO T-202, Viscosity of Asphalts by Vacuum Capillary Viscometer

2.1.6. AASHTO T-228, Specific Gravity of Semi-Solid Bituminous Materials

2.1.7. AASHTO MP1, Performance-Graded Asphalt Binder

2.2. ASTM Standards

2.2.1. ASTM D 4402, Standard Test Method for Viscosity Determinations of Unfilled
Asphalts Using the Brookfield Thermosel Apparatus

2.3. ALDOT Procedures

2.3.1. ALDOT-258, Mechanical Analysis of Extracted Aggregate

2.3.2. ALDOT-372, Approval of RAP Stockpiles

2.3.3. ALDOT-384, Mix Design Procedure for Superpave Level One

2.4. Other Documents

2.4.1. The Asphalt Institute Manual, SP-1, Performance Graded Binder Specification and
Testing, The Asphalt Institute, Lexington, KY, Current Edition.
ALDOT Procedures Alabama Dept. of Transportation
ALDOT-388 Bureau of Materials and Tests
Revision: 5/8/96 Testing Manual
Page 2 of 9

2.4.2. The Asphalt Institute Manual, SP-2, Superpave Level 1 Mix Design, The Asphalt
Institute, Lexington, KY, Current Edition.

2.4.3. The Asphalt Institute Manual, MS-2, Mix Design Methods for Asphalt Concrete, The
Asphalt Institute, Lexington, KY, Current Edition.

3. Evaluate Reclaimed Asphalt Pavement

3.1. Sample and test the RAP stockpile according to ALDOT-372.

3.2. Determine the gradation of the extracted aggregate by ALDOT-258.

3.3. Recover approximately 100 g of binder by AASHTO T-170. If the binder can not be
recovered from the RAP (i.e. the RAP contains less than 1% binder) treat the RAP as an
aggregate.

3.4. Determine the viscosity of the reclaimed binder at 140°F (60°C) by AASHTO T-202. If
possible, run three to five samples and take the average, however, one to two will suffice.

3.5. If the viscosity of the binder is too high to easily measure, measure penetration at 77°F
(25°C) by AASHTO T-49 and viscosity at 135°C by AASHTO T-201; using the Asphalt
Consistency Temperature Chart (Figure 1), estimate the viscosity at 140°F (60°C).

For example, suppose that at 77°F (25°C) the recovered binder has a penetration of 25, and at
275°F (135°C) the recovered binder has a viscosity of 4,500 centistokes. Using the Asphalt
Consistency Temperature Chart, the viscosity at 140°F (60°C) estimated to be 6,000 pascal-
seconds (60,000 poises).

NOTE:To convert the viscosity in centistokes to poises multiply the viscosity in stokes by
the specific gravity of the binder (from AASHTO T-228). To convert the viscosity in poises
to pascal-seconds divide the viscosity in poises by ten (10).

3.6. The average value of the viscosity of the recovered asphalt will later (see section 4.6) be
plotted on the left vertical axis on Figure 2, "Viscosity Blending Chart."
Alabama Dept. of Transportation ALDOT Procedures
Bureau of Materials and Tests ALDOT-388
Testing Manual Revision: 5/8/96
Page 3 of 9

Example 1, Figure 1

Asphalt Consistency – Temperature Chart

ALDOT Procedures Alabama Dept. of Transportation
ALDOT-388 Bureau of Materials and Tests
Revision: 5/8/96 Testing Manual
Page 4 of 9

4. Estimate Rap Blend Properties (From MS-2)

4.1. Using the extracted RAP aggregates, estimate the percent of RAP to be used in the mixture to
design an aggregate structure required in ALDOT-384 (the most practical amounts are 25%
or less).

4.2. Estimate the asphalt binder demand of the combined aggregate blend using section 5.3 of
ALDOT 384.

4.3. Estimate the percent of new asphalt in the mix using the following formula:

Prb X % RAP
Pnb = Pb –
100

Where:
Pnb = estimated percent of new binder (recycling agent) in recycled mix.
% RAP = percent RAP aggregate (by mass of total aggregate).
Pb = percent binder content estimated in section 4.2.
Prb = percent binder content determined in section 3.1.

For example, suppose the estimated binder demand is 5.4%, the binder content of the RAP is
4.7% and 25% of the aggregate comes from the RAP (the new aggregate content is 75%).

4.7% X 0.25
Pnb = 5.4% - = 4.2% new binder in mix (estimated)
100

4.4. Where R is the percentage ratio of new to old binder, the percent of new binder, Pnb, to the
total binder content, Pb, is calculated by the following formula:

100 X Pnb
R=
Pb

For example, using the values from sections 4.2 and 4.3 above, the binder demand, Pb, is
5.4% and the new binder in mix, Pnb, is 4.7%.

4.2
R = 100 X = 78 Percent
5.4

4.5. Select the desired target viscosity of the final binder (check the specifications, this is usually
300 Pa-s or 3,000 Poises).

4.6. Use Figure 2, Asphalt Cement Blending Chart, to estimate the viscosity of the new binder
(recycling agent) to be used. Plot the viscosity of the aged RAP binder on the left hand
vertical scale from section 3.4 or 3.5. Draw a vertical line representing the percentage of
new asphalt, R, from section 4.4 and determine its intersection with the horizontal line
representing the target viscosity from section 4.5. Then draw a straight line from the RAP
binder viscosity through this intersection point until it intersects the right vertical scale. The
Alabama Dept. of Transportation ALDOT Procedures
Bureau of Materials and Tests ALDOT-388
Testing Manual Revision: 5/8/96
Page 5 of 9

binder viscosity through this intersection point until it intersects the right vertical scale. The
point on the right vertical scale is the estimated viscosity of the new binder (recycling agent)
used to obtain the target viscosity in section 4.5.

For example, using the values from sections 3.5 and 4.4, suppose the aged RAP binder
viscosity is 6,000 Pascal-seconds and 78 percent of the total binder in the mix will be new
binder. Also assume the mix target viscosity is 300 Pascal-seconds. Using the Asphalt
Cement Blending Chart the new binder used in the mix should have a viscosity of 130 Pa-s.
If this recycling agent may not be used, according to the specifications, reduce the amount of
RAP to be used and recalculate.

5. Modifications to ALDOT-384, Mix Design Procedure for Superpave Level I

5.1. Use ALDOT-384 with the following modifications, adding the same percentage of RAP to
each batch while mixing.

5.2. Use the percentage of binder needed as estimated in step 4.2 as the estimate of the mix design
content (from section 5.3 in ALDOT-384).

5.3. When drying the aggregates prior to bathing do not dry the RAP above 140°F (60°C). If
possible, air dry the RAP to avoid further hardening.

5.4. When batching, do not mix the RAP with the other aggregates. Keep the RAP dry, in a
separate container until mixing.

5.5. Heat the aggregates, still separate from the RAP, approximately 10°C higher than in
ALDOT-384. Charge the heated mixing bowl with the heated aggregates.

5.6. Dry mix the RAP into the heated aggregates for approximately 30 seconds. Then add the
recycling agent (binder) and mix as in ALDOT-384 (i.e. a mini-mum of two specimens at
each of the following binder contents: Pb-0.5%, Pb, Pb+0.5% and Pb+1.0%). If the mixture
is too stiff for complete coating and mixing, return to step 4.4 and elevate the aggregate
temperature further. If the recycling agent smokes at this elevated temperature while mixing
the percentage of RAP used and the mixing temperature should be reduced.

5.7. Compaction, density and voids analysis, and selection of optimum asphalt binder content are
as in ALDOT-384.
ALDOT Procedures Alabama Dept. of Transportation
ALDOT-388 Bureau of Materials and Tests
Revision: 5/8/96 Testing Manual
Page 6 of 9

Example 2, Figure 2

Viscosity Blending Chart

Alabama Dept. of Transportation ALDOT Procedures
Bureau of Materials and Tests ALDOT-388
Testing Manual Revision: 5/8/96
Page 7 of 9

6. Viscosity, Dust Proportion, and Fine Aggregate Angularity

6.1. Make at least one batch of at least 5,000 g according to section 4 of this procedure at the
optimum binder content as determined by ALDOT-384.

6.2. Extract and recover the asphalt binder by AASHTO T-164 and T-170. Save the remaining
aggregate. Determine the viscosity of the recovered asphalt binder using AASHTO T-202.

6.3. Determine if this viscosity meets the specifications.

6.4. Check the aggregate properties of the aggregate (saved in step 5.2) to determine if they meet
the specifications. Particularly check the dust to effective asphalt ratio (dust proportion) and
the fine aggregate angularity (uncompacted voids analysis).

6.5. If step 6.3 fails to meet the specifications use a lower viscosity recycling agent or reduce the
percentage of RAP. If step 6.4 fails to meet the specifications the aggregate structure
(percentage RAP or RAP source) must be changed.
ALDOT Procedures Alabama Dept. of Transportation
ALDOT-388 Bureau of Materials and Tests
Revision: 5/8/96 Testing Manual
Page 8 of 9

Figure 1

Asphalt Consistency – Temperature Chart

Alabama Dept. of Transportation ALDOT Procedures
Bureau of Materials and Tests ALDOT-388
Testing Manual Revision: 5/8/96
Page 9 of 9

Figure 2

Viscosity Blending Chart