Designing HMA Mixtures With High RAP Content: A Practical Guide
Designing HMA Mixtures With High RAP Content: A Practical Guide
Designing HMA Mixtures With High RAP Content: A Practical Guide
Designing HMA
Mixtures with
High RAP Content
A Practical Guide
Contact information for NAPA elsewhere in this recently
digitized document may be out of date. Please use the
contact information on this page if you wish to reach
the assocation.
NAPA Members are dedicated to providing the highest quality HMA paving materials and pavements, and
to increasing the knowledge of quality HMA pavement design, construction, maintenance and rehabilitation.
NAPA also strongly supports the development and dissemination of research, engineering and educational
information that meets America’s needs in transportation, recreational, and environmental pavements.
NATIONAL ASPHALT
PAVEMENT ASSOCIATION
NAPA Building 5100 Forbes Blvd. Lanham, MD 20706-4407
Tel: 301-731-4748 Fax: 301-731-4621
Toll free 1-888-468-6499 www.hotmix.org
This publication is designed to provide information of interest to NAPA Members and is not to be considered
a publication of standards or regulations. The views of the authors expressed herein do not necessarily
reflect the decision making process of NAPA with regard to advice or opinions on the merits of certain
processes, procedures, or equipment.
COPYRIGHT NOTICE
Publications produced and published by the National Asphalt Pavement Association (NAPA) are copyrighted
by the Association and may not be republished or copied (including mechanical reproductions) without
written consent. To obtain this consent, contact the Association at the address given in this publication.
by
David E. Newcomb
E. Ray Brown
Jon A. Epps
NATIONAL ASPHALT
PAVEMENT ASSOCIATION
CONTENTS
Introduction............................................................................................................5
Background.......................................................................................................5
Purpose and Scope...........................................................................................6
Overview ...............................................................................................................7
Materials Evaluation............................................................................................11
RAP . .............................................................................................................11
Aggregate........................................................................................................13
Binder..............................................................................................................16
Additives and Modifiers...................................................................................16
Mix Design............................................................................................................19
Introduction......................................................................................................20
Sample Preparation.........................................................................................20
Laboratory Mixing and Compaction.................................................................20
Volumetric Testing............................................................................................20
Determination of Optimum Binder Content.....................................................21
Binder Testing..................................................................................................21
Mechanical Property Testing...........................................................................21
Plant Verification..................................................................................................23
Initial Settings..................................................................................................23
Testing.............................................................................................................24
Adjustments.....................................................................................................24
Test Strip.........................................................................................................24
Production.......................................................................................................25
Quality Control.....................................................................................................27
Introduction......................................................................................................27
Testing.............................................................................................................27
Adjustments.....................................................................................................31
Summary..............................................................................................................33
References...........................................................................................................35
TABLES
Stockpiled Aggregate
1
Aggregates Testing
Size
Roadway Laboratory According Aggregate
2
Sample Crushing to Plant Testing
RAP
Recycled Stockpile(s)
Asphalt Binder
Pavement Extraction
and Recovery
Stockpile Separate According Binder PG Properties
Sample to Stockpile(s) Content Tests or
Regional 3
Properties
(for >25% RAP)
Virgin Binder PG Binder Testing 4
1 Stockpile Aggregates
Combine Aggregates
to Meet Gradation and
Quality Requirements
2 RAP Aggregates
Choose Highest %
RAP that Satisfies Perform
Both Gradation and Mix Design
3 RAP Binder PG Requirements
Combine Asphalt
to Meet PG Grading
Requirements
4 Virgin Binder (for >25% RAP)
with disposal of the used solvent, which is increasingly could have a predominant effect, in which case
problematic, and the testing requires a great deal other methods of characterization would need to be
of time. The second method is shorter, and if there explored. However, it would be an important issue
is sufficient cause to believe that aging causes an to resolve through research in order to minimize the
asymptotical change in binder stiffness (less change amount of solvent extraction and recovery.
in stiffness later in service), then an assumption can The regional characterization of RAP could be
be made on the basis of a regional characterization accomplished through either a national research
of RAP binder. This would require a research effort program such as NCHRP or as a series of pooled
to define aged binder characteristics on a regional fund studies through the Federal Highway Research
basis to investigate the viability of such an approach. Program. The objective would be to estimate the binder
It is possible that other factors such as crude source properties of RAP according to geographical locations
FIGURE 2
Mix Design Procedure
Combine Stockpile Heat Add RAP at Heat RAP and Add Virgin Binder
Aggregates for Aggregates Predetermined Virgin Materials at 4 Asphalt Contents
Gradation Percent -2 gyratory samples each
Compact Determine AC Prepare Gyratory Volumetric Analysis –
to Requirements content for 96% Samples at Optimum %G mm1 VMA, Air Voids
G mm @ N des Virgin Binder Content
Performance Testing
Rut, Perm. Def.,
Thermal Cracking, Final
Fatigue, Modulus, Design
Moisture Sensitivity
Durability
FIGURE 3
Plant Verification Procedure
Compare to Mix Performance Testing–
Test Volumetrics Design and Adjust Mix Rut, Perm. Def., Thermal
%G mm1, VMA,VFA Specs.–Air Voids, Proportions Cracking, Fatigue, Modulus,
VMA,VFA Moisture Sensitivity Durability
Penetration at 77Fo
70
-
60 – Beaver Co.
- Lycoming Co.
50 – Washington Co.
Lebanon Co.
- Cracking first observed
40 –
-
30 –
-
20 –
-
10
–
–
-
-
0 20 40 60 80 100 120 140
Life of Pavement, months
FIGURE 5
Change in Viscosity with Time (after Petersen, 1989)
Log Viscosity,
poise, 25Co 8
- ●
■
■
●
■
7 – ■
■
●
▲
▲
● ▲▲
-
■ ●
● ▲
●▲
6 – ■
●
● Asphalt A
■ Asphalt H
-
■
▲ Asphalt J
▲
5 –
-
–
–
-
0 20 40 60 80 100 120
Pavement Age, months
D5444. The main difference between the RAP and of the final HMA mixture. In the Superpave system,
stockpile aggregates gradation procedures is that the control points are set according to the nominal
ash content from solvent extraction must be accounted maximum aggregate size. The restricted zone has
for in the RAP aggregate, if solvents were used. been removed from most specifications. Requirements
For stockpile and RAP aggregates not subjected to that sometimes cause problems include the amount of
solvent extraction, AASHTO T11 or ASTM C117 can material passing the No. 200 (0.075 mm) sieve size,
be used in quantifying the amount of material passing the dust to asphalt ratio, voids in mineral aggregate
the 0.075-mm (No. 200) sieve. (VMA), the amount of natural sand in the combined
The combined gradation of RAP and stockpile mixture, and complete mixing of the old and new
aggregates must meet the gradation requirement binders.
[ ]
Gsb = Pba Gse Abrasion procedure. Thus, it is more of a wear test.
+1
100Gb Cleanliness
Aggregate cleanliness can be tested through sev-
Where: Gmm = theoretical maximum specific eral means, but again, the RAP aggregate was already
gravity of RAP used in HMA, so testing it for cleanliness may be su-
perfluous. Virgin aggregate should be subjected to the
Gb = specific gravity of RAP binder
normal evaluation used within a jurisdiction. The sand
Pb = RAP binder content equivalent value can be found using AASHTO T176
Gse = effective specific gravity of aggregate or ASTM D2419. Organic impurities can be quanti-
Gsb = bulk specific gravity of aggregate fied by AASHTO T21 or ASTM C40. Clay lumps and
friable particles are tested for according to AASHTO
Pba = absorbed binder, % weight of T112 or ASTM C142.
aggregate
Particle Shape and Angularity
McDaniel and Anderson (2001) recommend an Particle shape and angularity are especially impor-
estimated Pba of 1.5 percent, if data from similar tant for aggregates that are closer to the pavement
aggregate sources are not available. If absorption data surface. Superpave usually defines requirements
are available from past records on similar aggregates, according to traffic level and position within the pave-
then it should be used as the estimate. They also ment structure (within or below 100 mm (4 inches) of
recommend a value of 1.020 for Gb, and since the the surface).
FIGURE 6
Methods for Selecting RAP Content for the Desired Properties
T critical, C T critical, C
88 88
82 82
76 76
70 70
64 64
58 58 54.3
52 l l l l l l 52 l l l l l l
0% 20% 40% 60% 80% 100% 0% 20% 40% 60% 80% 100%
Percentage of RAP Percentage of RAP
Mineral Fillers
Mineral fillers are employed to serve a number
Additives and Modifiers of functions in recycled mixtures. They can be used
to help fill the voids in mineral aggregate, increase
stability, meet aggregate gradation requirements, and
Anti-stripping Additives improve the bond at the binder-aggregate interface.
As with virgin mixtures, moisture sensitivity is The amount of filler is usually restricted by the dust
sometimes a problem in recycled mixtures where to binder ratio specified in mix design. In recycled
stripping was the major distress in the RAP being mixtures, additional mineral fillers must be used
used. This also may be of concern when there is a lack carefully since the recycling process often generates
of bond between a softer virgin asphalt and stockpile a considerable amount of fine material. If there is too
aggregate. In any case, moisture sensitivity should much dust generated by milling or crushing operations,
be evaluated under the mixture design process, and then there may be little to no room for additional fines
either liquid anti-stripping agents or lime should be in the virgin aggregate, depending upon the amount
used if necessary. The choice whether to use a liquid of RAP to be used.
or lime is usually based upon economy and perfor-
Compacted Mix
Depending upon the requirements for field volu-
metric testing, the following parameters should be
Test Strip
examined: In many cases, a section of the project will be
Air Voids (lab compacted): The air void content set aside for the construction of a test strip. If this
should be within one percent of the target voids at is not the case, then a test strip may be built off
Ndesign. the project, but the pavement support conditions
Coarse aggregate angularity D5821 Combined cold feed 1-5 Medium – Low
Flat and Elongated Particles D4791 Combined cold feed 1 - 5 Medium – Low
Los Angeles abrasion T96 C131 Combined cold feed 1 - 5 Medium – Low
1 Frequency and types of testing will depend upon variability of source materials and the intended end-use of the HMA.
Historical records and materials evaluation should be consulted before determining testing frequency.
TABLE 2
Suggested Quality Control Schedule for RAP
Frequency and types of testing will depend upon variability of source materials and the intended end-use of the HMA.
1
Historical records and materials evaluation should be consulted before determining testing frequency.
2 If the RAP stockpile is built ahead of production and additions are not being made to the pile, it may be possible to dramatically reduce
the sampling frequency.
TABLE 4
Suggested Quality Control Schedule for HMA Mixtures (after Epps et al, 2002)
Symbol When You Know Multiply By To Find Symbol Symbol When You Know Multiply By To Find Symbol
LENGTH LENGTH
inches inches 25.4 millimeters mm mm millimeters 0.039 inches in
ft feet 0.305 meters m m meters 3.28 feet ft
yd yards 0.914 meters m m meters 1.09 yards yd
mi miles 1.61 kilometers km km kilometers 0.621 miles mi
AREA AREA
in2 square inches 645.2 millimeters squared mm2 mm2 millimeters squared 0.0016 square inches in2
ft2 square feet 0.093 meters squared m2 m2 meters squared 10.764 square feet ft2
yd2 square yards 0.836 meters squared m2 ha hectares 2.47 acres ac
ac acres 0.405 hectares ha km2 kilometers squared 0.386 square miles mi2
mi2 square miles 2.59 kilometers squared km2
VOLUME VOLUME
fl oz fluid ounces 29.57 milliliters mL mL milliliters 0.034 fluid ounces fl oz
gal gallons 3.785 liters L L liters 0.264 gallons gal
ft3 cubic feet 0.028 meters cubed m3 m3 meters cubed 35.315 cubic feet ft3
yd3 cubic yards 0.765 meters cubed m3 m3 meters cubed 1.308 cubic yards yd3
NOTE: Volumes greater than 1000 L shall be shown in m3.
MASS MASS
oz ounces 28.35 grams g g grams 0.035 ounces oz
lb pounds 0.454 kilograms kg kg kilograms 2.205 pounds lb
T short tons 0.907 megagrams Mg Mg megagrams 1.102 short tons(2000 lb) T
(2000 lb)
5M3/07mg
National Asphalt Pavement Association
NAPA Building
5100 Forbes Blvd.
Lanham, Maryland 20706-4407
www.hotmix.org
[email protected]
Tel: 301-731-4748
Fax: 301-731-4621
Toll Free: 1-888-468-6499
QIP 124