INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

International Conference Transportation Infrastructure Projects Conception To Execution

January 7-10, 2019

Authors

Ankit Sharma*, G.D. Ransinchung R.N.**, Praveen Kumar***

*Research Scholar, IIT Roorkee, India

**Associate Professor, IIT Roorkee, India

*** Director, NIT Delhi, India

Adaptation and Performance of Hot Mix Asphalt Recycling Technology in India and Abroad : A

Review

Content

• Why RAP Recycling?

• Development of RAP-HMA Technology.

• What are Rejuvenators?

• Status of RAP-HMA in India and Abroad.

• Specifications of RAP- HMA.

• Conclusions.

33

What is Next ?

44

Save the National Asset

RAP

Rejuvenators

55

Reclaimed Asphalt Pavement (RAP)

• Recycling of asphalt pavements by reclaiming them, called

Reclaimed Asphalt Pavement.

• Reclamation of pavement consist of adding softer grade of

binder, appropriate rejuvenators and virgin aggregates.

66

RAP is worth the virgin material it replaces.

Source : http://www.apa-mi.org/docs/RAP2012LRW.pdf

77

Economy using RAP material (5% Bitumen Content)

• Or 2860 Rupees per ton of RAP.

Quantity of RAP material

Total RAP 30,000 t

Bitumen 1500 t

Aggregates 28,500 t

Cost Saving by RAP material

Bitumen 630 Lacs

Aggregates 228 Lacs

RAP 858 Lacs

88

Cost variation on using RAP

Source: http://raptech.us/library/Asphalt-Professional-Nov-2014.pdf

99

Overlay can Experience Cracks and Rerutting

Source: https://www.h-a-d.hr/pubfile.php?id=792

1010

Milling and Inlays Prevent Rutting

Source: https://www.h-a-d.hr/pubfile.php?id=792

Overlay Changes Bridge Clearance

Milling creates a Grooved

Surface

Environmental Benefits.

Development of RAP Recycling

• Pre- 1970s: A Novelty (RAP)

• 1970- 1985: Rising to Meet a Need (RAP)

• 1985- 2006: Standard Practices (RAP and RAS)

• 2006- 2015: A Revival (RAP and RAS)

• 2015- Present: Balance Mixture Design Method

Pre- 1970s: A Novelty (RAP)

• Warren Brothers Co. started recycling at the

beginning of 20th Century.

• In 1931, Singapore rehabilitated road by

recycling and they lasted for 14 years before

World War- II.

• In 1948, recycling was used in Mumbai to

rehabilitate the roads, lasted for 30 years

before any subsequent reconstruction.

1970-1985: Rising to Meet a Need (RAP)

• The Arab Oil Embargo of mid- 1970 force

industries to find ways to save petroleum

cost.

• Rejuvenators have been used with RAP

materials.

• Researchers focused on technical aspects of

RAP recycling.

Ageing of Asphalt Pavement

Ageing !!!

• The use of RAP material is limited due to

stiffness and workability issues related to

RAP, hence rejuvenating cream or anti ageing

cream is used for asphalt called- rejuvenators.

Fig.: Rejuvenating action exampleSource : https://thumbs.dreamstime.com/z/beauty-skincare-concept-no-aging-wrinkles-14508503.jpg

Rejuvenators

• Rejuvenator are the material which soften the

aged RAP mix.

• Improves Cracking Performance without

compromising rutting performance.

Figure: Various rejuvenators

Central plant recycling (Little, Dallas N., Epps, 1980)

S.No. Rejuvenators RAP incorporation Pavement Layer

1 Cyclogen L (Recycling Oil) 100%, Surface, Base Course

2 AR- 2000 and Extender Oil 80% Surface

3 AC- 10 70% Surface Course

4 AC (200/300 Pen) 50% Surface and Base Course

5 AR- 8000 and Paxole (Softening Agent) 100% Surface

6 AR- 2000 70% Surface

7 AC-5 85%, 93% Base, Surface

8 E.A. 11-M (Emulsified Asphalt) and AC-10 30-100% Base

9 AC-10 and Softening Agent 85-100% and 77-100% Surface

10 Cyclopave (Recycling Oil) 72% Surface

Evaluation of Rejuvenator’s

Effectiveness with Conventional Mix

Testing for 100% Reclaimed Asphalt

Pavement Mixtures

Martins Zaumanis, Rajib B. Mallick, and Robert Frank

M. Zaumanis and R. B. Mallick, Civil and Environmental Engineering Department, Worcester Polytechnic Institute, 100 Institute Road,

Worcester, MA 01609.

R. Frank, RAP Technologies, LLC, 217 Belhaven Avenue, Linwood, NJ 08221.

Sample Preparation

• Binder used in the study was extracted from RAP by using toluene

as a solvent.

RAP binder was extracted using Toluene.

Sample Preparation

+Plant Oils

Refined Tallow (9%)

Distilled Tall Oil (9%)

Organic Blend (9%)

Waste-derived oils

WEO Bottoms (18%)

WEO (18%)

Engineered Products

WEO+FT Wax (18%)

Traditional and Non-Traditional

Refinery Base Oil

Paraffinic Base Oil (18%)

Aromatic Extract (18%)

Naphthenic Flux Oil (18%)

1

2

3

4

5

6 7

8

9

Mixing Time : 40 minutes.Mixing Temp. 135˚C

2424

Bitumen Test Results

Rejuvenator Kinematic Viscosity @135˚C (mm2/s)

Extracted RAP binder 2054

Virgin Nutsar PG 64-22 474

Organic Blend 831

Refined Tallow 612

Paraffin Base Oil 379

Aromatic Extract 406

Naphthenic Flux Oil 699

WEO+FT wax 1006

WEO bottoms 2054

WEO 457

Distilled Tall Oil 893

2525

Rejuvenator dosages selection

2626

Conclusion

S. No. Rejuvenator Type Rejuvenator Percentage (%)

Low Temperature

Properties

1 Distilled Tall Oil 12.7 ✓

2 WEO 18.2 ×

3 WEO bottoms >20 ×

4 WEO + FT wax >20 ×

5 Naphthenic Flux Oil >20 ✓

6 Aromatic Extract 18.3 ✓

7 Paraffin Base Oil 18.3 ×

8 Refined Tallow 9.7 ✓

9 Organic Blend 11.2 ✓

1985-2006: Standard Practices (RAP)

• SuperPave Mix Design specification

reduced the usages of RAP due to

confounding impression of RAP material in

contractors mind.

• NCHRP 09-12 project includes the

performance of RAP by Superpave design

mixture criteria.

2828

RAP-HMA Production

Source: http://www.morerap.us/files/rap-summit-10-08/brock-maximizing-rap-use.pdf

2006- 2015: A Revival

• Petroleum price raised during Great Recession

in late 2008.

• FHWA established RAP Expert Task Group.

RAP- ETG

State DOTs1 FHWA2 AASHTO3 NAPA4 NCAT5

Brief Findings of Expert Group

• NCHRP 09-46 reported that asphalt mix upto50% RAP performed well w.r.t. climateconditions and traffic loading conditions.

• 30% RAP incorporated surface courseperformed equivalent to virgin mixture.

• Results from NCAT pavement Test Trackindicates improved performance in terms ofraveling and cracking by using softer gradeof bitumen.

2015- 2018: Balance Mix Design Method

Thermal Cracking

Softener

Thermal Cracking

Softener

Rutting Resistance

Softener

Balance Design

2015- 2018: Balance Mix Design Method

Adaptation of HMA recycling Technology in various

countries

Production of HMA and WMA in 2007–2012

Usages of RAP in intermediate layers: USA states

Usages of RAP in surface layers: USA states

• FHWA promotes recycling through “FHWA Recycled Materials Policy” Administrator Message by Frederick G. Wright, Jr., Executive Director, FHWA.

• According to NAPA, by 2007, average RAP usages was 12%.

• By 2009, increased to 16.2%.• By 2012, increased to 20%.• Current guidelines for using RAP in Superpave mixes

were based on NCHRP Report 452.• For high RAP incorporation guidelines, NCHRP 09-46

Report can be referred.

RAP: USA

Recommended process for sampling and testing RAP samples

Ignition Method

Solvent Extraction Method

JMF for RAP

MDOT RAP Spec 12SP501 (G) 20112011 to Present (Superpave)

• Tier 1 - 0% to 17% RAP (binder replacement)– Use same grade (design binder grade)

• Tier 2 - 18% to 27% RAP (binder replacement)– At least one grade lower for the low temperature

– Optional- lowering the high temperature one grade

• Tier 3 - 28% RAP (binder replacement)– Use a blending chart to determine the high and

low temperature values

Source: https://www.fhwa.dot.gov/pavement/recycling/98042/07.cfm

Binder Selection Guidelines for RAP Mixtures According to AASHTO M 323

Sr. No. Amount of RAP Recommendation

1 <15% No change in binder selection.

2 15% to 25% Select virgin binder one grade softer than normal

(e.g., select a PG 58-28 if PG 64-22 would

normally be used)

3 >25% Refer blending chart provided in ASTM D4887,

2016.

Adaptation of HMA Recycling in India

• In India the first reclaimed asphalt pavement was constructed in 1948 which serves uninterrupted for 30 years.

• Recycling of Asphalt Pavement is the leading research in India right now in pavement sector.

• IRC : 37- 2012 guidelines on Cold Recycling of RAP material are based on South African Bitumen and Tar association (SABITA) and Asphalt Mix Manual (MS-14) by Asphalt Institute, USA.

• There is a need to formulate Mix Design Guidelines for Hot Mix Asphalt (HMA) and Cold Mix Asphalt (CMA) of RAP material for Indigenous conditions.

Selection of virgin grade of bitumen for recycling purpose (India)

Sr. No. Amount of RAP Recommendation

1 <20% Same as specified in IRC 111, 2009.

2 21% to 30% One grade softer than as specified in IRC 111,

2009.

3 >30% Refer blending chart provided in ASTM D4887,

2016.

Source : Draft prepared for Indian Roads Congress, 26 February 2013. “Tentative Guidelines for Hot Recycled Plant-mixed Dense Graded Bituminous Mixes”

Indian Technical Circulars

• Two technical circulars :1. 48/2010 "Use of Reclaimed existing bituminous

material to upgrade an existing bituminous pavement in NHAI project" dated 24-02-2010 (NHAI, 2010) and,

2. 100/2012: "Use of Reclaimed Asphalt Pavement (RAP) Materials" dated 04-05-2012 (NHAI, 2012)

• These have been issued to contractors by National Highway Authority of India (NHAI) for using RAP material in Surface or base/ binder course of main road or service road. Comptroller and Auditor General (C&AG) of NHAI demands consolidated details of RAP material at NHAI in a table given below:

Indian Technical Circulars

• Two technical circulars :1. 48/2010 "Use of Reclaimed existing bituminous

material to upgrade an existing bituminous pavement in NHAI project" dated 24-02-2010 (NHAI, 2010) and,

2. 100/2012: "Use of Reclaimed Asphalt Pavement (RAP) Materials" dated 04-05-2012 (NHAI, 2012)

• These have been issued to contractors by National Highway Authority of India (NHAI) for using RAP material in Surface or base/ binder course of main road or service road. Comptroller and Auditor General (C&AG) of NHAI demands consolidated details of RAP material at NHAI in a table given below:

Name of

State

Name of

PIU

Name of

Stretch

Length

(km)

Status of

use of

RAP (if

used)

Reason

for not

using RAP

Conclusions

• Cracking resistance lowers by increasing RAPcontent, but not universally true.

• Softer Grade Bitumen or Rejuvenators,improved Cracking Resistance.

• Moisture Susceptibility is not generallyaffected by RAP content.

• Lower levels of binder replacement, bindergrading remain same as of virgin binder.

Conclusions

• Higher levels of binder replacement,combined binder grading increases both thehigh and low temperature grades.

• Stiffness of mixture increased with binderreplacement.

• Rutting Resistance improved at all binderreplacement levels.

References

• An Overview of Recycling and Reclamation Methods for Asphalt Pavement Rehablitation. (1992). Annapolis, MD.

• Kandhal, P. S. (2016). BITUMINOUS ROAD CONSTRUCTION IN INDIA (2016th ed.). PHI Learning. Retrieved from https://www.phindia.com/Books/BookDetail/OTc4LTgxLTIwMy01MjU4LTI

• David E. Newcomb, J. A. E. F. Z. (2016). Use of RAP & RAS in High Binder Replacement Asphalt Mixtures : A Synthesis. Retrieved from http://driveasphalt.org/assets/content/resources/SR213_-_RAP-RAS_Synthesis-lr.pdf

• Wright, F. G. (2015). Administrator’s Message “FHWA Recycled Materials Policy”. Retrieved December 15, 2018, from https://www.fhwa.dot.gov/legsregs/directives/policy/recmatpolicy.htm

• Willis, J. R., & Marasteanu, M. (2013). Improved Mix Design, Evaluation, and Materials Management Practices for Hot Mix Asphalt with High Reclaimed Asphalt Pavement Content. WASHINGTON, D.C. https://doi.org/10.17226/22554

• E-C 188, T. R. C. (2014). Application of Reclaimed Asphalt Pavement and Recycled Asphalt Shingles in Hot-Mix Asphalt: National and International Perspectives on Current Practices. In Transportation Research Circular E-C188 (p. 78). Transportation Research Board. Retrieved from http://onlinepubs.trb.org/onlinepubs/circulars/ec188.pdf

Thank You ☺

The science of recycled materials for road work is still relatively new. As the technology

continues to be improved, the use of RAP will become even more widespread, and the

environmental benefits will climb.