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ERA-NET ROAD RECYPMA possibilities for high quality RECY cling of P olymer M odified A sphalt

ERA-NET ROAD RECYPMA possibilities for high quality RECY cling of P olymer M odified A sphalt. Final Results. Possibilities for high quality recycling of polymer modified asphalt. Project results. This project/programme was initiated by ERA-NET ROAD,

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ERA-NET ROAD RECYPMA possibilities for high quality RECY cling of P olymer M odified A sphalt

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  1. ERA-NET ROADRECYPMApossibilities for high quality RECYcling of Polymer Modified Asphalt Final Results

  2. Possibilities for high quality recycling of polymer modified asphalt Project results This project/programme was initiated by ERA-NET ROAD, a project funded by the European Commission 30.09.2013

  3. Project partners 30.09.2013 • Project partners: • TNO (project coordinator) – Greet Leegwater • Danish Road Directorate, DRD – Erik Nielsen • Delft University of Technology, TU Delft – Gang Liu • University of Zilina, UNIZA – Jozef Komačka • Project is part of the program “ENR2 Design: Rapid and Durable Maintenance Methods and Techniques”.

  4. Outline 30.09.2013 • Goal • State of the Art • Materials • Laboratory investigation on binders • Laboratory investigation of asphalt mixes • Microscopy analyses • Environmental and economic benefits • Conclusions and recommendations

  5. Background 30.09.2013 PMB have been used in the past decades for premium pavements; RA containing PMB and premium aggregates are now harvested from roads; Recycling at the highest practical potential is aimed for to prevent down cycling.

  6. Project Goal 30.09.2013 • Investigate the possibilities for recycling polymer modified asphalt from surface layers into new high quality surface layers using hot mix recycling. • Technical possibilities; • Benefits; • Challenges for full scale application.

  7. State of the Art 30.09.2013 • Three objectives of literature research • Experience with RA containing PMB in full scale production; • Extraction method for PMB; • Method for laboratory mixing.

  8. Practical experience RA containing PMB 30.09.2013 • Well documented experience is limited, only challenges can be described; • Quality assessment before harvesting; • Binder: content, modification type and level, aging level, etc. • Aggregate gradation and quality, pollution with dust etc. • Handling in plant • Heating requirements (e.g. double drum); • Stickiness of the RA in storage and transportation.

  9. Binder extraction method 30.09.2013 • Literature review • Questionnaire to leading laboratories and research institutions in Europe. Resulted in the following extraction method: • EN 12697-1 and -3; • Solvent used dichloromethane (methylene chloride).

  10. Mixing procedure 30.09.2013 Based on literature review and questionnaires: • Mix dry virgin aggregates 30 s. • Add reclaimed asphalt and mix 30 s. • Add new binder and special fillers and mix for 90 s. • If necessary prolong the last period to achieve full coverage of the aggregates.

  11. Materials used in laboratory 30.09.2013 • Three types of RA harvested from three countries; • Stone Mastic Asphalt (SMA11) in Denmark, 22 years old • Porous Asphalt (PA4/8) in the Netherlands, 7 years old. • Asphalt concrete (AC11) in Slovakia, 15 years old. All mixtures contained an SBS polymer modified bituminous binder.

  12. Materials used in laboratory 30.09.2013 Binders • Binders from RA are extracted and combined with virgin binders in 15 and 40% ratio’s. • Virgin binders two different types: pengrade (PGB) and polymer modified binder (PMB).

  13. Materials used in laboratory 30.09.2013 Three asphalt mixes are created in 5 varieties. A PGB with 15% RA would not result in enough polymer to create a network.

  14. Binder properties 30.09.2013 The testing program for the recovered and blended binders: • Penetration, Softening Point • DSR master curves • Viscosity measurements • FTIR (functional chemical groups) • GPC (molecular size analyses)

  15. Binder properties 30.09.2013 Master curves material from Denmark With PGB With PMB

  16. Binder properties 30.09.2013 Conclusions binder research • Polymer behaviour is visible in old binders; • Blended polymer modified binders can behave similar to virgin polymer modified binders; • Models predict the behaviour of blended binders based on constituents (e.g. LogPen.); • High mixing temperatures are required.

  17. Performance of asphalt mixes 30.09.2013 The testing program for the mixtures: • Water sensitivity test; • Wheel tracking test; • Stiffness test; • Fatigue test.

  18. Water sensitivity 30.09.2013 High ITSR values, water sensitivity meets requirements for surface layers. Correlation between Pen values of blended binders and ITS values of mixes, except PA.

  19. Rutting resistance 30.09.2013 The wheel tracking test: • No rutting for all asphalt with PMB, mixtures with PMB showed a similar performance with or without RA. • Mixtures with PGB showed rutting, addition of RA resulted in less rutting. • Effect of PMB in RA, or aged binder in RA

  20. Stiffness test 30.09.2013 Mixtures with RA containing PMB have a higher stiffness compared to the mixtures without RA. • Positive: More bearing capacity • Negative: A higher risk of low temperature cracking

  21. Fatigue test 30.09.2013 • Fatigue test only performed on AC11 • Mixture with virgin PMB and no RA was most fatigue resistant, addition of RA lead to a reduced performance. • Addition of RA to PGB mixture improved fatigue resistance.

  22. Performance of asphalt mixes 30.09.2013 Conclusions asphalt mixture research: Based on limited test results on mixtures it is assumed that up till 40% high quality RA from old surface layers in new surface layers will result in comparable asphalt performance. Future research is needed for validation of this assumption.

  23. Microscopy analyses Details from micrograph of AC 11 with PMB and 40 % RA (Figure represents 0.80 x 1.06 mm) 30.09.2013 • Thin sections showed polymer presence in all RA types. • Some inhomogeneity's are observed in asphalt mixtures containing RA.

  24. Environmental and economic benefits 30.09.2013 • Environmental analyses based on LCA • Cost analyses is base on Life Cycle Cost analyses, that account for service life. • Functional unit • 3.5 m wide asphalt surface high trafficked road • 1 km long • 50 years • Data on costs and hauling distances obtained from suppliers and contractors.

  25. Environmental benefits 30.09.2013 Recycling reduces environmental impact, if calculated with ReCIPe: • 15 % recycled material reduces the loading by around 10 %; • 40 % recycled material in the mix reduces the loading by approximately 25-30 %. PMB increasesthe environmental impact per kg binder, asitisassumedthat PMB increasesservicelifebothfactorsbalanceeachother out.

  26. Environmental benefits 30.09.2013 The binder determines 40-55 % of the environmental impact.

  27. Environmental benefits 30.09.2013 Different European LCA methods show a different view on the negative impact of binders, therefore the used method can influence the ranking of the different scenario’s.

  28. Economic benefits 30.09.2013 Recycling reduces costs • 40 % recycled material in the mix reduces the (LCC) of polymer modified asphalts by approximately 10-18 %. • Again the binder is a dominant factor, it determines 70% of the material costs

  29. Conclusions 30.09.2013 There are technical possibilities for recycling of surface layers into surface layers. • The binder in RA still contains an active part of polymer. • Mixture performance shows that a good performance in surface layers can be realized with respect to water sensitivity, stiffness and rutting resistance. Economic and ecological benefits are significant.

  30. Recommendations 30.09.2013 Large scale application requires; • Service life quantified in more detail when using RA; • Dealing with practical issues related to full scale application; • Quality assessment and assurance of the RA. All issues could be addressed during pilot studies in real roads across Europe.

  31. Thank your for your attention 30.09.2013

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