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HIGH RAP MIXTURES

HIGH RAP MIXTURES. Properties of Plant Mixes Containing High Asphalt Binder Replacement. Gerry Huber. Heritage Research Group. Objective. How much RAP can be used? Considerations Quality product Mixing plant Placement Compaction. Is RAP Available?. Scope.

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HIGH RAP MIXTURES

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  1. HIGH RAP MIXTURES Properties of Plant Mixes Containing High Asphalt Binder Replacement Gerry Huber Heritage Research Group

  2. Objective • How much RAP can be used? • Considerations • Quality product • Mixing plant • Placement • Compaction

  3. Is RAP Available?

  4. Scope • How much RAP can go through a plant? • Trials up to 70% • Produce and Place on Low Volume Road • Measure quality • Measure properties

  5. RAP Coarse RAP Fine RAP Shingles Asphalt Binder Replacement

  6. Typical Asphalt Binder Content • RAP 4 – 5% • Fine RAP 5 – 7% • Coarse RAP 2 – 3% • Manufacturer Scrap 18 – 22% • Post Consumer 22 – 25%

  7. Experiment • Field Experiment • Focus on High Binder Replacement • RAP • Post Consumer Asphalt Shingles

  8. RAP 50% 60% 70% Post Consumer Shingles 0% 3% Counter flow drum mix plant Embedded burner RAP inlet capacity Mixing chamber volume Water injection Mixing aid Phase One

  9. Phase One Mixes

  10. Discharge Temperature

  11. Aggregate Temperature

  12. Drum Temperature

  13. 60% RAP

  14. 70% RAP

  15. Decisions from Phase One • Maximum 50% RAP • Drum Shell Temperature • max 800 F • Aggregate Temperature • max 700 F • Exhaust Temperature • min 220 F • max 390 F

  16. Phase Two Experiment • Counterflow drum mix plant • With mixing drum • 19 mm NMPS • 1.0 in crushed gravel • ½ in crushed limestone • ½ in pea gravel • Natural sand

  17. Counter Flow Drum RAP Feeder Mixer Drum

  18. 1.0 inch Crushed Gravel

  19. ½ inch Crushed Limestone

  20. ½ inch Pea Gravel

  21. Natural Sand

  22. Phase Two Recycled Materials • Fine RAP • Coarse RAP • Post Consumer Shingles

  23. Post Consumer Shingles

  24. Post Consumer Shingles

  25. Coarse RAP (½ to 1 inch)

  26. Coarse RAP (½ to 1 inch)

  27. Fine RAP (minus ½ inch)

  28. Fine RAP (minus ½ inch)

  29. Recycled Components

  30. Asphalt Binder Replacement

  31. Discharge Temperature

  32. Aggregate Temperature

  33. Volumetric Properties

  34. Asphalt Binder Grade

  35. Blending Analysis • M323 to calculatethe limiting amount • Predicted Temperature of Blend

  36. Blending Analysis • For multiple recycled materials

  37. Calculated vs Measured

  38. Cantabro Loss Test (Durability) • LA Abrasion Test Machine • Test withoutSteel Balls

  39. Cantabro Test (Durability)

  40. Placement • County Road resurfacing • 50 mm base • 19.0-mm mix • 38 mm surface • Placed • May 31, 2011 • June 1, 2011

  41. Haul time 30 minutes approx Weather 85F sunny Paver Roadtec RP150 50 to 60 ft/min Compactor Bomag BW266 3 vibratory passes, 1 static Construction Conditions

  42. Existing Condition

  43. Laydown Operation

  44. Uncompacted Mat

  45. Compaction

  46. Compacted Mat

  47. Paving Crew Observations • Flows through paver • Mat lays well • (little handwork in this application) • Compacts well • No tenderness

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