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Recent Research on Use of RAP in HMA and RHMA
John Harvey
University of California Pavement Research Center
California Asphalt Pavement Association
Spring Asphalt Pavement Conference
8 March 2024
Ontario
Why Use RAP in HMA and RHMA?
• Cost Effectiveness: can reduce cost for material
producer and buyer
• Virgin binder costs a lot more than binder in RAP
• Environmental Benefits: can reduce global warming
potential and other environmental impacts
• Depending on transport, processing and use of recycling
agents
• Finite Resource Conservation: reduces use of finite
aggregate sources
As long as get same or better performance
• Rutting
• Not too soft in first 5 years
• Age-related (block) cracking
• Not too stiff and unable to relax thermal
contraction strains at intermediate
temperatures after aging
• Fatigue
• Desirable properties depend on
structural design and where used in
structure
• Low temperature cracking
• Same as age-related but at extreme low
temperatures
• Moisture damage
• Dependent on binder and aggregate
chemistry, water permeability
(compaction)
• All are critical in surface lift except
fatigue and moisture damage
• Fatigue involves whole structure
• Moisture damage happens anywhere
• All except fatigue are mix
performance only, fatigue involves
structure design
• Interaction of stiffness (controlling
bending strain) and fatigue (at a given
strain)
• Includes reflective cracking when asphalt
placed over cracked asphalt, concrete or
cemented base
Why performance determines whether RAP use
beneficial or not: simple example
Analysis period = 60 yrs
Material A Material B
0.85 GWP or $ 1.0 GWP or $
15 year life 20 year life
15 20
30 40
45
Total GWP or $ Total GWP or $
3.4 3.0
Overview of Caltrans/UCPRC High RAP Studies
• High RAP Laboratory Factorial Study, lab mixes
• One gradation and aggregate source
• Two RAP sources
• Two binders, PG64 and PG58, different crude sources
• 0, 25 and 50% RAP binder replacement
• Three rejuvenating agents
• High RAP and RAS pilot projects, plant mixes
• Four pilot projects built, three with testing completed, more coming
• 0, 25 to 40% RAP, 10 or 15% RAP+3% RAS combinations
• Mix designs to meet same binder and mix property as control 0% RAP mix
• JMF and QA sample testing
Overview of Caltrans/CalRecycle/UCPRC RAP in RHMA Studies
• RAP in RHMA and RHMA Thickness Heavy Vehicle
Simulator/Lab/CalME Simulation Study, plant mixes
• Two gradations
• 0 and 10% coarse RAP
• Two thicknesses for each gradation: 0.2 ft and 0.4 or 0.5 ft
• Additional lab mix testing of mixes with two other AR binders, open graded
lab mixes
• CalME simulations of all variables: gradation, RAP, binder source, RAP source,
thickness
• RAP in RHMA-G, plant mixes
• Five pilots built and tested
• 0 and 10% RAP
• Testing during QA
Performance related binder
tests used in studies
• PG characterization of virgin and extracted
RAP and RAS binders (AASHTO R28, T313)
• PG characterization of extracted blended
virgin/RAP/RAS/RA binders
• Frequency sweeps to determine stiffness
master curves and Black space diagrams
• Glover-Rowe aging related cracking testing
• Delta Tc analysis (AASHTO R29)
• Fourier transform infrared (FTIR)
spectroscopy tests to track changes in binder
chemistry with aging
1E-01
1E+00
1E+01
1E+02
1E+03
1E+04
1E-04 1E-02 1E+00 1E+02 1E+04
Complex
Shear
Modulus
(kPa)
Reduced Frequency (Hz)
Master Curve Low Temperature
Intermediate Temperature High Temperature
0
0.1
0.2
0.3
0.4
0.5
0.6
800
1,000
1,200
1,400
1,600
1,800
2,000
Normalized
Absorbance
Units
Wavenumber (cm-1)
Carbonyl
Performance related mix
tests used in studies
• Dynamic modulus (AASHTO T 378; specimens
prepared in a gyratory compactor)
• Flexural modulus (AASHTO T 321; specimens
prepared using a rolling wheel compactor)
• Repeated load triaxial (RLT, flow number, AASHTO
T 378; specimens prepared in a gyratory
compactor)
• Beam fatigue (AASHTO T 321; specimens
prepared using a rolling wheel compactor)
• IDEAL-CT indirect tensile strength test (IDEAL-CT,
ASTM D 8225, specimens prepared in a gyratory
compactor)
• Used on early projects: I-FIT (AASHTO T393,
specimens prepared in a gyratory compactor)
• Used on recent projects: Caltrans draft protocol
for medium term oven aging (MTOA) 0
2
4
6
8
10
12
14
16
18
20
0 5 10 15
Load
(kN)
Displacement (mm)
P100
P85 =85%P100
P75 =75%P100
P65 =65%P100
L85
L75
L65
High RAP Laboratory Study
• Background at conception of study in 2019
• Little known about RAP/RAS impact on mechanical properties of HMA
• Little known about recycling agent impact on mechanical properties of HMA
• What is the best approach to dose recycling agent?
• Goal
• Study how the mechanical properties of the HMA change upon the addition
of high contents of RAP and RAS (between 25 and 50% binder replacement)
and how the RAP effects (e.g. decrease in cracking resistance) can be offset by
using recycling agents
Original slides prepared by Angel Mateos
Recycling Agent Dose Determination
• Match high PG of the Control mix virgin
binder (Target PGH = 67.5°C)
Mix with 25% RAP A
PG 64-16
virgin
RAP A
Example...
25%
75%
PGH = 74.8°C
PGH = 66.8°C
PG 64-16
virgin
RAP A
19.0%
75%
Aromatic
6.0%
PG 64-16
virgin
RAP A
21.8%
75%
Tall oil
3.2%
PG 58-28
virgin
RAP A
21.0%
75%
Aromatic
4.0%
PG 58-28
virgin
RAP A
22.5%
75%
Tall oil
2.5%
PGH = 67.5°C
PGH = 68.3°C
PGH = 67.7°C
What are the effects of the addition of high RAP content on the mechanical properties of the
HMA? Property What we were expecting What we measured
Stiffness
Increase in stiffness, particularity at
high temperatures
As expected
1 000
10 000
100 000
1 000 000
10 000 000
1.E-05 1.E-03 1.E-01 1.E+01 1.E+03 1.E+05
Axial
dynamic
modulus
(psi)
Reduced frequency (Hz)
100% PG64, 0% RAP, 0% Rej
75% PG64, 25% RPG102, 0% Rej
75% PG64, 25% RPG109, 0% Rej
What are the effects of the addition of high RAP content on the mechanical properties of the
HMA? Property What we were expecting What we measured
Stiffness
Increase in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Decrease Opposite!!!
1 000
10 000
100 000
1 000 000
10 000 000
100 1000
Fatigue
life
Peak-to-peak strain (με)
100% PG64, 0% RAP, 0% Rej
75% PG64, 25% RPG102, 0% Rej
What are the effects of the addition of high RAP content on the mechanical properties of the
HMA? Property What we were expecting What we measured
Stiffness
Increase in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Decrease Opposite!!!
1 000
10 000
100 000
1 000 000
10 000 000
100 1000
Fatigue
life
Peak-to-peak strain (με)
100% PG64, 0% RAP, 0% Rej
PG64-16 w/RAP10% (ELD-49)
PG64-16 w/RAP0% (ELD-49)
PG64-16 w/RAP18% (SAC-49)
PG64-16 w/RAP25% (SAC-49)
PG64-16 w/RAP15% (GLEN-5)
PG64-16 w/RAP15% (NAPA-29)
Statewide Median
- The Control mix 4PB fatigue
performance is very low
compared to other Caltrans
mixes with PG64 from other
sources
- Increasing RAP binder %
without RA increases fatigue
performance
What are the effects of the addition of high RAP content on the mechanical properties of the
HMA? Property What we were expecting What we measured
Stiffness
Increase in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Decrease Opposite!!!
Rutting resistance Improve As expected
Ideal Results Strength increase & IdealCT decrease As expected
0
5
10
15
20
25
30
0.0 2.0 4.0 6.0 8.0 10.0 12.0
Load
(kN)
Displacement (mm)
100% PG64, 0% RAP, 0% Rej
75% PG64, 25% RPG102, 0% Rej
75% PG64, 25% RPG109, 0% Rej
IdealCT = 79
IdealCT = 68
IdealCT = 20
Can the RAP addition effects be predicted based on testing of the blended binder?
✓ Overall, the effect on rutting resistance and mix stiffness can be predicted... and
indirectly Ideal ITS (ITS strongly corelated to mix stiffness)
✓ Nonetheless, the effect on fatigue resistance and IdealCT cannot be predicted
0
2 000 000
4 000 000
-40 -35 -30 -25 -20 -15 -10 -5 0
Axial
dynamic
modulus
@
68°F
(20°C)
&
10+4
Hz
(psi)
PG low of binder blend (°C)
100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej
100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 25% RPG109, 0% Rej
0
50
100
150
200
250
300
0 10 20 30 40
Ideal
strength
(psi)
PG intermediate (°C)
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40
IdealCT
PG intermediate (°C)
0
50
100
150
200
250
0 10 20 30 40
4PB
ε6
PG intermediate (°C)
What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP
content?
Property What we were expecting What we measured
Stiffness
Decrease in stiffness, particularity at
high temperatures
As expected
1 000
10 000
100 000
1 000 000
10 000 000
1.E-05 1.E-03 1.E-01 1.E+01 1.E+03 1.E+05
Axial
dynamic
modulus
(psi)
Reduced frequency (Hz)
100% PG64, 0% RAP, 0% Rej
75% PG64, 25% RPG102, 0% Rej
75% PG64, 19% RPG102, 6% Aromatic
75% PG64, 21.8% RPG102, 3.2% TallOil
By using recycling agent, can the mechanical properties of the HMA with high RAP
content be restored back to the properties of the HMA with low RAP content?
Property Can be restored?
Stiffness Yes
Fatigue resistance
???
• No improvement for PG64-16
• Yes for PG58-28
Rutting resistance
No need to restore; need to check RA does
not produce rutting problems
Ideal Results
Overall yes, with exceptions (IdealCT for
PG58-28)
• Overall Yes, with some caveats
What is the recommended approach to determine recycling agent dose?
Initial considerations: What is the goal of adding the recycling agent?
✓Restore the mechanical properties of the mix
with high RAP/RAS content back to the
properties of the control mix with either no
RAP/RAS or low/standard RAP/RAS content
✓Optimizing mix properties for different
applications (thin surface, thick overlay, etc)
within the balanced mix design framework
Approach 1
Approach 2
What is the recommended approach to determine recycling agent dose?
Initial considerations: Recycling agent dose Overshooting
• A common approach to determine recycling agent dose: restore PGH of the base binder
What do we mean by “Overshooting”?
-15
-10
-5
0
5
10
15
20
PGH PGI PGL
PG
verus
PG
of
base
binder
(PG
64-16)
100% PG64, 0% RAP, 0% Rej
50% PG64, 50% RPG102, 0% Rej
50% PG64, 41.9% RPG102, 8.1% TallOil
PG "compliant" zone
This should be
our target
The target should be
meeting PG
specifications:
• PGH ≥ Required PGH
• PGI ≤ Required PGI
• PGL ≤ Required PGL
• Not matching PGH of
base binder
Conclusions
• Most of the negative effects of RAP/RAS addition can be offset by using recycling
agents and/or step-down binder
• By using recycling agents and/or step-down binder, introducing high RAP/RAS content
(up to 50% binder replacement) in HMA while maintaining performance is doable
• Restoring the PGH of the binder blend may result in unnecessarily high recycling
agent dose that may hurt performance HMA with high RAP/RAS
• Out of the different parameters evaluated in this study, the PGI of the binder blend
and the ITS measured in the Ideal cracking test were found to relate to HMA stiffness
at intermediate temperature, which is related to 4PB fatigue life and structural
bending
• Two approaches for dosing the recycling agent have been proposed:
o Approach 1 focuses on restoring the stiffness of the HMA at intermediate
temperature
o Approach 2 focuses on meeting the BMD PRS by using the minimum amount of
recycling agent
High RAP and RAS pilot projects
• San Joaquin 26
(built Oct 2022):
• PG64-28M control
binder
• 0% RAP and RAS
• 15% RAP (mainline)
• 25% RAP+RA
• 30% RAP+RA
• 35% RAP+RA
• 40% RAP+RA
• 25% RAP+3%RAS+RA
• El Dorado 49
(built Nov 2021):
• PG64-16 control
binder
• 0% RAP and RAS
• 10% RAP (mainline)
• 3% RAS+RA
• 3% RAS+10% RAP+RA
• San Bernardino 215
(built Aug 2022):
• PG64-28M control
binder
• 0% RAP
• 23% RAP (mainline)
• 25% RAP+RA
• 30% RAP+RA
• 35% RAP+RA
• 40% RAP+RA
In process: Ventura 150 (built Sep 2023), Contra Costa 4 (to be built in 2024)
Plots prepared by Jeff Buscheck, Justin Chu, Angel Mateos, Heather Tom, Anai Ramirez-Cazares
JMF PG binder grade checks: SBD 215
JMF PG binder grade checks: SJ 26
QA IDEAL-CT: SJ 26
Flexural fatigue ElD 49
26
Medium
Term Oven
Aging
(MTOA)
compared to
reheating
effects on
Indirect
Tensile
Strength
(psi)
y = 0.791x + 13.024
R² = 0.5259
0
20
40
60
80
100
120
140
160
180
200
0 50 100 150 200
Box:
IdealCT
Index
(#)
Bucket: IdealCT Index (#)
y = -35.56ln(x) + 261.34
R² = 0.5237
0.0
50.0
100.0
150.0
200.0
250.0
300.0
0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
Indirect
Tensile
Strength
(psi)
IdealCT Index (#)
SJ 26 Buckets
SJ 26 Boxes
SJ 26 MTOA
SBd 215 Buckets
SBd 215 Boxes
SBd 215 MTOA
JMF Trials
y = 0.4379x + 11.758
R² = 0.5325
0
20
40
60
80
100
120
140
160
180
200
0 50 100 150 200
MTOA:
IdealCT
Index
(#)
Reheated: IdealCT Index (#)
y = 1.0002x + 20.692
R² = 0.7106
0
50
100
150
200
250
300
0 50 100 150 200 250 300
MTOA:
Indirect
Tensile
Strnegth
(psi)
Reheated: Indirect Tensile Strength (psi)
Mix Aging
27
y = 0.791x + 13.024
R² = 0.5259
0
20
40
60
80
100
120
140
160
180
200
0 50 100 150 200
Box:
IdealCT
Index
(#)
Bucket: IdealCT Index (#)
y = -35.56ln(x) + 261.34
R² = 0.5237
0.0
50.0
100.0
150.0
200.0
250.0
300.0
0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0
Indirect
Tensile
Strength
(psi)
IdealCT Index (#)
SJ 26 Buckets
SJ 26 Boxes
SJ 26 MTOA
SBd 215 Buckets
SBd 215 Boxes
SBd 215 MTOA
JMF Trials
y = 0.4379x + 11.758
R² = 0.5325
0
20
40
60
80
100
120
140
160
180
200
0 20 40 60 80 100 120 140 160 180 200
MTOA:
IdealCT
Index
(#)
Reheated: IdealCT Index (#)
Mix Aging
Medium
Term Oven
Aging
(MTOA)
compared to
reheating
effects on
IDEAL-CT
index value
(CT #)
Preliminary Observations
• Different base binders and rejuvenating agents and different
base binders can be used to engineer mixes that have same or
better performance than control mixes with no RAP or RAS
• Mixes with up to 40% RAP
• Mixes with 3% RAS
• In many cases, the performance is better than the mainline
mixes meeting current specifications:
• <15% RAP
• <25% RAP and a stepped down PG binder
• Data from additional pilot projects and further analysis will be
used to arrive at preliminary recommendations
• Testing IDEAL-CT specimens after MTOA draft method for all
pilot projects
RAP in RHMA and RHMA Thickness Heavy Vehicle
Simulator/Lab/CalME Simulation Study
HVS Test Track, Four RHMA-G
Plant Mixes, 0.2’ and thicker
• ½” no RAP
• 0.2 and 0.4 ft thicknesses
• ½” with 10% RAP
• 0.2 ft thick
• 3/4” no RAP
• 0.2 ft thick
• 3/4” with 10% RAP
• 0.5 ft thick
• Additional Laboratory Mixes
with Plant Sampled Binders
• Same aggregates and ½ “
gradation
• Two plant sampled AR
binders:
• PG64 base from But-162
• PG70 base from Imp-186
• Two RAP sources
• Coarse RAP, less aged
• Fine RAP, more aged
HVS Track Experiment Design
Section RHMA-G Mix Thickness Purpose in the Experiment
(ft.) (mm)
704 1/2 in. NMAS, no RAP 0.2 60 Control for all 1/2 in. RHMA-G mixes
703 1/2 in. NMAS, no RAP 0.4 120 Compare two layers with single layer
701
1/2 in. NMAS with 10%
RAP, no binder
replacement
0.2 60
Compare mix with RAP to control mix for
same layer thickness
698 3/4 in. NMAS, no RAP 0.2 60
Control for all 3/4 in. RHMA-G mixes.
Compare 3/4 in. mix with 1/2 in. mix
700
3/4 in. NMAS with 10%
RAP, no binder
replacement
0.5 150
Compare two layers, both with RAP, to
two layers with no RAP
HVS and HWT Rut Testing Summary
HVS
• Four of the five sections had
similar trends
• Control section (1/2” no RAP)
had a faster rate of permanent
deformation
• Due to underlying base rutting
• RAP and NMAS did not appear
to have a significant effect,
with silo aging/stiffness
appearing to have a larger
influence
0.0
0.5
1.0
1.5
2.0
2.5
3.0
1/2in.; No RAP 1/2in.; With RAP 3/4in.; No RAP 3/4in.; With RAP
Rut
Depth
after
35k
Reps
(mm)
Mix
HWT
Silo Time and RAP Effects on Flexural Stiffness
• MixA (1/2", 0% RAP, 64-
16 AR), estimated silo
storage: 8 to 10 hours
• Other mixes, estimated
silo storage: 0 to 2 hours
• Axial modulus only
showed silo effect
High temp Low Temp
RAP Effects on Flexural Stiffness for Additional Binders
• Expected effects on
stiffness from including
RAP, and including more
aged fine RAP
• Mostly at intermediate
temperatures
• Generally mixed small
effects on fatigue for all
mixes
High temp Low Temp
Combined effects of 10% RAP in RHMA-G on stiffness
and fatigue life using CalME simulations
• Many questions addressed:
• Pavement fatigue and reflective cracking performance?
• Considering: inclusion of RAP, RHMA-G aggregate NMAS, softer coarse RAP
and stiffer fine RAP, different AR binders, RHMA-G thicknesses, full-depth
RHMA-G
• Analyzed for three types of structures with different thicknesses for
each:
• New Asphalt on asphalt overlays
• Asphalt on asphalt overlays
• Asphalt on concrete overlays
Selected CalME simulation conclusions
• For “thin” overlays (<= 0.25 ft thick) RHMA overlays on cracked asphalt pavement, the
results for 10% RAP vs no RAP depended on the base binder and RAP properties
• Silo aging can have a larger effect on RHMA simulated performance than 10% RAP
• For RHMA-G on HMA in “thick” total asphalt layers
• Adding 10% RAP and RAP from different sources had different effects on simulated
performance, depending on the asphalt rubber binder and its base binder, as well as
pavement structure type and RHMA thickness
• For full depth RHMA versus RHMA/HMA in an application of 0.5 ft of total new asphalt
• Full depth RHMA can be beneficial when the RHMA has good performance, and worse when
it doesn’t
• Adding RAP generally had a beneficial effect on using full depth RHMA compared with
RHMA with no RAP
10% RAP in RHMA-O: Cantabro loss
• RHMA-O lab mixes made with
But-162 and Imp-186 plant
sampled RA binders with 0 and
10% RAP
• Cantabro durability test results
showed no detrimental effect of
using 10% coarse RAP
IMP 86 PG70 RHMA-O
with no RAP mix before
and after Cantabro
RAP in RHMA-G Pilot Projects Comparing 0 and 10% RAP
Some Preliminary Conclusions and Recommendations
• High RAP HMA mixes up to 40 or 50% RAP
• Can be engineered to meet performance related specifications producing similar or
better performance for rutting, fatigue, stiffness, low temperature cracking
• Virgin binder source and grade, RAP mix binder and aggregates, and rejuvenating
agents are tools to engineer desired properties for different design scenarios (thin
overlay [PM], thick overlay, surface vs underlying lifts)
• Range of fatigue performance for a given stiffness controlled by virgin binder
source; IDEAL-CT and other fracture tests only correlate with stiffness not fatigue
• Need performance related specifications for mix design, including a fatigue test
• 10% RAP in RHMA-G and RHMA-O
• 10% RAP in RHMA-G will generally result in similar fatigue performance in surface
overlays, better or worse than no RAP depending on individual mix properties
• 10% coarse RAP in RHMA-O appears to not hurt Cantrabro (raveling) performance
• Use of RHMA-G in surfaces thicker than 0.2 ft
• Allow designers to consider RHMA-G layers up to 0.5 ft when using CalME
Reports
• High RAP laboratory study: report under Caltrans review
• RAP in RHMA and RHMA thickness HVS testing:
https://escholarship.org/uc/item/7wq3s753
• RAP in RHMA and RHMA thickness laboratory study and CalME
simulation study: report under Caltrans review
• High RAP and RAS pilot studies:
• El Dorado 49: https://escholarship.org/uc/item/8h67s9z0
• San Bernardino 215 and San Joaquin 26: reports being prepared
• Ventura 150: testing not yet completed
• RAP in RHMA five pilot studies: report under Caltrans review
• Environmental life cycle assessment (LCA) and life cycle cost analysis
in progress for all of above
Thanks to:
• UCPRC Asphalt Team
• UCPRC HVS Testing Team
• Caltrans Office of Asphalt
Pavement Technical Leads
• CalRecycle Technical Leads
• Caltrans Research
• Contractors on pilot projects
and test sections
www.ucprc.ucdavis.edu
Questions
What are the effects of the addition of high RAP content on the mechanical properties of the HMA?
Property What we were expecting What we measured
Stiffness
Increase in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Decrease Opposite!!!
Rutting resistance Improve As expected
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0 10 000 20 000 30 000 40 000
Rut
(in.)
Wheel passes
100% PG64, 0% RAP, 0% Rej
75% PG64, 25% RPG102, 0% Rej
75% PG64, 25% RPG109, 0% Rej
Hamburg Wheel Tracking Test
0
5 000
10 000
15 000
20 000
25 000
30 000
35 000
40 000
50 60 70 80
HWT
test:
Number
of
passes
to
0.5
in.
(12.5
mm)
PG high (°C)
Can the RAP addition effects be predicted based on testing of the blended binder?
✓ Overall, the effect on rutting resistance and mix stiffness can be precited... and
indirectly Ideal ITS (ITS strongly correlated to mix stiffness)
✓ Nonetheless, the effect on fatigue resistance and IdealCT could not be predicted
0
2 000 000
4 000 000
-40 -35 -30 -25 -20 -15 -10 -5 0
Axial
dynamic
modulus
@
68°F
(20°C)
&
10+4
Hz
(psi)
PG low of binder blend (°C)
100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej
100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 25% RPG109, 0% Rej
0
500 000
1 000 000
1 500 000
2 000 000
2 500 000
3 000 000
3 500 000
-40 -30 -20 -10 0
Axial
dynamic
modulus
@
68°F
(20°C)
&
10+4
Hz
(psi)
PG low (°C)
0
200 000
400 000
600 000
800 000
1 000 000
1 200 000
1 400 000
0 10 20 30 40
Axial
dynamic
modulus
@
68°F
(20°C)
&
1
Hz
(psi)
PG intermediate (°C)
0
5 000
10 000
15 000
20 000
25 000
30 000
50 60 70 80
Axial
dynamic
modulus
@
68°F
(20°C)
&
10-4
Hz
(psi)
PG high (°C)
Can the RAP addition effects be predicted based on testing of the blended binder?
✓ Overall, the effect on rutting resistance and mix stiffness can be precited... and
indirectly Ideal ITS (ITS strongly corelated to mix stiffness)
✓ Nonetheless, the effect on fatigue resistance and IdealCT cannot be predicted
0
2 000 000
4 000 000
-40 -35 -30 -25 -20 -15 -10 -5 0
Axial
dynamic
modulus
@
68°F
(20°C)
&
10+4
Hz
(psi)
PG low of binder blend (°C)
100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej
100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 25% RPG109, 0% Rej
High Temp
(rutting)
Intermediate Temp
(fatigue)
Low Temp
(fatigue and
thermal cracking)
What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content?
Property What we were expecting What we measured
Stiffness
Decrease in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Increase
No effect for PG64-16!!!
As expected for PG 58-28
0
50
100
150
200
250
300
350
400
100% PG64 75% PG64 75% PG64 75% PG64 100% PG58 75% PG58 75% PG58 75% PG58
0% RAP 25% RPG102 19% RPG102 21.8% RPG102 0% RAP 25% RPG102 21% RPG102 22.5% RPG102
0% Rej 0% Rej 6% Aromatic 3.2% TallOil 0% Rej 0% Rej 4% Aromatic 2.5% TallOil
0% BR 25% BR 25% BR w/Rej 0% BR 25% BR 25% BR w/Rej
PG64 PG58
4PB
ε
6
Not
Tested
in 4PB
What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content?
Property What we were expecting What we measured
Stiffness
Decrease in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Increase
No effect for PG64-16!!!
As expected for PG 58-28
Rutting resistance Decrease Not consistent
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0 10 000 20 000 30 000 40 000
Rut
(in.)
Wheel passes
100% PG64, 0% RAP, 0% Rej
75% PG64, 25% RPG102, 0% Rej
75% PG64, 19% RPG102, 6% Aromatic
75% PG64, 21.8% RPG102, 3.2% TallOil
In this case, the Aromatic improved rutting
resistance while Tall Oil did the opposite...
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 10 000 20 000 30 000 40 000
Rut
(in.)
Wheel passes
100% PG58, 0% RAP, 0% Rej
75% PG58, 25% RPG102, 0% Rej
75% PG58, 21% RPG102, 4% Aromatic
75% PG58, 22.5% RPG102, 2.5% TallOil
What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content?
Property What we were expecting What we measured
Stiffness
Decrease in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Increase
No effect for PG64-16!!!
As expected for PG 58-28
Rutting resistance Decrease Not consistent
In this case, the Tall Oil improved rutting
resistance while Aromatics did the opposite...
What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content?
Property What we were expecting What we measured
Stiffness
Decrease in stiffness, particularity at
high temperatures
As expected
Fatigue resistance Increase
No effect for PG64-16!!!
As expected for PG 58-28
Rutting resistance Decrease Not consistent
Ideal Results Strength decrease & IdealCT increase
As expected for strength
Not consistent for IdealCT
0
50
100
150
200
250
0
20
40
60
80
100
120
140
160
100% PG64 75% PG64 75% PG64 75% PG64 100% PG58 75% PG58 75% PG58 75% PG58
0% RAP 25% RPG102 19% RPG102 21.8%
RPG102
0% RAP 25% RPG102 21% RPG102 22.5%
RPG102
0% Rej 0% Rej 6% Aromatic 3.2% TallOil 0% Rej 0% Rej 4% Aromatic 2.5% TallOil
0% BR 25% BR 25% BR w/Rej 0% BR 25% BR 25% BR w/Rej
PG64 PG58
Strength
(psi)
IdealCT
RA did not improve
IdealCT of PG58
mixes
JMF PG binder grade checks: ElD 49
QA IDEAL-CT: ElD 49
QA IDEAL-CT: SBd 215

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Update on the latest research with regard to RAP

  • 1. Recent Research on Use of RAP in HMA and RHMA John Harvey University of California Pavement Research Center California Asphalt Pavement Association Spring Asphalt Pavement Conference 8 March 2024 Ontario
  • 2. Why Use RAP in HMA and RHMA? • Cost Effectiveness: can reduce cost for material producer and buyer • Virgin binder costs a lot more than binder in RAP • Environmental Benefits: can reduce global warming potential and other environmental impacts • Depending on transport, processing and use of recycling agents • Finite Resource Conservation: reduces use of finite aggregate sources
  • 3. As long as get same or better performance • Rutting • Not too soft in first 5 years • Age-related (block) cracking • Not too stiff and unable to relax thermal contraction strains at intermediate temperatures after aging • Fatigue • Desirable properties depend on structural design and where used in structure • Low temperature cracking • Same as age-related but at extreme low temperatures • Moisture damage • Dependent on binder and aggregate chemistry, water permeability (compaction) • All are critical in surface lift except fatigue and moisture damage • Fatigue involves whole structure • Moisture damage happens anywhere • All except fatigue are mix performance only, fatigue involves structure design • Interaction of stiffness (controlling bending strain) and fatigue (at a given strain) • Includes reflective cracking when asphalt placed over cracked asphalt, concrete or cemented base
  • 4. Why performance determines whether RAP use beneficial or not: simple example Analysis period = 60 yrs Material A Material B 0.85 GWP or $ 1.0 GWP or $ 15 year life 20 year life 15 20 30 40 45 Total GWP or $ Total GWP or $ 3.4 3.0
  • 5. Overview of Caltrans/UCPRC High RAP Studies • High RAP Laboratory Factorial Study, lab mixes • One gradation and aggregate source • Two RAP sources • Two binders, PG64 and PG58, different crude sources • 0, 25 and 50% RAP binder replacement • Three rejuvenating agents • High RAP and RAS pilot projects, plant mixes • Four pilot projects built, three with testing completed, more coming • 0, 25 to 40% RAP, 10 or 15% RAP+3% RAS combinations • Mix designs to meet same binder and mix property as control 0% RAP mix • JMF and QA sample testing
  • 6. Overview of Caltrans/CalRecycle/UCPRC RAP in RHMA Studies • RAP in RHMA and RHMA Thickness Heavy Vehicle Simulator/Lab/CalME Simulation Study, plant mixes • Two gradations • 0 and 10% coarse RAP • Two thicknesses for each gradation: 0.2 ft and 0.4 or 0.5 ft • Additional lab mix testing of mixes with two other AR binders, open graded lab mixes • CalME simulations of all variables: gradation, RAP, binder source, RAP source, thickness • RAP in RHMA-G, plant mixes • Five pilots built and tested • 0 and 10% RAP • Testing during QA
  • 7. Performance related binder tests used in studies • PG characterization of virgin and extracted RAP and RAS binders (AASHTO R28, T313) • PG characterization of extracted blended virgin/RAP/RAS/RA binders • Frequency sweeps to determine stiffness master curves and Black space diagrams • Glover-Rowe aging related cracking testing • Delta Tc analysis (AASHTO R29) • Fourier transform infrared (FTIR) spectroscopy tests to track changes in binder chemistry with aging 1E-01 1E+00 1E+01 1E+02 1E+03 1E+04 1E-04 1E-02 1E+00 1E+02 1E+04 Complex Shear Modulus (kPa) Reduced Frequency (Hz) Master Curve Low Temperature Intermediate Temperature High Temperature 0 0.1 0.2 0.3 0.4 0.5 0.6 800 1,000 1,200 1,400 1,600 1,800 2,000 Normalized Absorbance Units Wavenumber (cm-1) Carbonyl
  • 8. Performance related mix tests used in studies • Dynamic modulus (AASHTO T 378; specimens prepared in a gyratory compactor) • Flexural modulus (AASHTO T 321; specimens prepared using a rolling wheel compactor) • Repeated load triaxial (RLT, flow number, AASHTO T 378; specimens prepared in a gyratory compactor) • Beam fatigue (AASHTO T 321; specimens prepared using a rolling wheel compactor) • IDEAL-CT indirect tensile strength test (IDEAL-CT, ASTM D 8225, specimens prepared in a gyratory compactor) • Used on early projects: I-FIT (AASHTO T393, specimens prepared in a gyratory compactor) • Used on recent projects: Caltrans draft protocol for medium term oven aging (MTOA) 0 2 4 6 8 10 12 14 16 18 20 0 5 10 15 Load (kN) Displacement (mm) P100 P85 =85%P100 P75 =75%P100 P65 =65%P100 L85 L75 L65
  • 9. High RAP Laboratory Study • Background at conception of study in 2019 • Little known about RAP/RAS impact on mechanical properties of HMA • Little known about recycling agent impact on mechanical properties of HMA • What is the best approach to dose recycling agent? • Goal • Study how the mechanical properties of the HMA change upon the addition of high contents of RAP and RAS (between 25 and 50% binder replacement) and how the RAP effects (e.g. decrease in cracking resistance) can be offset by using recycling agents Original slides prepared by Angel Mateos
  • 10. Recycling Agent Dose Determination • Match high PG of the Control mix virgin binder (Target PGH = 67.5°C) Mix with 25% RAP A PG 64-16 virgin RAP A Example... 25% 75% PGH = 74.8°C PGH = 66.8°C PG 64-16 virgin RAP A 19.0% 75% Aromatic 6.0% PG 64-16 virgin RAP A 21.8% 75% Tall oil 3.2% PG 58-28 virgin RAP A 21.0% 75% Aromatic 4.0% PG 58-28 virgin RAP A 22.5% 75% Tall oil 2.5% PGH = 67.5°C PGH = 68.3°C PGH = 67.7°C
  • 11. What are the effects of the addition of high RAP content on the mechanical properties of the HMA? Property What we were expecting What we measured Stiffness Increase in stiffness, particularity at high temperatures As expected 1 000 10 000 100 000 1 000 000 10 000 000 1.E-05 1.E-03 1.E-01 1.E+01 1.E+03 1.E+05 Axial dynamic modulus (psi) Reduced frequency (Hz) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej
  • 12. What are the effects of the addition of high RAP content on the mechanical properties of the HMA? Property What we were expecting What we measured Stiffness Increase in stiffness, particularity at high temperatures As expected Fatigue resistance Decrease Opposite!!! 1 000 10 000 100 000 1 000 000 10 000 000 100 1000 Fatigue life Peak-to-peak strain (με) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej
  • 13. What are the effects of the addition of high RAP content on the mechanical properties of the HMA? Property What we were expecting What we measured Stiffness Increase in stiffness, particularity at high temperatures As expected Fatigue resistance Decrease Opposite!!! 1 000 10 000 100 000 1 000 000 10 000 000 100 1000 Fatigue life Peak-to-peak strain (με) 100% PG64, 0% RAP, 0% Rej PG64-16 w/RAP10% (ELD-49) PG64-16 w/RAP0% (ELD-49) PG64-16 w/RAP18% (SAC-49) PG64-16 w/RAP25% (SAC-49) PG64-16 w/RAP15% (GLEN-5) PG64-16 w/RAP15% (NAPA-29) Statewide Median - The Control mix 4PB fatigue performance is very low compared to other Caltrans mixes with PG64 from other sources - Increasing RAP binder % without RA increases fatigue performance
  • 14. What are the effects of the addition of high RAP content on the mechanical properties of the HMA? Property What we were expecting What we measured Stiffness Increase in stiffness, particularity at high temperatures As expected Fatigue resistance Decrease Opposite!!! Rutting resistance Improve As expected Ideal Results Strength increase & IdealCT decrease As expected 0 5 10 15 20 25 30 0.0 2.0 4.0 6.0 8.0 10.0 12.0 Load (kN) Displacement (mm) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej IdealCT = 79 IdealCT = 68 IdealCT = 20
  • 15. Can the RAP addition effects be predicted based on testing of the blended binder? ✓ Overall, the effect on rutting resistance and mix stiffness can be predicted... and indirectly Ideal ITS (ITS strongly corelated to mix stiffness) ✓ Nonetheless, the effect on fatigue resistance and IdealCT cannot be predicted 0 2 000 000 4 000 000 -40 -35 -30 -25 -20 -15 -10 -5 0 Axial dynamic modulus @ 68°F (20°C) & 10+4 Hz (psi) PG low of binder blend (°C) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej 100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 25% RPG109, 0% Rej 0 50 100 150 200 250 300 0 10 20 30 40 Ideal strength (psi) PG intermediate (°C) 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 IdealCT PG intermediate (°C) 0 50 100 150 200 250 0 10 20 30 40 4PB ε6 PG intermediate (°C)
  • 16. What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content? Property What we were expecting What we measured Stiffness Decrease in stiffness, particularity at high temperatures As expected 1 000 10 000 100 000 1 000 000 10 000 000 1.E-05 1.E-03 1.E-01 1.E+01 1.E+03 1.E+05 Axial dynamic modulus (psi) Reduced frequency (Hz) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 19% RPG102, 6% Aromatic 75% PG64, 21.8% RPG102, 3.2% TallOil
  • 17. By using recycling agent, can the mechanical properties of the HMA with high RAP content be restored back to the properties of the HMA with low RAP content? Property Can be restored? Stiffness Yes Fatigue resistance ??? • No improvement for PG64-16 • Yes for PG58-28 Rutting resistance No need to restore; need to check RA does not produce rutting problems Ideal Results Overall yes, with exceptions (IdealCT for PG58-28) • Overall Yes, with some caveats
  • 18. What is the recommended approach to determine recycling agent dose? Initial considerations: What is the goal of adding the recycling agent? ✓Restore the mechanical properties of the mix with high RAP/RAS content back to the properties of the control mix with either no RAP/RAS or low/standard RAP/RAS content ✓Optimizing mix properties for different applications (thin surface, thick overlay, etc) within the balanced mix design framework Approach 1 Approach 2
  • 19. What is the recommended approach to determine recycling agent dose? Initial considerations: Recycling agent dose Overshooting • A common approach to determine recycling agent dose: restore PGH of the base binder What do we mean by “Overshooting”? -15 -10 -5 0 5 10 15 20 PGH PGI PGL PG verus PG of base binder (PG 64-16) 100% PG64, 0% RAP, 0% Rej 50% PG64, 50% RPG102, 0% Rej 50% PG64, 41.9% RPG102, 8.1% TallOil PG "compliant" zone This should be our target The target should be meeting PG specifications: • PGH ≥ Required PGH • PGI ≤ Required PGI • PGL ≤ Required PGL • Not matching PGH of base binder
  • 20. Conclusions • Most of the negative effects of RAP/RAS addition can be offset by using recycling agents and/or step-down binder • By using recycling agents and/or step-down binder, introducing high RAP/RAS content (up to 50% binder replacement) in HMA while maintaining performance is doable • Restoring the PGH of the binder blend may result in unnecessarily high recycling agent dose that may hurt performance HMA with high RAP/RAS • Out of the different parameters evaluated in this study, the PGI of the binder blend and the ITS measured in the Ideal cracking test were found to relate to HMA stiffness at intermediate temperature, which is related to 4PB fatigue life and structural bending • Two approaches for dosing the recycling agent have been proposed: o Approach 1 focuses on restoring the stiffness of the HMA at intermediate temperature o Approach 2 focuses on meeting the BMD PRS by using the minimum amount of recycling agent
  • 21. High RAP and RAS pilot projects • San Joaquin 26 (built Oct 2022): • PG64-28M control binder • 0% RAP and RAS • 15% RAP (mainline) • 25% RAP+RA • 30% RAP+RA • 35% RAP+RA • 40% RAP+RA • 25% RAP+3%RAS+RA • El Dorado 49 (built Nov 2021): • PG64-16 control binder • 0% RAP and RAS • 10% RAP (mainline) • 3% RAS+RA • 3% RAS+10% RAP+RA • San Bernardino 215 (built Aug 2022): • PG64-28M control binder • 0% RAP • 23% RAP (mainline) • 25% RAP+RA • 30% RAP+RA • 35% RAP+RA • 40% RAP+RA In process: Ventura 150 (built Sep 2023), Contra Costa 4 (to be built in 2024) Plots prepared by Jeff Buscheck, Justin Chu, Angel Mateos, Heather Tom, Anai Ramirez-Cazares
  • 22. JMF PG binder grade checks: SBD 215
  • 23. JMF PG binder grade checks: SJ 26
  • 26. 26 Medium Term Oven Aging (MTOA) compared to reheating effects on Indirect Tensile Strength (psi) y = 0.791x + 13.024 R² = 0.5259 0 20 40 60 80 100 120 140 160 180 200 0 50 100 150 200 Box: IdealCT Index (#) Bucket: IdealCT Index (#) y = -35.56ln(x) + 261.34 R² = 0.5237 0.0 50.0 100.0 150.0 200.0 250.0 300.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 Indirect Tensile Strength (psi) IdealCT Index (#) SJ 26 Buckets SJ 26 Boxes SJ 26 MTOA SBd 215 Buckets SBd 215 Boxes SBd 215 MTOA JMF Trials y = 0.4379x + 11.758 R² = 0.5325 0 20 40 60 80 100 120 140 160 180 200 0 50 100 150 200 MTOA: IdealCT Index (#) Reheated: IdealCT Index (#) y = 1.0002x + 20.692 R² = 0.7106 0 50 100 150 200 250 300 0 50 100 150 200 250 300 MTOA: Indirect Tensile Strnegth (psi) Reheated: Indirect Tensile Strength (psi) Mix Aging
  • 27. 27 y = 0.791x + 13.024 R² = 0.5259 0 20 40 60 80 100 120 140 160 180 200 0 50 100 150 200 Box: IdealCT Index (#) Bucket: IdealCT Index (#) y = -35.56ln(x) + 261.34 R² = 0.5237 0.0 50.0 100.0 150.0 200.0 250.0 300.0 0.0 20.0 40.0 60.0 80.0 100.0 120.0 140.0 160.0 Indirect Tensile Strength (psi) IdealCT Index (#) SJ 26 Buckets SJ 26 Boxes SJ 26 MTOA SBd 215 Buckets SBd 215 Boxes SBd 215 MTOA JMF Trials y = 0.4379x + 11.758 R² = 0.5325 0 20 40 60 80 100 120 140 160 180 200 0 20 40 60 80 100 120 140 160 180 200 MTOA: IdealCT Index (#) Reheated: IdealCT Index (#) Mix Aging Medium Term Oven Aging (MTOA) compared to reheating effects on IDEAL-CT index value (CT #)
  • 28. Preliminary Observations • Different base binders and rejuvenating agents and different base binders can be used to engineer mixes that have same or better performance than control mixes with no RAP or RAS • Mixes with up to 40% RAP • Mixes with 3% RAS • In many cases, the performance is better than the mainline mixes meeting current specifications: • <15% RAP • <25% RAP and a stepped down PG binder • Data from additional pilot projects and further analysis will be used to arrive at preliminary recommendations • Testing IDEAL-CT specimens after MTOA draft method for all pilot projects
  • 29. RAP in RHMA and RHMA Thickness Heavy Vehicle Simulator/Lab/CalME Simulation Study HVS Test Track, Four RHMA-G Plant Mixes, 0.2’ and thicker • ½” no RAP • 0.2 and 0.4 ft thicknesses • ½” with 10% RAP • 0.2 ft thick • 3/4” no RAP • 0.2 ft thick • 3/4” with 10% RAP • 0.5 ft thick • Additional Laboratory Mixes with Plant Sampled Binders • Same aggregates and ½ “ gradation • Two plant sampled AR binders: • PG64 base from But-162 • PG70 base from Imp-186 • Two RAP sources • Coarse RAP, less aged • Fine RAP, more aged
  • 30. HVS Track Experiment Design Section RHMA-G Mix Thickness Purpose in the Experiment (ft.) (mm) 704 1/2 in. NMAS, no RAP 0.2 60 Control for all 1/2 in. RHMA-G mixes 703 1/2 in. NMAS, no RAP 0.4 120 Compare two layers with single layer 701 1/2 in. NMAS with 10% RAP, no binder replacement 0.2 60 Compare mix with RAP to control mix for same layer thickness 698 3/4 in. NMAS, no RAP 0.2 60 Control for all 3/4 in. RHMA-G mixes. Compare 3/4 in. mix with 1/2 in. mix 700 3/4 in. NMAS with 10% RAP, no binder replacement 0.5 150 Compare two layers, both with RAP, to two layers with no RAP
  • 31. HVS and HWT Rut Testing Summary HVS • Four of the five sections had similar trends • Control section (1/2” no RAP) had a faster rate of permanent deformation • Due to underlying base rutting • RAP and NMAS did not appear to have a significant effect, with silo aging/stiffness appearing to have a larger influence 0.0 0.5 1.0 1.5 2.0 2.5 3.0 1/2in.; No RAP 1/2in.; With RAP 3/4in.; No RAP 3/4in.; With RAP Rut Depth after 35k Reps (mm) Mix HWT
  • 32. Silo Time and RAP Effects on Flexural Stiffness • MixA (1/2", 0% RAP, 64- 16 AR), estimated silo storage: 8 to 10 hours • Other mixes, estimated silo storage: 0 to 2 hours • Axial modulus only showed silo effect High temp Low Temp
  • 33. RAP Effects on Flexural Stiffness for Additional Binders • Expected effects on stiffness from including RAP, and including more aged fine RAP • Mostly at intermediate temperatures • Generally mixed small effects on fatigue for all mixes High temp Low Temp
  • 34. Combined effects of 10% RAP in RHMA-G on stiffness and fatigue life using CalME simulations • Many questions addressed: • Pavement fatigue and reflective cracking performance? • Considering: inclusion of RAP, RHMA-G aggregate NMAS, softer coarse RAP and stiffer fine RAP, different AR binders, RHMA-G thicknesses, full-depth RHMA-G • Analyzed for three types of structures with different thicknesses for each: • New Asphalt on asphalt overlays • Asphalt on asphalt overlays • Asphalt on concrete overlays
  • 35. Selected CalME simulation conclusions • For “thin” overlays (<= 0.25 ft thick) RHMA overlays on cracked asphalt pavement, the results for 10% RAP vs no RAP depended on the base binder and RAP properties • Silo aging can have a larger effect on RHMA simulated performance than 10% RAP • For RHMA-G on HMA in “thick” total asphalt layers • Adding 10% RAP and RAP from different sources had different effects on simulated performance, depending on the asphalt rubber binder and its base binder, as well as pavement structure type and RHMA thickness • For full depth RHMA versus RHMA/HMA in an application of 0.5 ft of total new asphalt • Full depth RHMA can be beneficial when the RHMA has good performance, and worse when it doesn’t • Adding RAP generally had a beneficial effect on using full depth RHMA compared with RHMA with no RAP
  • 36. 10% RAP in RHMA-O: Cantabro loss • RHMA-O lab mixes made with But-162 and Imp-186 plant sampled RA binders with 0 and 10% RAP • Cantabro durability test results showed no detrimental effect of using 10% coarse RAP IMP 86 PG70 RHMA-O with no RAP mix before and after Cantabro
  • 37. RAP in RHMA-G Pilot Projects Comparing 0 and 10% RAP
  • 38. Some Preliminary Conclusions and Recommendations • High RAP HMA mixes up to 40 or 50% RAP • Can be engineered to meet performance related specifications producing similar or better performance for rutting, fatigue, stiffness, low temperature cracking • Virgin binder source and grade, RAP mix binder and aggregates, and rejuvenating agents are tools to engineer desired properties for different design scenarios (thin overlay [PM], thick overlay, surface vs underlying lifts) • Range of fatigue performance for a given stiffness controlled by virgin binder source; IDEAL-CT and other fracture tests only correlate with stiffness not fatigue • Need performance related specifications for mix design, including a fatigue test • 10% RAP in RHMA-G and RHMA-O • 10% RAP in RHMA-G will generally result in similar fatigue performance in surface overlays, better or worse than no RAP depending on individual mix properties • 10% coarse RAP in RHMA-O appears to not hurt Cantrabro (raveling) performance • Use of RHMA-G in surfaces thicker than 0.2 ft • Allow designers to consider RHMA-G layers up to 0.5 ft when using CalME
  • 39. Reports • High RAP laboratory study: report under Caltrans review • RAP in RHMA and RHMA thickness HVS testing: https://escholarship.org/uc/item/7wq3s753 • RAP in RHMA and RHMA thickness laboratory study and CalME simulation study: report under Caltrans review • High RAP and RAS pilot studies: • El Dorado 49: https://escholarship.org/uc/item/8h67s9z0 • San Bernardino 215 and San Joaquin 26: reports being prepared • Ventura 150: testing not yet completed • RAP in RHMA five pilot studies: report under Caltrans review • Environmental life cycle assessment (LCA) and life cycle cost analysis in progress for all of above
  • 40. Thanks to: • UCPRC Asphalt Team • UCPRC HVS Testing Team • Caltrans Office of Asphalt Pavement Technical Leads • CalRecycle Technical Leads • Caltrans Research • Contractors on pilot projects and test sections www.ucprc.ucdavis.edu Questions
  • 41. What are the effects of the addition of high RAP content on the mechanical properties of the HMA? Property What we were expecting What we measured Stiffness Increase in stiffness, particularity at high temperatures As expected Fatigue resistance Decrease Opposite!!! Rutting resistance Improve As expected 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0 10 000 20 000 30 000 40 000 Rut (in.) Wheel passes 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej Hamburg Wheel Tracking Test
  • 42. 0 5 000 10 000 15 000 20 000 25 000 30 000 35 000 40 000 50 60 70 80 HWT test: Number of passes to 0.5 in. (12.5 mm) PG high (°C) Can the RAP addition effects be predicted based on testing of the blended binder? ✓ Overall, the effect on rutting resistance and mix stiffness can be precited... and indirectly Ideal ITS (ITS strongly correlated to mix stiffness) ✓ Nonetheless, the effect on fatigue resistance and IdealCT could not be predicted 0 2 000 000 4 000 000 -40 -35 -30 -25 -20 -15 -10 -5 0 Axial dynamic modulus @ 68°F (20°C) & 10+4 Hz (psi) PG low of binder blend (°C) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej 100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 25% RPG109, 0% Rej
  • 43. 0 500 000 1 000 000 1 500 000 2 000 000 2 500 000 3 000 000 3 500 000 -40 -30 -20 -10 0 Axial dynamic modulus @ 68°F (20°C) & 10+4 Hz (psi) PG low (°C) 0 200 000 400 000 600 000 800 000 1 000 000 1 200 000 1 400 000 0 10 20 30 40 Axial dynamic modulus @ 68°F (20°C) & 1 Hz (psi) PG intermediate (°C) 0 5 000 10 000 15 000 20 000 25 000 30 000 50 60 70 80 Axial dynamic modulus @ 68°F (20°C) & 10-4 Hz (psi) PG high (°C) Can the RAP addition effects be predicted based on testing of the blended binder? ✓ Overall, the effect on rutting resistance and mix stiffness can be precited... and indirectly Ideal ITS (ITS strongly corelated to mix stiffness) ✓ Nonetheless, the effect on fatigue resistance and IdealCT cannot be predicted 0 2 000 000 4 000 000 -40 -35 -30 -25 -20 -15 -10 -5 0 Axial dynamic modulus @ 68°F (20°C) & 10+4 Hz (psi) PG low of binder blend (°C) 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 25% RPG109, 0% Rej 100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 25% RPG109, 0% Rej High Temp (rutting) Intermediate Temp (fatigue) Low Temp (fatigue and thermal cracking)
  • 44. What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content? Property What we were expecting What we measured Stiffness Decrease in stiffness, particularity at high temperatures As expected Fatigue resistance Increase No effect for PG64-16!!! As expected for PG 58-28 0 50 100 150 200 250 300 350 400 100% PG64 75% PG64 75% PG64 75% PG64 100% PG58 75% PG58 75% PG58 75% PG58 0% RAP 25% RPG102 19% RPG102 21.8% RPG102 0% RAP 25% RPG102 21% RPG102 22.5% RPG102 0% Rej 0% Rej 6% Aromatic 3.2% TallOil 0% Rej 0% Rej 4% Aromatic 2.5% TallOil 0% BR 25% BR 25% BR w/Rej 0% BR 25% BR 25% BR w/Rej PG64 PG58 4PB ε 6 Not Tested in 4PB
  • 45. What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content? Property What we were expecting What we measured Stiffness Decrease in stiffness, particularity at high temperatures As expected Fatigue resistance Increase No effect for PG64-16!!! As expected for PG 58-28 Rutting resistance Decrease Not consistent 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0 10 000 20 000 30 000 40 000 Rut (in.) Wheel passes 100% PG64, 0% RAP, 0% Rej 75% PG64, 25% RPG102, 0% Rej 75% PG64, 19% RPG102, 6% Aromatic 75% PG64, 21.8% RPG102, 3.2% TallOil In this case, the Aromatic improved rutting resistance while Tall Oil did the opposite...
  • 46. 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0 10 000 20 000 30 000 40 000 Rut (in.) Wheel passes 100% PG58, 0% RAP, 0% Rej 75% PG58, 25% RPG102, 0% Rej 75% PG58, 21% RPG102, 4% Aromatic 75% PG58, 22.5% RPG102, 2.5% TallOil What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content? Property What we were expecting What we measured Stiffness Decrease in stiffness, particularity at high temperatures As expected Fatigue resistance Increase No effect for PG64-16!!! As expected for PG 58-28 Rutting resistance Decrease Not consistent In this case, the Tall Oil improved rutting resistance while Aromatics did the opposite...
  • 47. What are the effects of the recycling agent addition on the mechanical properties of HMA with high RAP content? Property What we were expecting What we measured Stiffness Decrease in stiffness, particularity at high temperatures As expected Fatigue resistance Increase No effect for PG64-16!!! As expected for PG 58-28 Rutting resistance Decrease Not consistent Ideal Results Strength decrease & IdealCT increase As expected for strength Not consistent for IdealCT 0 50 100 150 200 250 0 20 40 60 80 100 120 140 160 100% PG64 75% PG64 75% PG64 75% PG64 100% PG58 75% PG58 75% PG58 75% PG58 0% RAP 25% RPG102 19% RPG102 21.8% RPG102 0% RAP 25% RPG102 21% RPG102 22.5% RPG102 0% Rej 0% Rej 6% Aromatic 3.2% TallOil 0% Rej 0% Rej 4% Aromatic 2.5% TallOil 0% BR 25% BR 25% BR w/Rej 0% BR 25% BR 25% BR w/Rej PG64 PG58 Strength (psi) IdealCT RA did not improve IdealCT of PG58 mixes
  • 48. JMF PG binder grade checks: ElD 49