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FHWA/TX-82/l0+252-l
4. Title and Subtitle 5. Report Dote
Unclassified Unclassified 34
Form DOT F 1700.7 (8-69)
MIXTURE DESIGN PROCEDURE FOR RECYCLED ASPILALT PAVEMENTS
by
Thomas W. Kennedy
Freddy L. Roberts
James N. Anagnos
conducted for
Texas
State Department of Highways and Public Transportation
by the
May 1982
The contents of this report reflect the views of the
authors, who are responsible for the facts and the
accuracy of the data presented herein. The contents
do not necessarily reflect the official views or
policies of the Federal Highway Administration. This
report does not constitute a standard, specification,
or regulation.
ii
PREFACE
This is the first in a series of reports dealing with the design and
characterization of recycled pavement materials. This report includes guide-
lines for use by the field engineer in deciding if a section of road is a
candidate for recycling, and, if so, developing a mixture design that will
pvovide satisfactory field performance. This report includes a step-by-step
design procedure as well as a description of the preliminary activities in-
volved in recycling asphalt concrete materials.
This report was completed with the assistance of many people. Special
appreciation is due to Messrs. Pat Hardeman and Eugene Betts for the extensive
field and laboratory evaluations that provided the background for this report.
Appreciation is expressed to Robert E. Long, Billy R. Neeley, C. Weldon
Chaffin, and District personnel of the Texas Snane Department of Highways and
Public Transportation for their assistance, both in the field and in securing
specimens and material samples. Appreciation is extended to Center for Trans-
portation Research staff for their assistance in the preparation of manuscript
materials. The support of the Federal Highway Administration, Department of
Transportation, is acknowledged.
Thomas W. Kennedy
Freddy L. Roberts
James N. Anagnos
May 1982
iii
LIST OF REPORTS
Report No. 252-1, "Mixture Design Procedure for Recycled Asphalt Pavements,"
by Thomas W. Kennedy, Freddy L. Roberts, and James N. Anagnos, provides an
evaluation and mixture design procedure that includes the use of salvaged
materials from a road that is to be recycled. May 1982.
iv
ABSTRACT
v
SUMMARY
vi
IMPLEMENTATION STATEMENT
vii
TABLE OF CONTENTS
PREFACE iii
LIST OF REPORTS iv
ABSTRACT. '. v
SUMMARY vi
INTRODUCTION. 1
DESIGN PROCEDURE
General Design 1
Determine Causes of Distress. 2
Sampling Plan • 5
Preliminary Design 6
Softening Agents. 6
New Aggregate 9
Antistripping Additives 10
Final Design 10
Recommended Indirect Tensile Design Values 17
RECOMMENDATIONS 22
REFERENCES. • 24
viii
INTRODUCTION
At the time this study was initiated there was no readily available and
accepted procedure for the design of recycled asphalt mixtures. Subsequently,
as a part of the study, a preliminary design procedure was formulated and has
been used on a number of projects (Refs 1, 3, and 4). The following recom-
mendations are based on the experience gained to date (Ref 2). It is antic-
ipated that modifications will be required as additional information and ex-
perience are developed.
The design procedure involves
(1) identifying the original cause of distress that created the need for
recycling,
(2) correcting the cause of the distress and/or restoring the asphalt
characteristics to a level appropriate for the mixture, and
(3) establishing the asphalt-additive content and virgin aggregates
required to produce a satisfactory mixture.
DESIGN PROCEDURE
The steps necessary for the design of recycled asphalt mixtures have
been subdivided into the following three categories
(1) general design,
(2) preliminary design, and
(3) final design.
1
2
It is essential that the cause of the distress which led to the need for
recycling be identified and corrected. The three most common basic causes in
Texas are
Texas experience would suggest that one or more of these causes are involved
in most failures leading to recycling.
A detailed condition survey should be conducted to determine the severity
and extent of the distress present on the job for which recycling is being
considered. The standard condition survey forms of the Texas State Department
of Highways and Public Transportation (DHT) should be used.
A separate condition survey should be conducted for each section of road
that is determined to be different, based on
For each section identified using the suggestions listed above, the types of
distress and the severity should be evaluated to determine the pr~mary cause
of the distress.
3
100 0
Fine Sand
Coarse Coarse
--Soil Binder - - - Sand Aggregate
Fig 1. Grading curves for dense graded asphalt concrete mixtures (Ref 4).
5
Sampling Plan
PRELIMINARY .DESIGN
Softening Agents
(1) Extract and recover asphalt from the salvaged mixture (Tex-2ll-F*).
(2) Mix the recovered asphalt with the selected types and amounts of
additives. Generally increments of 0.5 percent additive are ade-
quate.
(3) Measure the viscosity or penetration of the treated asphalt cement
(Tex-528-C or Tex-502-C, respectively*).
(4) Plot the relationship between the amount of additive and the
viscosity or penetration (Figs 2 and 3).
(5) Determine which additives or combinations of additives will prod~e
c:
20b
0 0 c
-I-----
150 - 200
-
0
- 150
I
-I- - - -- --
I
c
-
'-
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c:
I
I
:
I
0
CD 100·
a.. ~85-IOO
-_.'_._-------60-70
-._.=t-. - - - ' - ' -
50 --- - --=-- -=- _ I1 _
-I
- - _
- _-:-40-50
Fig 2. Typical relationships between penetration and percent softening agent for recovered
brittle asphalt cement and four softening agents.
"'-J
8
en 4,000
CD
en Designation Agent
.- 0 A A
a.
-
0
0 3,000
x
0
B
C
0 0 D
-
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LL
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0 2,000
v
- c
- ~
en
0
(J
1,000
en
> 0
0 1.0 2.0 3.0
0/0 Softening Agent
New Aggregate
According to Epps and Holmgreen (Ref 8), new aggregate may have to be
added to the mixture for one or more of the following reasons:
Antistripping Additives
Preliminary indications suggest that the Texas Freeze-Thaw Pedestal Test may
be quite valuable in evaluating potential antistripping additives and in
detecting potential adverse moisture effects on various asphalt-aggregate
combinations (Ref 11).
FINAL DESIGN
(3) Compare the results from Step 2 with those required in the current
specifications for conventional mixtures (Ref 12). For the Texas
State Department of Highways and Public Transportation, these
values for blackbases are
and for asphalt concrete for all mixtures, Hveem stability not less
than 30. However, recent experience with premature pavement failures
from low stabilities indicates that the stability value probably
should be at least 35 and perhaps as much as 40 for facilities
handling high volumes of heavy trucks.
(4) Test the prepared specimens using the static and repeated-load
indirect tensile tests. Tentative test procedures for the static
test are contained in Refs 13 and 14. Tentative test procedures
for the repeated-load indirect tensile test are contained in Refs
14 and 15.
12
(5) Compare the results from Step 4 with those obtained for conventional
mixtures. Properties recommended for consideration are
CJ)
~
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~
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cv 200 cv cv 200 cv
iii .-In In In
C c c
1000 c
cv cv cv 1000 cv
I- ~ l- I-
100
o o o o
o 0.5 1.0 1.5 2.0 2.5 3.0 3.5 o 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Additive I % by Weight of Mix ture Additive I % by Weight of Mixture
(a) With brittle asphalt cement. (b) With nonbrittle asphalt cement.
t-'
Fig 4. Effects of the amount of additive on tensile strength of salvaged mixtures. W
... Beaumont (AC-3 +0.05% Redicote + o YooK:um(AC-3 +006 % Redicote)
0.75 °/0 Reclomite • Houston (AC-3)
Iii Dallas (AC-3 w/4.4% Residual Asph.) /iii Houston (AC-3 +0.8 % Redicote)
0.6 ~ Dallas (AC-3 w/615 % Residual Asph.)
0.6 o Corpus Christi (AC-IO)
0Phorr (AC-3) 4 • Corpus Christi (AC-IO + Lime) 4
o Pharr (Flux Oil) D. Amorillo (AC·3)
a Pharr (Reclamite)
0 • Abilene (AC-3) o
Q..
en
II>
Q. Brittle
Q..
.lIi: Q. -$ Abilene (AC-20 +0.34 % Reclamite) .lIi:
<D 0.5 <D 0.5 dr Abilene (AC-3,Plant) <D
o
o rlt.J-----~Iii pen < 20 <Do 0 • Abilene (A C-20)
-$- Abilene (AC-3,Cores)
>-
3 >- >- 3~
o
o
-;; 0.4
en
o
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=-
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pen> 20
-W
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;:, ;:,
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00.2
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( /) -
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( /)
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-
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o
(f)
0.1 0.1
o I 10 o o
o 0.5 1.01.5 2.0 2.5 3.0 3.5 o 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Additive ,% by Weight of Mixture Additive I % by Weight of Mix ture
(a) With brittle asphalt cement. (b) With nonbrittle asphalt cement.
Fig 5. Effects of the amount of additive on static modulus of elasticity of salvaged mixtures.
~
... Beoumont (AC-3 +005% Redicote +
0.75% Reclamite) Nonbrittle
® Pharr (AC-3) pen> 20
1.0[-13 Pharr (Reclamite) 7 1.0 7
3 Pharr (Flux Oil)
iii Dallas (AC-3w/4.4 % Residual Asph.)
0.9 f- ... Dallas (AC-3 w/6.15% Residual Asph.) 0.9
6 6
o
o D...
If)
O.RlMtih . . Brittle D... If) 0.8 ~
0- ~ 0-
pen <20 ID
lD
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ID
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(.)
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::J "0 "0 "0
"0 o o o
o ~ ~ ~
~
-
c:
G>
0.3 2 C
G>
i: 0.3
G>
o Yoakum(AC-3 +0.06% -$ Abilene (AC-3)
Redicote) -$ Abilene(AC-20+
-l 2 -c:
G>
• Houston(AC-3) 0.34% Reclamite) If)
~ ~ Houston(AC-3+0.8 % ~ Abilene(AC-3,Plant)
If)
If)
0.2 G> 0.2 G>
G>
a:: a:: a:: a::
Redicote) • Abilene(AC-20) _
l:l. Amarillo (AC-3) -$-Abilene (AC-3,Cores)
0.1 0.1
oI I I I 10 o ~_ _~_ _- L_ _~_ _~ 0
o 0.5 1.0 1.5 2.0 2.5 3.0 35 4.0 o 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Additive I % by Weight of Mixture Additive I % by Weight of Mixture
(a) With brittle asphalt cement. (b) With nonbrittle asphalt cement.
Fig 6. Effects of the amount of additive on resilient modulus of elasticity of salvaged mixtures. .....
1....,
16
60
50
-:>.
-
..0
0
en 40
E
Q)
(I)
>
::I:
30
20
10
o
o 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Additive, % by Weight of Mixture
Results from previous studies have been used to evaluate the tensile
strength, static modulus of elasticity, and resilient modulus of elasticity
of both laboratory prepared and inservice asphalt mixtures. Since these
materials are performing satisfactorily in the field, they represent a guide
to the level of engineering properties that should provide satisfactory ser-
vice for recycled mixtures.
Based on the results reported for various types of asphalt mixtures (Refs
16, 17, and 18), typical values of mixture properties were obtained. Even
though additional theoretical work is needed to define the range of values
required, typical values for pavements in the state of Texas are shown in
Table 1. It is recommended that desirable values of engineering properties
be determined for the particular location and function of the proposed recycled
material.
An example of the use of the desired range of material properties to
select the percent additive is shown in Figs 8 through 10. Specimens are
prepared and tested at various additive contents and the results plotted as
in Figs 8 through 10. At the point where the line of best fit for the test
results intersects the middle of the acceptable range of properties, the
optimum percent additive for that property is obtained. For example, in Figs
8, 9, and 10 these percent additives are shown for each combination of asphalt
or asphalt and additive. The individual optimurns for the AC-3 are 2.9, 2.6,
and 2.7 for tensile strength, static modulus, and resilient modulus of elas-
ticity, respectively. Neither the AC-20 nor the AC-20 plus 0.34 percent
Rec1amite reduces the resilient modulus to the desirable range while maintain-
ing the tensile strength and static modulus in the desired range.
The range of additive for each of the'.properties that maintains the
engineering property within the desired range for the AC-3 is shown in Table
2. Therefore, only 2.7 percent AC-3 meets all three of the engineering prop-
erty requirements. It should be noted that other additives could be investi-
gated and might be acceptable. In fact, field c;ontro1 for this particular
mixture would probably prove to be very difficult.
18
Design Value
3000
-$- AC-3
• AC-20+0.34 % Reclamite
.. AC-3,Plant
• AC-20
.. AC -3 ,Cores
0
a..
2000
~
..
-
.c
0\
c:
CD
-
'-
( J)
CD
en Range of Values
c:
IJli'[I ,Jl i li'1 ilil .l;il lil lt1 1Ii;1 ,1 " ilrfl" j'lji~l lI:j:i l il
i 1
CD
I- 1000
Abilene District I
IH 20 I
I
I
I
I
0
a..
..!rt!
cD
0
-2
>-
()
AC-3
-en
0
AC - 20 + 0.34% Reclomite
AC- 3. Plant
AC-20
-
W
0
en
AC-3. Cores
:::J
:::J
"'0
0
::2:
-e-n
()
0
Abilene Dis tr iet
IH 20
5
0
Cl.
~
<D
0
->-
0 4
-en
0
Ran e of Values
w
-0
en
::J
::J
'0 3
0
~ Abilene District
-c
Q)
IH 20
en
Q)
~ AC-3
a:: 2 -$ AC- 20+0.34 % Reclomite
.•
-+ AC - 3. Plant
AC-20
AC - 3 Core!;
(1) Identify and correct the cause of pavement distress before consid-
ering recycling as an alternative.
(2) Utilize 50 percent new material and 50 percent salvaged material in
the recycled mixture. A practicaL maximum of salvaged material that
can be used in a recycled mixture is 70 percent.
(3) Design the mixture in the laboratory under conditions as nearly like
those expected in the field as possible. Once construction begins,
modify the mixture design only if field evaluations justify such a
change.
(4) Evaluate the following engineering properties for the laboratory
prepared mixtures in order to select optimum additive contents.
(a) s tabili ty ,
(b) unconfined compression,
(c) indirect tensile strength, and
(d) resilient modulus of elasticity.
(5) Increase the required Hveem stability for the recycled mixture to
35 or 40, depending on traffic volumes.
(6) Evaluate the water susceptibility of the recycled mixture using the
Texas Freeze-Thaw Pedestal Test.
(7) Evaluate proposed antis tripping additives for effectiveness before
selection.
(8) Operate the plant as it was designed; if problems develop, call in
equipment manufacturers for assistance before preparing a large
volume of recycled mixture.
22
23
24
25