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Recycling Methods:
Surface recycling: Done when the top layers fail, and recycling is done to that failure
portion.
Full depth reclamation: Done when pavement layers up to base layer is removed and
constructed again.
Hot in-place recycling:
Initially the pavement intended to be recycled is heated to a higher
temperature using suitable heating arrangement. This facilitates easier
removal of materials. After heating, the pavement surface is scarified
to the required depth.
Further, depending on the requirement fresh aggregate and binder are
added. The material is mixed well and compacted to the required
thickness. As this process consumes less time, least disruption to traffic
is caused. Also the transportation cost is less, as materials need not be
taken away.
Machinery required for this purpose being bulky in nature, sufficient
right-of-way is required. This becomes an important consideration for
in-place recycling within the city areas.
Cold in place recycling
The pavement is scarified with a scarifier. The scarified material is
crushed to the required gradation. Then the required amount of fresh
aggregates and binder in cold form (emulsion or cutback) is added. It is
compacted and left for aeration.
During this process additives like, cement, quick lime, fly ash may be
used.
The cold mix recycling takes care of local geometric correction of
pavement distresses like surface cracks being an in-situ process the
hauling cost is considerably low.
The air quality related problems during construction is almost
negligible as compared to hot mix process
Similar to hot in place recycling process, the machinery required being
bulky, sufficient maneuvering space should be available for operating
the equipment. Also, the lane needs to be closed for certain time so that
sufficient time is available for curing of freshly laid course.
Moisture content (when bitumen emulsion is used) needs to be given
importance as it influences gradation control, mixing and workability
of recycled mix to a large extent
This is the similar process as is the hot central plant mixing, except it does not
involve any heating, and therefore emulsion bitumen is used binder in most of
the cases.
Precise control on the mixing time is important. Over-mixing may cause
premature breaking of emulsified bitumen and under-mixing results in
insufficient coating of aggregates.
CASE STUDY:
The investigations are done for the hot mix recycling process since large
number of studies has been reported a conflicting conclusions like the
performance of hot mix recycled mixes in fatigue ,rutting or stiffness could be
better, worse or similar compared to the corresponding virgin mix.
Two RAP samples are collected at Kanpur city for the recycling investigations
are carried out on the design of the recycled mix and laboratory tests Marshal,
fatigue and fatigue done and compared their performance with the virgin mix.
Laboratory investigation
The basic requirements of the recycled mix design can be summarized as follows:
The quantity of old aggregates and new aggregates are to be adjusted in such a
way that the resultant gradation of aggregates conforms to the specified
gradation.
The quantity of the aged asphalt binder, virgin asphalt binder and the
rejuvenator, if any, are to be adjusted in such a way that the resultant viscosity
becomes equal to the desirable viscosity at operating temperature.
The total quantity of asphalt binder should be adjusted in such a way that it
satisfies the desired asphalt binder quantity of the target mix.
The other volumetric and strength parameters of the mix should also be
satisfied.
The RAP samples are collected, proportioned, and mixed with virgin asphalt
binder and new aggregates, for various target bitumen contents. Standard
Marshall testing is conducted for estimation of the possible optimal binder
content. Further, creep and fatigue tests are performed on the recycled samples
in order to assess their performance.
The same tests are conducted for virgin mixes, with same specification, in
order to have a comparative idea of mix performance. The schematic plan of
the Study is presented in fig.1
The representative RAP samples are cleaned for deleterious materials and
aged asphalt binder and old aggregates are separated using Centrifuge
Bitumen Extractor(CBE) as per ASTM D2172
The average asphalt binder content of the RAP and the gradation of the old
aggregates present in RAP are found out. The virgin and extracted (aged)
binders are tested for their physical properties. The test results are given in
Table1, the gradation of RAP aggregates is presented in Fig. 2.
FIG.1 SCHEMATIC PLAN OF THE WHOLE STUDY
One way for estimating optimum binder content is to calculate the binder
demand to cover the approximate surface area of the aggregates with an
average film thickness. For SDBC as per asphalt institute guidelines it is
approximately calculated as 5.5%of total weight of the mix.
The proportion between the virgin and aged binder can be estimated by using
viscosity mixing rule as follows, so that the resultant mix achieves the target
viscosity at the reference temperature,
log e ( nt ) = pob log e ( no ) + pnb ( nn )
Where,
nt , no , nn Represent viscosity of target mix, aged and virgin binder at the
reference temperature.
pob , pnb
Represent fraction of aged and virgin binder, respectively
The minimum rolling temperature100 C, as specified by MORT&H guidelines
is chosen as the reference temperature. The target viscosity has been chosen as
2320 MPa s. This is basically the viscosity value observed in 60/70
penetration grade of binder at the target temperature. It means the target of the
present mix design Problem is to achieve a viscosity of the recycled mix (at
reference temperature) similar to that of 60/70 grade of bitumen, by using
80/100 grade of bitumen as the recycling agent. Having known the proportion
between the aged and virgin binder, percentage of binder present in RAP the
remaining desired parameters can be computed with the equations given
below.
TABLE 2:
100- N = k0
ε
Mix preparation
Process1: old binder+ virgin binder= homogenous mixture of required viscosity.
This mixture+ old aggregates+ fresh aggregates= recycled mix
Prcoess2: (broken RAP + fresh aggregates ---heated @high temperature and for this
known amount of virgin binder are added) = recycled mix.
Actually it is believed that the realistic situation is somewhere in between the two
cases. The above two cases represents the extreme cases. Four possible samples are
taken based on the above processing methods namely S1-T1,S1-T2,S2-T1,S2T2.
MARSHAL TESTS:
Approximate binder demand for SDBC estimated as 5.5%and it may not necessarily
be the optimum content of bitumen for the mix. So the tests are carried out at different
contents and results are tabulated.
Procedure:
Marshal samples are prepared for bitumen contents
of4.5%,5%,5.5%,6%,6.5%
It may be noted that as the target binder content changes, the
constituent proportions also gets changed and needs recalculation with
every time.
The recycled mix is poured into marshal’s mold, and then compacted
with marshal hammer with 175 blows on each face. The compacted
marshal are tested after 24h curing .weigh measurements are done for
estimating the volumetric parameters and samples are kept in water
bath @60 C for 30 minutes and then test for Marshal stability value
and flow values using Marshal testing machine.
Table 4 is the specifications given by MORT&H guidelines and table 3
shown are the results obtained for the tested samples and by comparing
them we can observe that the non-compliance is mainly with the
volumetric parameters .thus the optimum binder content for any of the
recycled mixes could not be conclusively established.
Testes have been conducted for the virgin mix, using the mid-point
gradation of the SDBC mix as specified by MORT&H, and the
common zone of binder content for which all the Marshall parameters
are satisfied is found to be ranging between 5.0% and 6.4% (refer
fig.4). Any binder content within the feasible zone can be adopted as
design value. However, binder content, close to middle portion of the
upper and lower limit of the feasible zone, entails a more reliable mix
design so; a binder content of 5.5% can be safely assumed as optimum
binder content for the virgin mix in this study.
DISCUSSIONS
It is seen that, the Marshall stability and flow values almost remained
within the permissible ranges and even comparable to the virgin mix. It
is only the volumetric parameter values that seem to go out of the
range.
A possible reason can be that for the recycled mix design process
adopted in the present case, first the quantities of RAP, virgin binder
and new aggregates are determined, and later the gradation of the new
aggregates are adjusted so as to closely match with the mid-point
gradation of SDBC. Since, the quantities of the old and new aggregates
are fixed beforehand, and so also the gradation of the old aggregates
(i.e., RAP gradation), the only parameter that can be varied is the
gradation of new aggregates. By this process, the achieved gradation
may not necessarily match the mid point gradation, considering all
possible gradations of the new aggregates.
Thus, there remains a need of developing specifications for recycled mixes for Indian
gradation.
TABLE 3:
Bitumen Air VMA(%) VFB(%) Marshal Marshal
content(%) voids(%) stability(KN) flow(mm)
4.5 5.04 17.8 71.6 7.0 1.66
5.0 3.59 16.7 78.5 10.7 1.80
5.5 3.43 16.7 79.5 8.8 2.20
6.0 2.43 15.8 84.6 7.6 2.30
6.5 2.43 14.9 83.7 7.0 2.35
TABLE 4:
PARAMETER PERMISSIBLE VALUE
Air voids (%) 3 to 5
VMA >14
VFB 65 to 78
Marshal stability(KN) >8.2
Marshal flow(mm) 2 to 4
FIG.4 schematic sketch showing feasible zones for SDBC virgin mix design
CREEP TEST:
Static creep test is one of the tests that can characterize rutting potential of a mix.
This involves application of known amount of static load for a specified duration at
constant temperature. Since the optimum binder content of the recycled mixes
could not be established conclusively from Marshall Test, it was decided to carry
out creep test over a range of binder content.
Recommendations made by Shell pavement design manual have been used for
performing creep test. This involves loading and unloading for a period of 1 h each
at a temperature of 40 C.
Schematic diagram of setup is shown in fig.5 it consists of a loading frame and a
pair of dial gauges. Loading frame is designed in such a way that it transfers the
load to the specimen axially. The samples are placed in between the smooth
surfaced ceramic plates with the flat surfaces horizontal. The dial gauges are fixed
at two places on the ceramic plates. The dial gauges are placed independent of the
loading frame which helps in accurate measurement of axial deformation.
The samples for creep test are prepared in similar way the samples are prepared for
Marshall testing. Each sample is tested after curing for 24 h. calculated amount of
load is placed at the end of the loading frame such that stress of 0.1 MPa is
developed in the sample. After a period of1 h, the load is removed. The
displacements are noted at different time intervals using dial gauges over the entire
period. A typical variation (for virgin mix sample with6.5% binder content) of
axial deformation with time (i.e., creep curve) is shown in Fig.6 The recoverable
strain values at different binder contents is plotted for various mixes in Fig.7
DISCUSSION:
Recoverable strain gradually increases with the binder content and then again starts
decreasing for all types of mixes. From Fig. 7 it is seen that for most of the mixes,
maximum recoverable strain is observed between 5.5% and 6.0% of binder
content.
Further, the permanent and recoverable strain components are compared in Fig. 8
for all types of mixes at particular binder content, chosen as 5.5% in the present
case.
It is seen that even though permanent strain component in virgin mix is less,
recoverable strain in recycled mix is comparable to that of virgin mix.
k1
1
N = k0
ε
Where,
N= number of load repetitions the beam can sustain till failure
∈ = tensile strain
k 0, k1 = regression coefficients
Fig. 10 presents the fatigue curves of the various mixes. The regression coefficients of
the fatigue equation, as well as the average initial stiffness values for all these types of
mixes are presented in Table 5
DISCUSSION:
From Fig. 10 it can be seen that at lower strain levels, the fatigue lives of the
recycled mixes are better or similar to that of virgin SDBC mix. However, at
higher strain level, the opposite trend is observed. Fatigue performance of S2-T1 is
observed to be poorest of all other mixes.
The stiffness values of Sample 1 recycled mixes are observed (refer Table 5) to be
higher than virgin mix. For Sample 2 it is observed to be reverse.
TABLE 5
Regression coefficients and initial stiffness of different mixes
Mix type Number of Regression R*R Avg. initial
samples coefficients stiffness(Mpa)
tested
K0 K1
Virgin mix 10 2.8150 1.3355 0.91 1477
S1-T1 9 0.5647 1.5458 0.92 1711
S1-T2 9 0.0631 1.8755 0.92 1723
REFERENCE:
• Pavement recycling mix design of central hot mix recycling asphalt.
• Pavement recycling by Wilson
• A work shop on pavement recycling conducted at IIT Kanpur during Dec’05.