Caltrans RAP/RAS Specification Overview

Tony Limas

Presentation Overview Definitions

Mix Design Requirements

Binder Testing at Verification/Production

RAP/RAS Requirements

Blending Aggregate

Definitions BR = Binder Replacement:

RAP and RAS BR: Based on % total binder content in mix (OBC)

RAP or RAS Substitution Rate: Based on DWA substituted for virgin aggregate

Static RAP or RAS Stockpile: Stockpiles that have not been augmented or changed while JMF is valid

Blending Aggregate: Used in RAS to enhance flowability

Mix Design

Maximum BR Lower Lift = 40%

• O.2 ft. from finished grade (exclusive of OGFC)

Maximum BR Top Lift = 25%

Up to 5% RAS allowed (based on DWA) RAP limited by maximum allowable BR

Mix OBC based on AASHTO PP 53

PP-53 Shingle Availability Factor ≤ 70 percent

Mix Design (con’t)

When BR is ≤ 25% • Contractor may request to use 1 PG Grade Lower

– Both upper and lower temperature classifications

When using RAP only if BR is >25% and ≤ 40%

• Use1 PG binder grade lower than specified binder – Both upper and lower temperature classifications

When using RAS or RAP/RAS • Recovered binder grade must be:

– Specified binder grade ± 1 PG grade Ex. 64-16 can indicate 70-10 - 58-22

Mix Design (con’t)

When using RAS binder modifiers are allowed • Recycling Agents • Rejuvenators • Wax Products

Must submit binder blending chart(s)

New mix design required if augmented RAP/RAS: • Avg. RAP or RAS binder content ▲> ±2.0% • Avg. RAP or RAS RICE ▲> ±0.60%

Mix Design (con’t)

When Using RAS Submit AASHTO PP 53 Calculations

• RAS aggregate gradation • Percent available RAP/RAS binder • RAS RICE (Gmm) • RAS aggregate specific gravity (Gsb or Gse)

Mix design containing RAS signed by PE or AMRL accredited Lab Mgr.

Mix Design (con’t)

Caltrans Binder Grade Requirements vs. RAP, RAS and RAP/RAS

Mix Type RAP ONLY1 RAS Only2,4 RAP/RAS2, 3, 4

Binder Replacement Binder Replacement Binder Replacement ≤25% 26% to 40% ≤25% 26% to 40% ≤25% 26% to 40%

Surface Courses

No Binder Change

Required (May Request to Drop 1 PG

Grade)

Binder Grade Determined by Blending Chart

Analysis

Binder Grade Determined by Blending Chart

Analysis

Lower Courses

No Binder Change

Required (May Request to Drop 1 PG

Grade)

Required to Drop 1 PG

Grade

Binder Grade Determined by Blending Chart

Analysis

Binder Grade Determined by Blending Chart

Analysis

Binder Grade Determined by Blending Chart

Analysis

Binder Grade Determined by Blending Chart

Analysis

Notes: 1. When only RAP used in mix, max RAP by weight ≤25%. 2. Max RAS by weight ≤5%. 3. No RAP by weight % limit when used in conjunction RAS (binder replacement rules govern). 4. Asphalt binder recovered from plant produced mix must be +/- 1 PG grade of specified binder grade.

Mix Design (con’t)

CEM 3512 - Page 4

Mix Design (con’t)

Blending Charts

High Temperature – G*/sinδ Original Binder

High Temperature – G*/sinδ RTFO Binder

Intermediate Temperature – G*sinδ RTFO Aged Binder

Low Temperature – BBR Stiffness PAV Aged Binder

Low Temperature – m-value PAV Aged Binder

Binder Testing in Production

When mix contains RAS: • Recovered Binder Test Frequency • At mix verification (Engineer) • At start-up evaluation1 (Contractor/Engineer) • 1/10,000 tons of HMA production2

– 1 Waived if <30 Days From Mix Verification Date – 2 1/per Project if RAS Stockpile is Static (not augmented)

RAP/RAS Requirements

Coarse RAP Percent Passing Quality Characteristic Test Method Requirement

1 ½ -inch sieve CTM 202* 100 1-inch sieve CTM 202* 98-100 3/8-inch sieve CTM 202* 0-10

* Maximum mechanical shaking time 10 minutes

RAP Stockpile Gradation Requirements

RAP/RAS Requirements (con’t)

Quality Characteristic Test Method Requirement 1 ½ -inch sieve CTM 202* 100 ¾” inch sieve CTM 202* 98-100 3/8-inch sieve CTM 202* 98–100

*Maximum mechanical shaking time 10 minutes

RAP Stockpile Gradation Requirements

Fine RAP Percent Passing

RAP/RAS Requirements (con’t)

RAS Stockpile Gradation Requirements

Percent Passing Quality Characteristic Test Method Requirement

3/8-inch sieve CTM 202* 100 No. 4 sieve CTM 202* 90–100 *Maximum mechanical shaking time is 10 minutes

RAP/RAS Requirements (con’t)

Acceptable RAS Source(s)

• Manufactured Waste

• Post Consumer Waste

Extraneous Material limit: ≤ 2% by weight of the RAS • Glass • Brick • Soil • Tar Paper • Wood • Plastic

RAP/RAS Requirements (con’t)

Metallic Material limit ≤1% by weight of RAS Certify RAS is asbestos free

• EPA 600/R-93/16 • EPA 600/M4-892-020

RAP and RAS mechanically combined or fed into

HMA plant in accordance with CT MPQP

RAP/RAS Requirements (con’t)

RAP and RAS Sampling during HMA Production • Composite belt sample at RAP collar or batcher feed

belt

Do not lime treat RAP or RAS

Adjusting RAP or RAS feed rate allowed during HMA production to maintain gradation

RAP/RAS Requirements (con’t)

Aggregate temperature ≤ 375F when mixed with the asphalt binder

RAP Quality Requirements (During HMA Production)

Quality Characteristic Test Method Requirement

Binder content (% within the average value reported) AASHTO T 164 ±2.0

Specific gravity (within the average value reported) AASHTO T 209 ±0.06

RAP/RAS Requirements (con’t)

RAS Quality Requirements (During HMA Production)

Quality characteristic Test method Requirement Binder content (% within the average value reported) AASHTO T 164 ±2.0

Specific gravity (within the average value reported) AASHTO T 209 ±0.06

Sand equivalenta, b AASHTO T 176 47 aReport test results as the average of 3 tests from a single sample. bUse of a sand reading indicator is required as shown in AASHTO T 176, Figure 1. Sections 4.7, 4.8, 7.1.2, and 8.4.3 do not apply.

Blending Aggregate

≤50% Blend Sand allowed in RAS (flowability) Blending Aggregate Gradation (Percent Passing)

Sieve size Target Value Limit Allowable tolerance 3/8" 100 --

No. 4 80-100 TV ± 6 No. 100 0-10 TV ± 5

Caltrans Implementation Timeline

RAP/RAS NSSP October 2014 • CT Seeking Contractors request for use by COC • Binder credit offset by risk factor = net credit to CT

Spring 2015: Construction Policy Directive (CPD

• Binder credit will likely be required

Fall 2015: NSSP placed in Standard Specifications • No credit due

Questions/Discussion