I-55 / 57 WARM MIX PROJECT

Jean-Paul FORT

COLAS Solutions Technical Center

2nd International Warm-Mix ConferenceOctober 13th – St. Louis

2008 – 2010 TRIAL SECTIONS

BPM NYN Rte 12SASOBIT H8

HRI Rte 54/44EVOTHERM DAT

BPM MWSRte 132Double Green

DELTA I-55/57 Foam Maxam

BPM NYC Rte 104B Foam Terex BPM NYC

River RdCECA RT 945

REEVES – Rte 42 3G, CECA, REDISET

3G

LARCO– Winston-Salem St. 3G3G

3G

BRANSCOME Hampton. Foam Gencor3G

BPM MWSCleves Foam Gencor

HRI Rte 42CECA

Works of AlbertaSASOBIT H8 -CECA

CWM

TERUSVancouverEVOTHERM-CWM

COLASKAJuneauSASOBIT H8 -Foam

Laboratory & Field Evaluations

TRIAL SECTIONS GUIDELINES

Mix Properties Test Procedures1. Materials Moisture - Total Evaporable Moisture Content of Aggregate T255

2. Mixes residual moisture ‐ Moisture Content of Asphalt Mixes T329

3. Volumetrics ‐ Comparative VMA and air voids R35

4. Moisture Sensitivity‐ Tensile Strength Ratio with Freeze/Thaw‐ Hamburg Loaded Wheel Test, HLWT

T283

T324

5. Mix Mechanical Performances

‐ APA rut susceptibility / HLWT TP63

‐ SPT Dynamic Modulus and Flow number TP62

6. Mix Low T° cracking ‐ Thermal Stress Restrained Specimen Test / DC(T) Fracture En. TP10

7. Binders Properties ‐ Recovered binders’ comparative PG study, including viscosity and the Multi Stress Creep & Recovery (MSCR) test.

T315

D7405

Production

Data

‐ Plant set-up

‐ Actual % Water added , Actual % RAP added

‐ Production rate, Fuel Consumption per ton

‐ Mix T° in Chute and in trucks

‐ Silo retention time

‐ Gas T° @ Dryer exit; Baghouse Inlet & Outlet

‐ O2, CO, NOx readings at fan

Construction

Data

‐ Temperature in-coming Trucks

- Density vs. Mat temperature vs.

Number of roller passes.

- Cores densities

I-55 / 57 WMA Project 2009-2010 Missouri

4

Project: I-55-57 PCC highway rehabilitation

260,000 tons Asphalt Mix in 2 years.

66 lanes-miles / 106 km

Binder course design: SP 190 PG 76-22 0% RAP – 125 Gyrations

Surface Course: Hot Mix Stone Matrix

Shoulders: Marshall Design

Mobile Plant: 400 t/h Parallel Flow Cedar Rapids70 tons surge bin

Foam Device: MAXAM – AQUABLACK.

Project Rte 132 Clermont Co , Ohio -10.2 miles

Part of 2008 ODOT 6 WMA DG Field Trials

Plant: Double Drum ASTEC w/ DG

7,500 tons intermediate course PG 64-28P;

6,500 tons surface course: Type 1H Heavy Traffic -75 blows 10% RAP PG 70-22P

Rte 132 WMA Project - 2008 Ohio

Foamed AC expansion facilitates coating at lower T°

Foamed AC is “Shear Thinning”:

WMA FOAM TECHNOLOGIES

Courtesy ASTEC

Low Viscositywith Shear

High Viscositywithout Shear

I-55 / 57 WMA Project

7

FHWA Mobile Laboratory on siteAMPT Asphalt Material Performance Testing

8

I-55 - I-57HMA WMA

Average Production T° 347°F / 175°C 293°F / 145 °CCompaction T° range 320-230°F

160-110°C275-212°F135-100°C

Average final compaction, % Gmm 94% 94%

Gsb AC (%) Gmm Gse Pba (%) VMA (%) Va (%) VFA (%) Lab Comp. T°HMA 2.689 4.4 2.520 2.698 1.0 13.5 3.4 74.4 315FWMA 2.687 4.5 2.519 2.705 1.9 13.4 3.2 75.9 290F

Contract Specifications ControlVolumetrics

Field Density

I-55 / 57 WMA Project

9

0

200

400

600

800

1000

1200

1400

Stre

ngth

(kPa

)

Delta I-55 SP190 PG 76-22 MAXAM Trial Tensile Strength with 95% Confidence Intervals & TSR %

HMA Dry Set HMA Cond. Set Series4

WMA Dry Set WMA Cond. Set

94%

81%

75%

80%

85%

90%

95%

100%

TSR

%

TSR

I-55 / 57 Delta Company

Missouri

0

200

400

600

800

1000

1200

Stre

ngth

(kPa

)

BPMI -MWS Type 1H - 10% RAP 70-22 Double Green Trial Tensile Strength with 95% Confidence Intervals & TSR %

HMA Dry Set HMA Cond. Set

WMA10%RAP Dry Set WMA10%RAP Cond. Set

Moisture SensitivityTensile Retained Strength Test – ASTM D4867

Rte 132 Barrett Paving

Ohio/

10

-4.5

-4

-3.5

-3

-2.5

-2

-1.5

-1

-0.5

0

Rut (

mm

)

Number of Wheel Passes

HLWT DELTA I-55 MAXAM WMA Trial Section

SP 190 HMA Control

SP190 WMA-16

-14

-12

-10

-8

-6

-4

-2

0

Rut (

mm)

Number of Wheel PassesHLWT BPMI MWS Rte 132 WMA Trial section

BPMI MWS HMA 10% RAP

BPMI MWS WMA 10% RAP

Hamburg Loaded Wheel TestClassifies asphalt mixtures in terms of rutting potential and moisture susceptibility

I-55 / 57 Delta Company

Missouri

Rte 132 Barrett Paving

Ohio/

-18

-16

-14

-12

-10

-8

-6

-4

-2

0

Rut (

mm)

Number of Wheel PassesBPMI MWS Rte 132 WMA & HMA Road Cores

HMA Control

WMA

11

APA Rutting susceptibilityClassifies asphalt mixtures in terms of rutting potential

-4.5

-4.0

-3.5

-3.0

-2.5

-2.0

-1.5

-1.0

-0.5

0.0

Number of Cycles

Rut D

epth

(mm

)

Delta I-55 SP190 PG 76-22 MAXAM Trial APA, 100lbs. 45.4 kg, 100 PSI 689.5 kPa, 64ºC,

HMA Control

Foam WMA

COLA

S

I-55 / 57 Delta Company

Missouri

Rte 132 Barrett Paving

Ohio/

0 2 4 6 80.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

Thousands Cycles

Rut D

epth

(mm

)

BPMI MWS Rte 132 PG 70-22 DG TrialAPA, 100lbs. 45.4 kg, 100 PSI 689.5 kPa, 64ºC

WMAHMA

12

100

1,000

10,000

100,000

1.0E‐05 1.0E‐03 1.0E‐01 1.0E+01 1.0E+03

E* M

Pa 

Reduced Frequencies (Hz)

Delta 1‐55 HMA & WMA E* Mastercurves  @ 20°C reference Temperature 

HMA

WMA

100

1,000

10,000

100,000

1.0E‐05 1.0E‐03 1.0E‐01 1.0E+01 1.0E+03

E* M

Pa 

Reduced Frequencies (Hz)

Rte 132 HMA & DG WMA E* Mastercurves @ 20°C reference Temperature 

HMA 10% RAP

WMA 10% RAP

AMPT Dynamic ModulusMeasures the stiffness of the mixtures at service loading frequencies and temperatures

Dynamic Modulus: -10% in average

I-55 / 57 Delta Company

Missouri

Rte 132 Barrett Paving

Ohio/

13

Low Temperature Cracking Disc-Shaped Compact Tension Test DC(T) ASTM D7313Fracture Energy – ATREL – Rantoul IL.

I-55 / 57 WMA Project

Courtesy W. Buttlar - Un. of Illinois

365 454

0

100

200

300

400

500

600

Frac

ture

Ene

rgy J

/m2

I-55 HMA Control – WMA Average Fracture Energy

HMA-360 WMA-305

CoV 10%CoV 5%

0

200

400

600

800

1000

1200

1400

0 100 200 300 400 500 600 700 800 900 1000

Tran

sver

se C

rack

ing

(ft/50

0ft)

Fracture Energy (J/m2) - CMOD Basis

DC (T) Fracture Energy at PG Low T° +10°C vs. Cracking - From Buttlar et al. (2010)

Fracture Energy +25%

I-55 / 57 WMA Project

Binder Testing ResultsSuperpave PG results

Multi-Stress & Recovery Test (MSCR)

14Tank PG 76-

22Rec. WMA

PGRec. HMA

PG.

0.000.020.040.060.080.100.120.140.160.18

Jnr C

reep

Com

plian

ce M

CR 64

°C

100 Pa3200 Pa

COLA

S

Tank PG 76-22 Rec. WMA

PGRec. HMA

PG.

0%10%20%30%40%50%60%70%80%90%

100%

% R

ecov

ery M

SCR

64C

100 Pa3200 Pa

COLA

S

Site Information I-55 I-57

Original PG binder PG 76-22(80.1 - 23.9)

PG 76-22(76.4 - 23.2)

Recovered from HMA PG 82-16(82.8 - 21.7)

PG 76-22(77.8 -24.0)

Recovered from WMA PG 76-16(80.6 - 21.3)

PG 76-22(78.8- 23.7)

Gel Permeation Chromatography

15

I-55 / 57 WMA Project

Progressive Degradation of the Polymer Network with Temperature

16

Field Compaction ControlMat Temperature and density at recorded vs. compaction energy (roller passes)

WMA full density achieved @ -30°F

Below 212°F - 200°F similar compactability as HMA

WMA full density achieved @ -30°F

Below 212°F - 200°F similar compactability as HMA

I-55 / 57 WMA Project

Screed

B1/B2-1V

B1/B2-2V

B1/B2-3V

B1/B2-4V

B1/B2-5VF6S

B1/B2 1V

43 5

B1/B2-6V

B1/B2 -7S

84.0

86.0

88.0

90.0

92.0

94.0

96.0

80100120140160

% C

ompa

ctio

n

Average Temperature (°C)

Mat Density vs. Surface Temperature & Roller Passes

HMA B1/B2 Vibr.

WMA Tandem B1/ B2 vib.

5 vibratory passes  2  Break Down rollers close to each other

2 Break Down rollers  in tandem behind paver 6 passes vibratory  + 1 

static 

Plant Controls: Emissions & Energy

17

I-55 / 57 WMA Project

June through December 

2009 

Mix Tons Av Mix T°Av. Agg.  Moist (%)

Av. KBTUs/ton

HMA 85,467347°F 175ºC

1.8 241

WMA 70,644300°F149 ºC

1.7 205

156,111‐47°F‐26°C ‐15%

Av. HMA Av. WMA Δ

Mix chute T°350°F177°C

307°F153°C

‐43°F‐24°C

CO ppm 1308.0 465.2 ‐64%

MAIN FINDINGSLaboratory Volumetrics – Laydown & Field Compaction:

Lab volumetrics & Field Compaction duplicated @ -30°F in average

Below 212°F, similar compactability as HMA

Polymer-Modified WMA Performance: Slightly lower Moduli in the linear viscoelastic domain of very small deformations

Due to lesser binder aging > better resistance to low T cracking

Better resistance to non-linear plastic deformations

Due to the lesser degradation of the Polymer network

Emissions & EnergyAverage 25°C / 45°C drop > -64% CO & -15% Energy 18

I-55 / 57 WMA Project

19

I-55 / 57 WMA Project

Thank You

MAXAM Aquablack

GENCOR Ultra foam

TEREX SystemASTEC Double Green

WMA FOAM TECHNOLOGIES

AESCO system