1

MODIFICATION OF ASPHALT BINDER WITH VARIOUS

PERCENTAGES OF CRUMB RUBBER IN

FLEXIBLE PAVEMENT

ZOHAIR AHMED ALTIEB AHMED

UNIVERSITI TEKNOLOGI MALAYSIA

4

MODIFICATION OF ASPHALT BINDER WITH VARIOUS PERCENTAGES OF

CRUMB RUBBER IN FLEXIBLE PAVEMENT

ZOHAIR AHMED ALTIEB AHMED

A project report submitted in partial fulfillment of the

requirements for the award of the degree of

Master of Engineering (Transportation)

Faculty of Civil Engineering

Universiti Teknologi Malaysia

JANUARY 2016

iii

Dedicated to my beloved parents, wife and friends

For their support

iv

ACKNOWLEDGEMENT

In the name of Allah, the most Gracious, the Dispenser of Grace, Salam to

Nabi Muhammad SAW. His companion and friends as well to all the people who

follow his path.

I would like to express my highest appreciation to my supervisor Dr. Md.

Maniruzzaman Bin A. Aziz for his advice, guidance and suggestions that he has

generously given. His constant advices and encouragement are very much

appreciated. The master project done with his guidance and advices.

Unforgettable, I would like to thank to Laboratory Technicians in Civil

Engineering Department, University Technology Malaysia (UTM) for his kind help

and guiding during laboratory work.

Besides, I would like to thank my parents, my wife and my family for their

support and encouragement. Their support really meaningful to me.

I would also like to express my deepest appreciation to all my sincere friends

that have supported and shared their ideas with me. Also not to forget their

cooperation in helping me to conduct my master project. Your helps are really

appreciated and will be remembered forever.

v

ABSTRACT

The scrap tires (crumb rubber) are being consumed every year, and these

waste tires are generating environmental issue and causing health hazard due to

burning this waste and increase the landfill space. The aim of the study is to use of

crumb rubber in asphalt binder mix with penetration grade 80-100 and performance

grade PG76. The asphalt binders were blended with waste crumb rubber in powder

form 40 mesh (0.425 micron) using wet process. The study focused on the crumb

rubber as partial replacement by (15, 20 and 25%) of total weight of modified asphalt

binder mix. The laboratory works were based on American Society for Testing and

Materials (ASTM) and (JKR/SPJ/2008-S4) standard of Malaysia, Several tests was

conducted such as Penetration, Softening point, Viscosity, Rolling Thin Film Oven

and Pressure Aging Vessel tests modified asphalt binder. The result shows positive

effect in which the penetration decreases as the partial replacement of crumb rubber

is increased 80-100 and PG76 blend asphalt binder. However, the PG76 asphalt

binder result shows lower penetration in both short term and long term aging

compared to 80-100 asphalt binder in term of stiffness. The results of softening point

test show that percentage of replacement of asphalt binder with crumb rubber

increases the temperature of 80-100 and PG76 asphalt binder mix, especially after

short term aging (RTFOT) test of PG76 at 20% replacement the temperature reached

85°C and decreased after long term aging (PAV) test to 75°C. However, with partial

replacement of asphalt binder with crumb rubber indicates resistance to higher

temperature susceptibility. The viscosity test results conclude that the PG76 asphalt

binder has higher viscosity compared to original PG76 and 80-100 asphalt binder

replacement with crumb rubber mix. The PG76 asphalt binder indicates the 20% is

the optimum crumb rubber replacement for short term aging (RTFOT) test. In the

long term aging (PAV) test, the viscosity reduced compared with (RTFOT) test.

vi

ABSTRAK

Tayar sekerap (serbuk getah) telah dihasilakn setiap tahun, dan sisa tayar ini telah

memberi kesah terhadap persekitaran dan membahayakan kesihatan disebabkan oleh

pembakaran sisa dan peningkatkan ruang tapak pelupusan. Tujuan kajian ini adalah

untuk menggunaan serbuk getah sebagai pengikat di dalam campuran asfalt

campuran pengikat dengan menggunakan asphalt penusukan gred 80-100 dan gred

prestasi PG76. Asfalt telah dicampur dengan sisa serbuk getah bersaiz 0.425 mikron

menggunakan proses basah. Kajian ini tertumpu kepada serbuk getah sebagai

pengganti asphalt sebanyak (15, 20 dan 25%) daripada berat bitumen. Kerja-kerja

makmal adalah berdasarkan kepada American Society for Testing and Materials

(ASTM) dan specifikasi Jabatan Kerja Raya (JKR), malaysia. Ujian yang dijalankan

adalah ujian penusukan, titik lembut dan kelikatan. Peringkat kedua mensimulasikan

ujian reologi melibatkan, Rolling Thin Film Oven Test (RTFOT) dan Pressure Aging

Vessel test (PAV). Keputusan menunjukkan kesan positif dimana kadar penusukan

berkurangan apabila penggantian serbuk getah meningkat (80-100 dan PG76 bitumen

campuran). Walaubagaimanapun keputusan bitumen PG76 menunjukkan kadar

penusukan yang lebih rendah terhadap kedua-dua ujian penuaan jangka pendek dan

jangka panjang berbanding bitumen 80-100 dari segi ketegangan. Hasil ujian titik

lembut menunjukkan bahawa peratusan penggantian bitumen dengan serbuk getah

meningkatkan terhadap bitumen 80-100 dan PG76 terutamanya selepas penuaan

jangka pendek (RTFOT). Suhu mencapai 85° C apabila penggantian sebuk getah

sebanyak 20% kemudian menurun kepada 75 ° C selepas penuaan jangka panjang

(PAV). Walaubagaimanapun, penggantian serbuk getah di dalam bitumen

menunjukkan peningkatan suhu yang lebih tinggi. Penggantian campuran serbuk

getah menunjukkan bitumen PG76 mempunyai kelikatan yang lebih tinggi

berbanding original PG dan 80-100. Bitumen PG76 menunjukkan optimum

penggantian serbuk getak adalah 20% untuk ujian penuaan jangka pendek (RTFOT).

Bagi ujian penuaan jangka panjang (PAV), kelikatan berkurangkan berbanding

dengan (RTFOT), boleh dikatakan secara PG76 dan 80-100 bitumen pada 25%

penggantian dengan serbuk getah.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES

LIST OF ABBREVIATIONS

xii

xiv

LIST OF APPENDICES xxi

1 INTRODUCTION 1

1.1 Introduction 1

1.2 Problem Statement 2

1.3 Objectives of Study 3

1.4 Scope of Study 4

1.5 Significant of Study 4

2 LITERATURE REVIEW 5

2.1 Asphalt Binder 5

2.2 Modification of Asphalt Binder 6

2.2.1 Principle of Bitumen Modification 7

viii

2.3 Crumb Rubber 8

2.3.1 Rubber and Crumb rubber in Civil

Engineering Application 10

2.4 Asphalt Rubber 11

2.5 Wet Process 12

2.5.1 Performance of Wet Process 13

2.6 Dry Process 14

2.7 Descriptions of Surface Distress Mechanisms 15

2.7.1 Permanent Deformation 15

2.7.2 Fatigue Cracking 16

2.8 Penetration Test 17

2.9 Softening Point Test 18

2.10 Viscosity Test 19

2.11 Aging of Asphalt Binder 20

3 METHODOLOGY 21

3.1 Introduction 21

3.2 Methodology Flow Chart and Laboratory Tests 22

3.3 Crumb Rubber Modified (CRM) Asphalt Binder 23

3.3.1 Crumb Rubber Modified Asphalt Binder 24

3.4 Penetration Test 26

3.4.1 Apparatus of Penetration Test 26

3.4.2 Procedures of Penetration Test 27

3.5 Softening Point Test 28

3.5.1 Apparatus of Softening Point Test 29

3.5.2 Procedures of Softening Point Test 29

3.6 Viscosity Test 30

3.6.1 Apparatus of Viscosity Test 31

3.6.2 Procedures of Viscosity Test 31

3.7 Rolling Thin Film Oven Test (RTFOT) 32

3.7.1 Apparatus of RTFOT Test 33

3.7.2 Procedures of (RTFOT) Test 33

3.8 Pressure Aging Vessel Test (PAV) 34

ix

3.8.1 Apparatus of PAV Test 35

3.8.2 Procedures of PAV Test 35

4 RESULTS AND DISCUSSION 37

4.1 Introduction 37

4.2 Chemical Components of Crumb Rubber 38

4.3 Penetration Properties Results 38

4.4 Softening Point Results 44

4.5 Rotational Viscometer Results 49

5 CONCLUSION AND RECOMMENDATIONS 56

5.1 Introduction 56

5.2 Conclusion 56

5.3 Recommendations 57

REFERENCES 58

Appendices 61

x

LIST OF TABLES

TABLE NO TITLE PAGE

3.1 Test Standard and Equipment 25

4.1 Chemical components of the crumb rubber powder

used in the study 38

4.2 Penetration results of penetration grade 80-100

unaged modified asphalt binder 39

4.3 Penetration results of PG76 unaged modified

asphalt binder 40

4.4 Penetration results of penetration grade 80-100 aged

modified asphalt binder after RTFOT test 41

4.5 Penetration results of PG76 aged modified asphalt

binder after RTFOT test 42

4.6 Penetration results of penetration grade 80-100 aged

modified asphalt binder after PAV test 43

4.7 Penetration results of PG76 aged modified asphalt

binder after PAV test 43

4.8 Softening point results of pentation grade 80-100

unaged modified asphalt binder 45

4.9 Softening point results of PG76 unaged modified

asphalt binder 45

4.10 Softening point results of penetration grade 80-100

aged modified asphalt binder after RTFOT test 46

4.11 Softening point results of PG76 aged modified

asphalt binder after RTFOT test 47

xi

4.12 Softening point results of penetration grade 80-100

aged modified asphalt binder after PAV test 48

4.13 Softening point results of PG76 aged modified

asphalt binder after PAV test 48

4.14 Viscosity for penetration grade 80-100 unaged

modified asphalt binder 50

4.15 Viscosity for PG76 unaged modified asphalt binder 50

4.16 Viscosity for penetration grade 80-100 aged

modified asphalt binder after RTFOT test 52

4.17 Viscosity for PG76 aged modified asphalt binder

after RTFOT test 52

4.18 Viscosity for penetration grade 80-100 aged

modified asphalt binder after PAV test 54

4.19 Viscosity PG76 asphalt binder mix aged after PAV

test 54

xii

LIST OF FIGURES

FIGURE NO TITLE PAGE

2.1 Industrial waste of crumb rubber 9

2.2 Different sizes of crumb rubber 9

2.3 Applications of crumb rubber 11

2.4 Wet process procedure 13

2.5 Permanent Deformation (Rutting) 16

2.6 Fatigue cracking 17

2.7 Penetration test results for different crumb rubber

contents 18

3.1 Flow Chart of Sample Preparation 22

3.2 Flow Chart of Experimental Works 23

3.3 Crumb rubber used in this study 24

3.4 Blending Process 25

3.5 Penetration test setup 28

3.6 Softening point test equipment 30

3.7 Rotational viscometer setup 32

3.8 Rolling Thin Film Oven Test ( RTFOT) machine 34

3.9 Pressure Aging Vessel (PAV) test equipment 36

4.1 Penetration value vs. percentages of crumb rubber

of penetration grade 80-100 and PG76 unaged

modified asphalt binder 41

4.2 Penetration value vs. percentages of crumb rubber

of penetration grade 80-100 and PG76 aged

modified asphalt binder after RTFOT test 42

xiii

4.3 Penetration value vs. percentages of crumb rubber

of penetration grade 80-100 and PG76 aged

modified asphalt binder after PAV test 44

4.4 Softening point vs. percentages of crumb rubber of

penetration grade 80-100 and PG76 unaged

modified asphalt binder 46

4.5 Softening point vs. percentages of crumb rubber of

penetration grade 80-100 and PG76 aged modified

asphalt binder after RTFOT test 47

4.6 Softening point vs. percentages of crumb rubber of

penetration grade 80-100 and PG76 aged modified

asphalt binder after PAV test 49

4.7 Viscosity vs. percentages of crumb rubber of

penetration grade 80-100 unaged modified asphalt

binder 51

4.8 Viscosity vs. percentages of crumb rubber of PG76

unaged modified asphalt binder 51

4.9 Viscosity vs. percentages of crumb rubber of 80-

100 penetration grade aged modified asphalt binder

after RTFOT test 53

4.10 Viscosity vs. percentages of crumb rubber of PG76

aged modified asphalt binder after RTFOT test 53

4.11 Viscosity vs. percentages of crumb rubber of

penetration grade 80-100 aged modified asphalt

binder after PAV test 55

4.12 Viscosity vs. percentages of crumb rubber of PG76

aged modified asphalt binder after PAV test 55

xiv

LIST OF ABBREVIATIONS

AASHTO - American Association State of Highway and Transportation

Officials

AR - Asphalt Rubber

ASTM - American Association for Testing and Materials

CR - Crumb Rubber

CRM - Crumb Rubber Modifier

G* - Complex Shear Modulus

HMA - Hot Mix Asphalt

JKR - Jabatan Kerja Raya

Pa.S - Pascal .Second

PAV - Pressure Aging Vessel

PG - Performance Grade

RTFOT - Rolling Thin Film Oven Test

δ - Phase Angle

xv

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Publication 61

1

CHAPTER 1

INTRODUCTION

1.1 Introduction

Asphalt binder is a rheological as well as polar molecular material. The

modification of asphalt binder is prompted mainly by the limitation of the

conventional refining practices used today in the production of asphalt binder from

crude petroleum oil. Alteration by specialized refining practices, chemical reaction,

and/or additives have been found to improve the contribution of asphalt binder and

also to the resistance of asphalt binder in various modes or resisting pavement

distress. In a recent survey of the State Highway Agencies in the United States of

America (USA), a total of 35 out of 47 agencies plan to increase the use of modified

binders in road construction. Twelve of the agencies were expecting to use the same

amount of modified asphalt binder and some agencies they plan to reduce the amount

of modified asphalt binder. The majority of the agencies have cited premature

distress such as rutting and fatigue cracking as the main reason for justifying the use

of modified binders (Bahia et al., 1997). Asphalt is extremely complex material;

complete chemical analysis might be not possible (Read and Whiteoak, 2003).

2

Several countries in Asia, Europe, and Africa have been used recycle rubber

or tires in various highways or roads applications for years ago. Although, crumb

rubber conserve the material utilized as a road construction material, and minimize

the landfill space that will reduce environmental impact. Many researchers, (Bahia

et al., 1994) concluded that crumb rubber modified (CRM) binders could produce

asphalt pavements with less traffic noise, less maintenance or corrective costs and

improved resistance of rutting and fatigue cracking resistance.

Modified asphalt binder materials, paving products can be made with crumb

rubber by several mixing or blending process including dry process. In the dry

process crumb rubber blend with hot aggregate before incorporate with asphalt

binder, and wet process the crumb rubber blend with asphalt binder before

incorporate with aggregate.

Based on the previous research, CRM asphalt binder requires is compaction

at a higher temperature than plain mixes (Amirkhanian and Corley, 2004). With

lower compaction temperatures, the use of CRM mixes might result in several

problems such as inadequate volumetric properties (i.e., high air voids) and poor

short-term and long-term performances. Also, the viscosity increase can negatively

effect on the workability of asphalt mixture and it requires the higher temperature to

maintain the binder viscosity for the proper workability.

1.2 Problem Statement

The design or life span for all highways and urban roads is 10-20 years.

Unfortunately, damage or distress on the pavement still occurs before reaching the

maximum period of the designed road serviceability. Among the major influence

factors contributing to this distress is due to repeat heavy traffic loading on the road

3

surface. Fatigue cracks result of repeated load of causing tensile strain bottom

pavement layer. Rutting of the road surface is mainly due to the buildup of

compressive strain at the top of subgrade layer, that majority occurs at those

countries whose higher pavement temperature, such as North Africa or South Asia

countries. Several trails were made in the past to modify asphalt binder using crumb

rubber to improve the performance of pavement surface for long design life.

Application of crumb rubber in Hot Mix Asphalt (HMA) is one of the uses in

asphalt mix or industrial mix plant, both to improve the performance of HMA or

consume the industrial waste issues.

1.3 Objectives of Study

The general objective of the study is to use waste crumb rubber with various

different percentages (15, 20, and 25%) as a partial replacement of the total weight of

blended asphalt binder mix using a wet process.

The specific objectives are:

1) To evaluate the physical properties of asphalt binder as a partial

replacement with crumb rubber at various percentages (15, 20 and 25%) by

total weight of blended asphalt binder mix.

2) To evaluate the aging performance of asphalt binder replacement with

crumb rubber for short and long term aging.

3) To determine the optimum percent of crumb rubber replacement in asphalt

binder mix content.

4

1.4 Scope of Study

The study will focus on the physical properties and performance of partial

replace of asphalt binder with different percentages (15, 20 and 25%) of crumb

rubber by total weight of asphalt binder mix. The asphalt binder will be using are

performance grade PG-76 and penetration grade 80-100. The different sample will

be prepared include the different percentage of crumb rubber in asphalt binder with

different mixing temperature.

The experimental procedure will be based on American Society for Testing

and Materials (ASTM) and (JKR/SPJ/2008-S4) and will be conducted in Highway

and Transportation Laboratory University Technology Malaysia (UTM). Several

tests will be conducted such as Penetration, Softening point, Viscosity, Rolling Thin

Film Oven and Pressure Aging Vessel tests to measure the properties of CRM

asphalt binder.

1.5 Significant of Study

The expected outcome of this study is the production of new developed

modified asphalt binder containing crumb rubber. The CRM asphalt binder is

designed to provide better riding quality and minimize the cost of pavement

construction using crumb rubber as partial replacement of asphalt binder. Finally,

CRM asphalt binder development will help to solve the industrial waste crumb

rubber and generate green and sustainable roads and highways.

58

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