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Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0...

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Warm Mix Asphalt “The Material of Today” Matthew Corrigan, P.E. Asphalt Pavement Engineer Federal Highway Administration Headquarters, Washington D.C. 1
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Page 1: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Warm Mix Asphalt “The Material of Today”

Matthew Corrigan, P.E. Asphalt Pavement Engineer

Federal Highway Administration Headquarters, Washington D.C.

1

Page 2: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

A child’s view… Courtesy of Dr. Ray Bonaquist’s Daughter

Hi I’m Hot Mix. 2

Hi I’m WMA.

Page 3: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

A child’s view… To Avoid © Issues…

Hi I’m Hot Mix. 3

Hi I’m WMA.

Page 4: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

• www.fhwa.dot.gov/everydaycounts

• EDC is designed to identify and deploy innovation aimed at shortening project delivery, enhancing the safety of our roadways, and protecting the environment.

• Accelerating Technology Deployment

The Every Day Counts Initiative

Page 5: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Selected Innovations (Round 1)

Warm Mix Asphalt (WMA)

The Safety Edge

Geo-synthetic Reinforced Structures (GRS)

Prefabricated Bridge Elements & Systems (PBES)

Adaptive Traffic Control Systems

5

Page 6: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

10 Regional EDC Summits Fall 2010

CA

AZ

CO

NM

TX

OK AR

LA

MO KY

AL GA

FL

VA

OH

MI

VT AK

VI

MT

NV

Guam

ME

WA

OR

UT KS

ID WY

ND

SD

MN

NE

WI

IA IL IN

MS

TN SC

NC

WV

PA

NY

CT NJ DE MD DC

MA NH

PR

HI

RI 1

2 3

4 5

6

7

8

9

10

6 6

Page 7: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Performance Metrics

1. By December 2011, 40 State DOTs and all Federal Lands Divisions will have a specification &/or contractual language that allows WMA on Federal-aid or Federal Lands projects.

2. By December 2012, at least 30 State DOTs will have achieved set targets for WMA usage.

7

Page 8: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Factors Driving Development

1 • Improve field compaction… less variable …

better performance!!!

2 • Environment- “Green Highway Construction”, reduce

energy consumption, CO2, and other emissions

3 • Worker comfort … reduced fatigue

4 • Extend paving season, increase usage of RAP,

and longer haul distances 8

Page 9: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

EDC WMA Memorable Message

• I.C. = I.P. Improved Compaction = Improved Performance

• F.E.W. key benefits – Fuel – Emissions – Worker Comfort

9 9

Page 10: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Currently more than thirty (30+) Technologies Marketed and

Available in the US.

How Many WMA Technologies are Available in the US?

10

KOLO

Mathy Tech. & Eng. Services and Paragon Technical Services, Inc

Lake Asphalt of Trinidad and Tobago

10

Page 11: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

General Technology Categories Material Processing • Ex. LEA (Hot Coated Coarse Agg + Moist Fine Agg + Additives)

Organic Additives • Waxes, Zeolite

Chemical Additives • Surfactants

Foaming Processing • Water Injection, Zeolite

Hybrid Systems Ex. H20 + Surfactant

11

Page 12: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Technology Overview • Many US technologies’ web-link at:

http://warmmixasphalt.com/wmatechnologies.aspx

“This listing does NOT constitute an endorsement or approval.”

12

Page 13: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Stakeholder Engagement WMA Technical Working Group

FHWA

NAPA

Industry

State DOT

State APA NCAT

AASHTO

Labor

NIOSH

13

Page 14: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

• WMA TWG Task Force 08-02 “National Program for WMA Technologies” – To utilize AASHTO National Transportation Product

Evaluation Program (NTPEP)

• Resulted in… NCHRP 20-07 Task 311 “Development of a Warm Mix Asphalt Technology Evaluation Program”

14

National Research Initiatives

Page 15: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

• NCHRP 9-43 “Mix Design Practices for Warm Mix Asphalt” $500,000

• NCHRP 9-47A “Engineering Properties, Emissions, and Field Performance” $900,000

• NCHRP 9-49 “Long Term Field Performance of Warm Mix Asphalt Technologies” – Phase I, Moisture Susceptibility - $450,000 – Phase II, Long-Term Performance - $900,000

15

National Research Initiatives

Page 16: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

• Final report completed and published as NCHRP Report 691 “Mix Design Practices for Warm-Mix Asphalt”

• http://trb.org/Main/Blurbs/Mix_Design_Practices_for_WarmMix_Asphalt_165013.aspx

NCHRP Project 09-43

Page 17: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

• Products: – Appendix to AASHTO R35 with commentary

“Special Mixture Design Considerations and Methods for Warm Mix Asphalt (WMA)”

– WMA Mix Design Workshop/Training Module • Being converted to web based training thru NHI

– Chapter on WMA Mix Design for the NCHRP Project 09-33 Mix Design Manual

– “Standard Practice For Measuring Properties of Warm Mix Asphalt (WMA) for Performance Analysis Using the AASHTO MEPDG” (AASHTO Darwin ME Software)

NCHRP Project 09-43

Page 18: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

New Resource www.ct.gov/dot/AASHTO-R35

18

Page 19: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Approved Laboratory Foaming Device

19

Page 20: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Actual Laboratory Foaming Device, 3+

Every Day Counts 20 D&H Equipment – Hydro Foamer

Wirtgen, WLB 10 S

PTi – THE FOAMER

Page 21: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Recycled Asphalt Binders … High temperature PG grade of recycled asphalt binder < or = planned compaction temperature

160

180

200

220

240

260

280

300

320

76 88 100 112 124 136 148 160

WM

A Co

mpa

ctio

n Te

mpe

ratu

re, o F

RAP High Temperature Grade, oC

RAS

RAP

Courtesy of Dr. Bonaquist

Page 22: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

TWG Proposed NCHRP projects for 2012: • D-05 Develop an Approach for Lab Mix Short

Term Aging That Correlates to Various HMA Plant Processing and Warm Mix Asphalts

• D-07 Short-Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

• D-08 Asphalt Foaming Characteristics for Warm Mix Asphalt Applications

• D-09 Laboratory Foaming and Mixing Processes for WMA Mix Design

22

National Research Initiatives

Page 23: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Combined into two NCHRP projects for 2012:

• NCHRP 9-52 “Short-Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing”

• NCHRP 9-53 “Asphalt Foaming Characteristics for Warm Mix Asphalt Applications”

23

National Research Initiatives

Page 24: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Proposed NCHRP project for 2013:

• “Recycled Asphalt Shingles (RAS) and Recycled Asphalt Pavement (RAP) in HMA/WMA Mixtures”

• Endorsment by: – SOM TS 2c Asphalt-Aggregate Mixtures – FHWA WMA Technical Working Group – FHWA RAP Expert Task Group – TRB Committee AFK10 General Issues in Asphalt

Technology

24

National Research Initiatives

Page 25: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Warm-Mix Asphalt: Best Practices, 2nd Edition – Stockpile Moisture Management – Burner Adjustments and

Efficiency – Aggregate Drying and Baghouse

Temperatures – Drum Slope and Flighting – Combustion Air – RAP usage – Placement Changes

Quality Improvement Series 125

25 25

Page 26: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

0%2%4%6%8%

10%12%14%

2009 2010 2011

4.7%

13.2%

WMA Usage Percentage of Total Asphalt Production in US

source: National Asphalt Pavement Association

26

Page 27: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

0%2%4%6%8%

10%12%14%

2009 2010 2011

6%

15%

WMA Usage Percentage of Asphalt Production for State DOTs

source: National Asphalt Pavement Association

27

Page 28: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Every Day Counts 28

Page 29: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing
Page 30: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing
Page 31: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

Every Day Counts 31

Page 32: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

www.warmmixasphalt.com

Page 33: Warm Mix Asphalt “The Material of Today” · Processing and Warm Mix Asphalts • D-7 Short0 -Term Laboratory Conditioning of WMA Mixtures for Mix Design and Performance Testing

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