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Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States Materials Group

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Page 1: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Asphalt Rubber Thin Overlays

August 29,2012

Rod Birdsall, PE

Consultant

All States Materials Group

Page 2: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

• Why Asphalt Rubber- (AR)

• AR Properties

• History of AR HMA

• AR Mix Types

• AR Mix Applications

• AR Warm Mix

• Summary

Outline of Presentation

Page 3: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Why Asphalt Rubber?

Rubber contains polymers which…

• Raises softening point to above 140º F.

– Resistance to rutting and shoving

– Resistance to asphalt migration and drain-down

• Increases low temperature flexibility of residue.

– Resistance to cracking

• Increases high temperature viscosity.

– Thicker film coatings on aggregate particles

– Higher asphalt content mixes / applications

– More asphalt = greater resistance to oxidation

– Increased long term durability

– Top PG Grading above 80

• Contains no water.

Page 4: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

ASTM D6114, Type II (Wet Process)

• 15-20% Crumb Rubber

– Typically 30-40 Mesh

– Processed from Scrap Tires

• Performance Graded Asphalt

– PG58-28 (or) PG 64-22

– Blend of the two to meet spec requirements

• On Site blending or at a facility

• Reaction process

– Elevate Temperature

– Mix for 1 hour

• Rubber particles swell, Suspension in Asphalt

Page 5: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Rubberized AC Products

Asphalt-Rubber Binder Terminal Blend Binder

From Shakir Shatnawi

Page 6: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Criteria AR TB PG

% Crumb

Rubber

15+ 3-15

Typically: 5-10

N/A

Specification ASTM D-

6114

Local AASHTO

M320

cP@375 F 1500-5000 500- 100-

Softening Pt.

F

140+ 130+ 115- Typical

ALF Cycles 300,000+ 100,000 100,000

Asphalt Comparisons

Page 7: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 8: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Final Test MatrixFinal Test Matrix

CRMA70-22

1

70-22

2

AB

3

SBS

4

TBCR

5

Elvo

6

70-22+

Fibers

7

70-22

8

SBS64-40

9

AB

10

SBS

11

Elvo

12

ALF Project Test Sections

Page 9: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 10: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 11: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

AR Background

• First developed in 1960’s

• Initially used in SAM and SAMI’s

• Now used in HMA

– AR OGFC

– AR Gap Graded

• ASTM D-6114 Binder Specification

• Not Proprietary

Page 12: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

History of AR HMA Usage

• National uses

– Arizona, California

– Florida, South Carolina

– Texas

• ASMG Experience

– MassDOT

• Several AR Gap Graded Projects (2008 – 2011)

– NJ projects

• 2009 – NJDOT I-78 AR OGFC

• 2010 – NJTA, Garden State Parkway AR OGFC

– NH DOT

• 2011 – AR Gap Graded Project

– Local Agencies

Page 13: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Why AR Mixes? • Benefits

– Longer Pavement Life

• Reduced Rutting

– AR = Higher Softening Point of PG Binder

• Reduced Oxidation

– Thicker Film Coatings = More Binder in Mix

• Reduced Cracking

– AR Properties = Greater Flexibility at Cold Temperatures

• Increased Long Term Durability

• Reduced Thickness

– Noise Reduction

• AR Properties Absorb Tire Noise

• Economic Alternative to Sound Barriers

– “Green” Process – Reuses Scrap Tires

Page 14: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Asphalt Rubber Binder – Blending

Super Sacks of CR

Rubber Hopper Mixing Chamber

Computerized Controls

Heat Exchanger

2 Compartment

Reaction Tank

Computer Interlock

Page 15: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Asphalt Rubber – Processed Tire

Rubber #30 Mesh

Page 16: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Asphalt Rubber Binder – Blending

Super Sacks of CR

Rubber Hopper Mixing Chamber

Computerized Controls

Heat Exchanger

2 Compartment

Reaction Tank

Computer Interlock

Page 17: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

I-78 NJ – AR OGFC

Page 18: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

I-78 NJ – AR OGFC (June, 2012)

Page 19: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Overlay Tester

• Sample size: 6’’ long by 3’’ wide by 1.5’’ high

• Loading: Continuously triangular displacement 5 sec loading and 5 sec unloading

• Definition of failure

– Discontinuity in Load vs Displacement curve

Fixed plate

2 mm (0.08

in)

Aluminum

plates

150 mm (6

in)

Sample

Movable plate

plate

Ram

direction

38 mm (1.5 in)

Page 20: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Typical Preservation Overlay Mixes

NJ I-95

AR OGFC

NJTA

Design

AR GGFC

296

27

310

39 7 81 33

756

1136

2363

HPTO 9.5H76 9.5mm SMA 12.5M76 12.5H76 12.5mm SMA MOGFC-1 AR-OGFC AR GG JMF NHDOT Rt.38

Surface Course Mixes

59oF, 0.025" Horizontal Deflection

Cyc

les

to F

ailu

re in

Ove

rlay

Tes

ter

NHDOT

Rt. 38

AR GGFC

Page 21: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

ON-BOARD SOUND INTENSITY (OBSI) EVALUATION

Page 22: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

NJDOT -10 Quietest Pavements Tested

96.2

96.897.0 97.1 97.1

97.998.1 98.1 98.2 98.3 98.3

94.0

94.5

95.0

95.5

96.0

96.5

97.0

97.5

98.0

98.5

99.0

99.5

100.0

CR-O

GFC

CR-O

GFC

MOGFC

-1

MOGFC

-1

12.5

mm

SP

9.5m

m S

MA

MOGFC

-1

PCC D

.G.

Nova

chip

®

Mic

ro-S

urfac

e

MOGFC

-2

So

un

d P

ressu

re (

dB

(A))

Vehicle Speed = 60 mph

Crumb Rubber

HMA

Page 23: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

What is Warm-Mix Asphalt (WMA)?

• Asphalt Mix produced at 40-100ºF less than

conventional HMA

– Various technologies and additives

• Chemical Additive (Surfactants)

• Organic Additives (Waxes – long chain

hydrocarbons)

• Foaming Processes

• Typically Produced @ 212-280ºF vs. 320ºF

• Produced and placed with conventional HMA equipment

• Can be used as Workability/Compaction aide

Page 24: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Why Use WMA?

• Environmentally Sound

• Reduces green house gas emissions

• Reduces energy use

• Reduces opacity and odor

• Improves workability

• Reduces binder aging

• Reduces paving temperatures

• Offers the potential to increase the % of RAP used in mix

• Offer the potential to extend the paving season

Page 25: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Overlay Tester Cracking Results

1284

2435

4020

914

2521

3627

0

500

1000

1500

2000

2500

3000

3500

4000

4500

40 55 77

Test Temperatures (F)

Ov

erl

ay

Te

ste

r (c

yc

les

)

AR-OGFC WMA

AR-OGFC

Horizontal Deflection = 0.025 Inches

NJ I78, 2009

Page 26: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Emissions Testing

• Looked at quantifying

emission reduction at

paver with and without

WMA

• Used portable

emissions tester

mounted to railing on

back of paver (where

workers would stand)

Page 27: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

I-78 AR OGFC – Emissions at Paver

Page 28: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

I-78 AR OGFC with Evotherm

Page 29: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

I-78 AR OGFC with Evotherm

Page 30: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

I-78 AR OGFC with Evotherm

Page 31: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

NJTA Garden State Parkway

Page 32: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Amherst, MA- AR GG

Page 33: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Amherst, MA – AR GG WMA

Page 34: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Amherst, MA- AR GG WMA

Page 35: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Amherst- ARGG WMA Air Data

0

20

40

60

80

100

120

140

160

0

50

100

150

200

250

300

350

7:2

2

7:2

9

7:3

4

7:3

9

7:4

4

7:5

0

7:5

6

8:0

1

8:0

7

8:1

2

8:1

7

8:2

2

8:2

7

9:2

3

9:2

8

9:3

4

9:3

9

9:4

4

9:4

9

9:5

5

10

:00

10

:05

10

:10

10

:15

10

:20

10

:25

10

:30

10

:35

10

:41

10

:46

10

:51

10

:56

HC

ad

CO

PP

M

Tem

pera

ture

°F

Time

Screed Temperature

Ambient Temperature Avg

HC Averages

CO Averages

Round Round

HMA WMA HMA

Tester started to pick up

increased HC before

Round Round

First HM Truck (31)

Tester Issues?

Page 36: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 37: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 38: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

• AR GG mix

• 12.5 mm Conventional mix control section

• Evaluating noise, crack resistance and durability over

time

• Article about project in Pavement Preservation

Journal, Summer 2012 issue

NHDOT Data

Page 39: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 40: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

MassDOT- AR-GG, I-295, August 2008

Page 41: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

MassDOT- AR-GG, I-295, June, 2012

Page 42: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

MassDOT- AR-BWC, I-295, June, 2012

Page 43: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

MassDOT AR-GG

Page 44: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

• Several projects on high volume roads

• AR GG Mix

• Over 400,000 tons bid or placed to date

• Consumed over 1 million tires

• Requires warm mix additive in all AR mixes

• Plan to do AR OGFC project

• Evaluating noise and performance

MassDOT Data

Page 45: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 46: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States
Page 47: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Plymouth, MA Rt. 3

• AR GG mix – 1/2 ‘’ nominal maximum size

• 7.5% ASTM D-6114 AR Binder

• 1 ¼’’ compacted over micro-milled surface

• 20,000 tons

• Current spec requires 55F pavement temperature

• With MassDOT pavement temperature was

reduced to 45F for last 5,000 tons

• Night Paving

• Resulted in reducing spec to 45 F

Page 48: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Plymouth, MA Rt. 3

-4

-3.5

-3

-2.5

-2

-1.5

-1

-0.5

0

0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000

Ave

rag

e R

ut

De

pth

(m

m)

Number of Passes

Hamburg Test Results - PA Landers Lab Produced ARGG Mix (Rt.3) Samples from All States Asphalt

Control NO ECOBIT

1.0% ECOBIT

Page 49: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

PaveCool (Minnesota DOT program)

Page 50: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Plymouth, MA Rt. 3

Page 51: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Plymouth, MA Rt. 3

Page 52: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Summary – Asphalt Rubber Mixes

• AR and Terminal Blend have completely different

properties

• AR Binder enhances the performance of mixes by

stiffening the binder, increasing elasticity (crack

resistance), and are resistant to migration

• AR mixes typically have 20% higher binder contents

• AR OGFC and ARGG mixes have been used

successfully in many states and climates with great

success

• AR mixes reduce rutting, oxidation, cracking and

pavement noise and provide smooth surfaces

Page 53: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

Summary – continued

• Utilizing best practices, AR mixes are user friendly

• AR mixes can easily be adapted to warm mix

applications reducing mix temperatures, emissions and

binder aging

• AR mixes consume old tires and are environmentally

friendly

Page 54: Asphalt Rubber Thin Overlays - Amazon Web Servicespavementvideo.s3.amazonaws.com/2012_Pavement...Asphalt Rubber Thin Overlays August 29,2012 Rod Birdsall, PE Consultant All States

THANK YOU

Products & Services

• WMA Binder

• CRMB for HMA

• PG Graded Binders

• Asphalt Rubber SAM & SAMI

• FiberMat® SAM & SAMI

• Bonded Pavements

• Chip Seals

• Liquid Calcium/Magnesium Chloride

• Full Depth Reclamation

• Hot & Cold Mix Asphalt

Rod Birdsall, PE

Consultant

(413) 687-2208 [email protected]