energy sustainable bituminous mixes - crp · energy sustainable bituminous mixes ... river sand...

Energy Sustainable Bituminous Mixes

María del Río Prat ; Elsa Sánchez Alonso; Ángel Vega Zamanillo; Daniel Castro Fresno; Miguel Ángel Calzada Pérez

Department of Transports – University of Cantabria

Variables that most influence Energy Consumption during the manufacturing and compacting processes of bituminous mixes

Objetive


M. Del Río; E. Sánchez; A. Vega;

D. Castro; M.A. Calzada (UC)OBJETIVES

Mixes with the same Mechanical Properties than conv entional mixes

� Static test: Sensitivity to water

� Dynamic test: Stiffness modulus

• Mix gradation: AC 22 , AC 16 and SMA 8

• Bitumen type : B-60/70 and B-13/22

• Bitumen contents : 4.6% - 5.5% w/m, in a range of 0.3%

• Tensoactives at different temperatures : 160°C, 140°C



D. Castro; M.A. Calzada (UC)VARIABLES ANALYZED

• Tensoactives at different temperatures : 160°C, 140°C

and 120°C

�T1 (pellets): 3.0 % w/b

�T2 (viscous liquid): 0.3 % w/b

• Aggregate nature, form and roughness : crushed (ophite

and limestone) and rounded aggregates.

80

90

100

Mix Gradiation

0

20

10

AC22: B-60/70 & B-13/22 AC16: B-60/70SMA 8: B-60/70 + Cellulose

Fibers (0.3% w/m)



D. Castro; M.A. Calzada (UC)MIX GRADATION

0

10

20

30

40

50

60

70

SIEVES UNE (mm)

AC 22

AC 16

SMA 8

% P

AS

S

% R

ET

AIN

ED

100

90

80

70

60

50

40

30

0.06

3

0.5 2 4 8

11.2 16 22 32

AC22

Nº Mixture

Bitumen

AGGREGATES Rounded aggregate

contentSieve Size (mm)

Type 22-11.5 11.5-8 8-4 4-2 2-0 0.5-0 %

M1 60/70Crushed Crushed Crushed Crushed Limestone Limestone

0.00.0M 13/22



D. Castro; M.A. Calzada (UC)MIX GRADATION

Crushed Crushed Crushed Crushed Limestone Limestone0.0M2 13/22

M3 60/70Rounded Rounded Rounded Rounded Limestone

Limestone + river sand 92.5

M4 13/22

M5 60/70Crushed Crushed Rounded Crushed Limestone Limestone

19.019.0M6 13/22

M7 60/70Crushed Rounded Crushed Crushed Limestone Limestone

13.513.5M8 13/22

M9 60/70Crushed Crushed Crushed Crushed Limestone

Limestone + river sand 10.0

M10 13/22

1. Energy consumption during manufacture

2. Analysis of the ease of compaction with thegyratory compactor



D. Castro; M.A. Calzada (UC)PARAMETERS STUDIED IN LABORATORY

3. Mechanical behaviour

� Sensitivity to water

� Stiffness modulus

� Time: 180 seconds of mixing

� 3,600 grams of mix

8

Energy Consumption

Emanufacture = Eaggregate + Ebitumen + Ewater+ Ecoating



D. Castro; M.A. Calzada (UC)1. ENERGY CONSUMPTION DURING MANUFACTURE

0

1

2

3

4

5

6

7

0 20 40 60 80 100 120 140 160 180

Acc

um

ula

ted

En

erg

y (

W.h

)

Time (s)

INFLUENCE OF MIX GRADATION

• Types of gradation: SMA 8 (6.3% w/m) and AC16 (4.85% w/m)

• Manufacture temperature: 160°C

0,400

0,500

Influence of gradation




without bitumen

-0,100

0,000

0,100

0,200

0,300

0,400

0 20 40 60 80 100 120

∆E

ne

rgy

(W

.h)

Time (s)

AC16Surf SMA 8

• Bituminous mix: AC16 B-60/70 (reference)

• Two tensoactive additives:

�T1 (adhesion agent, polymers and resin): 3.0% w/b



D. Castro; M.A. Calzada (UC)

INFLUENCE OF TEMPERATURE AND ADDITIVES

1. ENERGY CONSUMPTION DURING MANUFACTURE

�T1 (adhesion agent, polymers and resin): 3.0% w/b

�T2 (adhesion agents): 0.3% w/b

• Temperatures: 160°C , 140°C and 120°C

AC16 0,4

0,6

0,8

1

∆E

(W

.h)

AC16 SURF B60/70





� Reference Mix : consumption at 160°C was lower than at 140°C and 120°C .

AC16 without bitumen

-0,2

0

0,2

0 15 30 45 60 75 90 105 120 135 150 165 180

∆E

(W

.h)

t (s)

0,100

0,200

0,300

0,400

0,500

E (

W.h

)

Influence of Additive T2 with Temperature

0,100

0,200

0,300

0,400

0,500

∆E

(W

.h)

Influence of Additive T1 with Temperature





� With both additives , mixes made at 120°C consumed lessenergy during the manufacture process.

-0,200

-0,100

0,000

0,100

0 20 40 60 80 100 120 140 160

∆

Time (s)-0,200

-0,100

0,000

0,100

0 20 40 60 80 100 120 140 160

∆E

(W

.h)

Time (s)

• Type of mix: AC22

� Mixes M1-M10





INFLUENCE OF AGGREGATE NATURE AND BITUMEN


• 4 percentages of bitumen B-60/70 and B-13/22

� From 4.6% to 5.5 % w/m in range of 0.3%

0,1

0,2

0,3

0,4

0,5

0,6

Var

iatio

n(W

.h)

Aggregate Influence. 4.9% bitumen




INFLUENCE OF AGGREGATE NATURE

-0,4

-0,3

-0,2

-0,1

0

0,1

0 15 30 45 60 75 90 105 120 135 150 165 180

Ene

rgy

Var

iatio

n

t (s)

M1 (0% Rounded) M3 (92.5% Rounded) M9 (10% river sand) Cantos 12,5/8 M5 (19% Rounded)M7 (13.5% Rounded)

� The use of rounded aggregates decrease the energy consumption.

0,3

0,4

0,5

0,6

Ene

rgy

Var

iatio

n(W

.h)

Bitumen influence in Mixtures with Rounded Aggregat es (M4)




INFLUENCE OF BITUMEN CONTENT

� When % bitumen increased the energy consumption is reduced in allmixes.

� Mixes with B-60/70 consumed less energy than those with B-13/22.

0

0,1

0,2

0 15 30 45 60 75 90 105 120 135 150 165 180

Ene

rgy

t(s)

B-13/22 4.6% B-13/22 4.9% B-13/22 5.2% B-13/22 5.6%

Shear Effort (kN/m2) and Density (kg/m3)

EN 12697EN 12697--31: P 31: P verticalvertical = 600 = 600 kPakPa αα = 0.82= 0.82°° ww= 30 r.p.m.= 30 r.p.m.

2. DETERMINATION OF THE EASE OF COMPACTIONEnergy Sustainable Bituminous Mixes



N= 200 N= 200 cyclescycles

EN 12697-10: Compactability Factor (K)

Self-compaction(V1)

Vi=-K·Ln (N)+V1

Vi = -4.09ln(N) + 25.00R² = 0.994

25

30



D. Castro; M.A. Calzada (UC)2. DETERMINATION OF THE EASE OF COMPACTION

R² = 0.994

0

5

10

15

20

1 10 100 1000

% A

ir V

oids

(Vi)

Nº Cycles (N)

K

• Types of gradation: SMA 8 (6.3% w/m) and AC16 (4.85% w/m)

• Compaction temperature: 160°C




INFLUENCE OF MIX GRADATION

Vi = -3.32Ln(N) + 25.09R² = 0.99620

25

30

% A

ir V

oids

SMA 8

K2Vi = -3.01Ln(N) + 26.07

R² = 0.99720

25

30

% A

ir V

oids

AC16

2. DETERMINATION OF THE EASE OF COMPACTION

K1

Type of Mix V 1 (real) Equation K R 2

AC16 25.3 V = -3.01Ln (N) + 26.1 3.01 0.997

SMA 8 24.1 V = -3.32 Ln (N) + 25.1 3.32 0.996

R² = 0.996

0

5

10

15

1 10 100 1000

% A

ir V

oids

Nº Cycles

K2R² = 0.997

0

5

10

15

20

1 10 100 1000

% A

ir V

oids

Nº Cycles

K1

� T1 presented higher values of K factor compared to Reference mix.

� T2 presented a similar compactability behaviour than theReference mix.

3,30K factor-Temperature of compaction






2,50

2,70

2,90

3,10

3,30

Reference Additive T1 Additive T2

K F

acto

r

Temperature ( °C)

160ºC 140ºC 120ºC

Vi = -3.99ln(N) + 23.40R² = 0.997

Vi = -3.91ln(N) + 23.51R² = 0.996

02468

101214161820222426

1 10 100 1000

% A

ir V

oids

Nº Cycles

K1

K2




INFLUENCE OFAGGREGATE

NATURE


M1 (5.6 % B-60/70) M1 (5.2% B-60/70)

Vi(M1)= -3.90ln(N) + 25.92R² = 0.995

Vi(M3) = -2.75ln(N) + 14.17R² = 0.981

02468

101214161820222426

1 10 100 1000

%A

ir V

oids

Nº Cycles M1 (4.9 % B-60/70) M3 (4.9% B-60/70)

K1

K2

V1= 25.92

V1= 14.17





Vi = -2.81ln(N) + 15.80R² = 0.992

5

10

15

20

25

% A

ir V

oids

(V

i) Vi = -3.58ln(N) + 22.00R² = 0.996

5

10

15

20

25

% A

ir V

oids

(V

i)


0

0

50

100

150

200

250

300

350

400

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

She

ar E

ffort

(kN

/m2 )

Nº Cycles (N)

M3 (92.5%)

0

0

50

100

150

200

250

300

350

400

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

She

ar E

ffort

(kN

/m2 )

Nº Cycles (N)

M1 (0%)

Representation of shear effort depending on the number of cycles.

Mix M3 Mix M1






Drop of the shear effort 98% maximum theorical density




Representation of accumulated shear effort (area accumulatedunder the curve of the previous curve) opposite to percentage ofcompaction (% Gmm).

118 Cycles

Shear*%Gmm

Acc

umul

ated

Are

a

45 Cycles

Acc

umul

ated

M3 (92.5% Rounded)M1 (100% Ophite)

Comparison of the ease of compaction of mixes manufactured

with different percentages of rounded aggregates

30000

35000

40000

45000

Are

a (

Cyc

le·K

N/m

2)




0

5000

10000

15000

20000

25000

M1-M2 M3-M4 M5-M6 M7-M8 M9-M10

Are

a (

Cyc

le·K

N/m

2)

B-60/70 B-13/22

Spanish Standards (PG-3):

Adhesivity between binder and aggregates.




ITSd

ITSw= (%) ITSR

3. Mechanical Behaviour SENSITIVITY TO WATER (EN 12697-12)

Static Machine

ITSR (%)

Surface layer 85%

Bin/Base layers 80%

Pre-treatment: Vacuum machine (50 mm Hg)

ITSd

� TENSOACTIVE AND TEMPERATURE INFLUENCE (AC16 B-60/70)

� Reference mix : 160ºC fullfilled the Spanish Standard (85%), but

not at 140ºC and 120ºC (~ 50%)

� Additivated mixes : at 160ºC and 140ºC, with both additives




3. Mechanical Behaviour SENSITIVITY TO WATER (EN 12697-12)

carried out the standard (80%), but at 120ºC only the additive T1

fulfilled the norm.

� AGGREGATE INFLUENCE (AC22 B-60/70 and B-13/22)

� Satisfied the specifications contained in the article 542 of the PG-3.

3. Mechanical BehaviourSTIFFNESS (EN 12697-26: Annex C. Indirect Traction)




)(

)27,0( Sm hz

vF

×+×=

EN 12697EN 12697--26: 26: Temperature: 20ºC; Applied load time = 124ms

12000

14000

16000

Sm

(MP

a)

Influence of Aggregate Nature and Bitumen Type

The type of binder has more influence than the

nature of aggregates.

0

2000

4000

6000

8000

10000

B-60/70 B-13/22 B-60/70 B-13/22 B-60/70 B-13/22 B-60/70 B-13/22 B-60/70 B-13/22

M1-M2 (0%) M3-M4 (92.5%) M5-M6 (19%) M7-M8 (13.5%) M9-M10 (10%)

Sm

(MP

a)

� MIX GRADATION: AC16 needed lower energy than SMA

� ADDITIVES: the energy consumption at 120120 ºCºC was lower than

Reference mix at 160ºC.

� AGGREGATE NATURE: mixes manufactured with rounded



D. Castro; M.A. Calzada (UC)CONCLUSIONS I

Variables that reduce the Manufacture energy consumption

� AGGREGATE NATURE: mixes manufactured with rounded

aggregates improves the mixing process in relation to mixes with

crushed aggregates.

� TYPE AND PERCENTAGE OF BITUMEN: the use of soft bitumens (B-

60/70) and high percentages reduce the manufacture energy

consumption.

� MIX GRADATION: Discountinous mixtures are more easilycompacted than continuous.

� ADDITIVES: At all the temperatures, the use additive T1 eases thecompaction process.



D. Castro; M.A. Calzada (UC)CONCLUSIONS II

Ease of Compaction

Analyzing the factor K: mixes with similar initial air v oids

compaction process.

Analyzing the area accumulated under the shear effort curve

� AGGREGATE NATURE: mixes manufactured with rounded aggregatesare more workable and easier to compact than those manufactured withcrushed aggregate.

� TYPE AND PERCENTAGE OF BITUMEN: the use of soft bitumen(B-60/70) and higher percentages reduce the shear effort required tocompact the mixtures.

CONCLUSIONS IIIEnergy Sustainable Bituminous Mixes



� All mixes (AC22 and AC16) made at 160ºC satisfied the Spanish

Standard (80-85%).

� The sensitivity to water is improved using both additives at each

temperature .

Mechanical behavior of the mixes

Sensitivity to water

temperature .

� The type of binder had more influence than the nature of the aggregates.

The plastic deformations of mixes with rounded aggregates can be

removed using harder bitumens.

� AC22 produced with B-13/22 satisfied the specifications marked on the

PG-3 (11,000 MPa).

Stiffness modulus

• The development of the FENIX PROJECT hasbeen possible thanks to the financial contribution ofthe Centre for Technological and IndustrialDevelopment (CDTI) in the framework of the



D. Castro; M.A. Calzada (UC)ACKNOWLEDGMENTS

Ingenio 2010 programme, through the CENITProgramme.

• The authors are grateful to all organizations andcompanies participating in the FENIX PROJECT(http ://www .proyectofenix.es ).

THANK YOU FOR YOUR ATTENTIONTHANK YOU FOR YOUR ATTENTION




Email: Email: [email protected]

energy sustainable bituminous mixes - crp · energy sustainable bituminous mixes ... river sand...

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