transfer of appropriate crumb rubber modified bitumen ......transfer of appropriate crumb rubber...

Transfer of appropriate crumb

rubber modified bitumen

technology to WA Stage 2: Gap Graded Asphalt

This report documents the binder and

mix design process based on Draft

Specification 517 - Crumb Rubber Gap

Graded Asphalt

Commercial in confidence June 2019

Transfer of appropriate crumb rubber modified bitumen technology to WA 2019-002

ABN 68 004 620 651

Victoria

80A Turner Street

Port Melbourne VIC 3207

Australia

P: +61 3 9881 1555

F: +61 3 9887 8104

[email protected]

Western Australia

191 Carr Place

Leederville WA 6007

Australia

P: +61 8 9227 3000

F: +61 8 9227 3030

[email protected]

New South Wales

2-14 Mountain St

Ultimo NSW 2007

Australia

P: +61 2 9282 4444

F: +61 2 9280 4430

[email protected]

Queensland

21McLachlan Street

Fortitude Valley QLD 4006

Australia

P: +61 7 3260 3500

F: +61 7 3862 4699

[email protected]

South Australia

Level 11,

101 Grenfell Street

Adelaide SA 5000

Australia

P: +61 8 7200 2659

F: +61 8 8223 7406

[email protected]

for Main Roads Western Australia

Reviewed

Project Leader

Elsabe van Aswegen

Quality Manager

Joe Grobler 014241-1 June 2019

Commercial in confidence

- iii - June 2019

SUMMARY

WARRIP Project 2019-002: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 2, focussed on facilitating the use of crumb rubber modified (CRM) binder in gap graded asphalt (GGA). This interim report documents the binder and mix design development of a CRM GGA mix by Fulton Hogan.

Fulton Hogan was selected as the industry partner for WARRIP Project 2019-002, as well as WARRIP Project 2016-011: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 1, which focussed on CRM in open graded asphalt.

A new draft specification was developed in August 2018 (Main Roads 2018) that outlined the products and materials, mix design, manufacture and transport, placing of asphalt and as built and handover requirements of CRM GGA for pavement wearing courses. Draft Specification 517 was used by Fulton Hogan to develop a CRM binder and CRM GGA mix.

A 20 ton trial section was constructed on 1 March 2019 at Fulton Hogan’s Hazelmere Plant. The plant trial was conducted to evaluate the workability of the designed mix during production and experiment with rolling sequence and roller settings.

The following was concluded during the binder and mix design process following Draft Specification 517:

Fulton Hogan (2018) developed and tested a 20% and 18% CRM binder. They commented that if a crumb rubber content greater than 18% is desired, a softer base binder may be required or the use of combining oils considered, as the 20% CRM blend did not comply to the viscosity requirements.

There are differences between the viscosity measured by the Brookfield viscometer (AGPT/T111) and the Rion VT-06 handheld viscometer (ASTM D7741/D7741M), but it appears to give the same result at 175 °C. The supplier of a CRM binder needs to be aware of this.

Testing and adherence to the specification requirements with or without warm mix additive can lead to confusion during the design process.

The Superpave Mix Design method is specified in this draft specification. This method has not been widely used in WA and it led to a steep learning curve in using it.

The mix was more workable than expected during the construction of the trial section.

The main recommendation based on the binder and mix design process is that the use of warm mix additives should be included throughout the binder and mix design process.

Although the Report is believed to be

correct at the time of publication,

Australian Road Research Board, to the

extent lawful, excludes all liability for loss

(whether arising under contract, tort,

statute or otherwise) arising from the

contents of the Report or from its use.

Where such liability cannot be excluded,

it is reduced to the full extent lawful.

Without limiting the foregoing, people

should apply their own skill and

judgement when using the information

contained in the Report.


- iv - June 2019

More training will be required for the use of the Superpave Mix Design method utilised in this specification.

ACKNOWLEDGEMENTS

This project was supported by AAPA, particularly Dr Erik Denneman, and industry partner, Fulton Hogan.



- v - June 2019

CONTENTS:

1 INTRODUCTION ................................................................................................................... 1

1.1 Background ........................................................................................................................... 1

1.2 Purpose ................................................................................................................................. 1

1.3 Approach ............................................................................................................................... 1

2 DEVELOPING CRUMB RUBBER MODIFIED GAP GRADED ASPHALT .............................................................................................................................. 3

2.1 Specification 517 Crumb Rubber Gap Graded Asphalt .......................................................... 3

2.2 Products and Materials .......................................................................................................... 3 2.2.1 Crumb Rubber Modified Binder, Clause 517.06 ....................................................... 3 2.2.2 Bitumen Emulsion, Clause 517.07............................................................................ 9 2.2.3 Aggregate, Clause 517.08 ........................................................................................ 9 2.2.4 Mineral Filler, Clause 517.11 .................................................................................... 9 2.2.5 Adhesion Agent, Clause 517.12 ............................................................................. 10 2.2.6 Crumb Rubber, Clause 517.13 ............................................................................... 11

2.3 Asphalt Mix Design, Clause 517.26 ..................................................................................... 11 2.3.1 General, Clause 517.26.01 .................................................................................... 11 2.3.2 Design Criteria, Clause 517.26.02 .......................................................................... 12 2.3.3 Approval of Asphalt Mix Design, Clause 517.26.03 ................................................ 18

2.4 Manufacture and Transport .................................................................................................. 18 2.4.1 Crumb Rubber Modified Binder, Clause 517.30 ..................................................... 18 2.4.2 Mixing Plant, Clause 517.31 ................................................................................... 20 2.4.3 Manufacture of Asphalt, Clause 517.32 .................................................................. 20 2.4.4 Testing, Clause 517.35 .......................................................................................... 21 2.4.5 Transport, Clause 517.37 ....................................................................................... 22

2.5 Placing of asphalt ................................................................................................................ 23 2.5.1 General, Clause 517.41 ......................................................................................... 23 2.5.2 Surface Preparation, Clause 517.42 ....................................................................... 23 2.5.3 Equipment, Clause 517.43 ..................................................................................... 24 2.5.4 Tack coat, Clause 517.44 ....................................................................................... 25 2.5.5 Weather Conditions, Clause 517.46 ....................................................................... 25 2.5.6 Joints, Clause 517.47; Longitudinal Joints, Clause 517.48; Transverse Joints,

Clause 517.49 and Terminal Joints, Clause 517.50 ............................................... 25 2.5.7 Asphalt Construction Drawings, Clause 517.51 ...................................................... 26 2.5.8 Compaction, Clause 517.54 ................................................................................... 26 2.5.9 Compaction Requirements, Clause 517.55 ............................................................ 27 2.5.10 Surface Requirements, Clause 517.56 ................................................................... 28 2.5.11 Opening Finished Works to Traffic, Clause 517.57 ................................................. 28

3 CONCLUSIONS AND RECOMMENDATIONS .................................................................... 29



- vi - June 2019

3.1 Conclusions ......................................................................................................................... 29

3.2 Recommendations ............................................................................................................... 29

REFERENCES ............................................................................................................................. 31

APPENDIX A PLANT TRIAL RESULTS ........................................................................ 35



- vii - June 2019

TABLES

Table 2.1: Binder design profile (Table 517.1) ........................................................................ 4 Table 2.2: Base bitumen rheological properties ...................................................................... 4 Table 2.3: 18% CRM binder results ........................................................................................ 5 Table 2.4: 20% CRM binder results ........................................................................................ 6 Table 2.5: Binder properties at production (Table 517.2) ........................................................ 8 Table 2.6: Crushed aggregate properties for asphalt as required in Specification

511, Table 511.7 .................................................................................................... 9 Table 2.7: Combined filler requirements (Table 517.3) ......................................................... 10 Table 2.8: Filler PSD (Table 517.4) ....................................................................................... 10 Table 2.9: Combined filler requirements (Table 517.3) ......................................................... 10 Table 2.10: Filler PSD (Table 517.4) ....................................................................................... 10 Table 2.11: Properties of crumb rubber as required in Specification 511, Table

511.14 .................................................................................................................. 11 Table 2.12: PSD limits (Table 517.5) ...................................................................................... 12 Table 2.13: Design criteria (Table 517.6) ................................................................................ 12 Table 2.14: Trial 1, 2 and 3 gap graded mix results ................................................................ 15 Table 2.15: Design PSD for gap graded mix ........................................................................... 17 Table 2.16: Viscosity at production (Table 517.8) ................................................................... 19 Table 2.17: Asphalt and filler testing frequency (Table 517.9)................................................. 21 Table 2.18: Pavement temperatures for placement (Table 517.10) ........................................ 25 Table 2.19: Rolling sequence on different lanes and resulting compactions. .......................... 28 Table 3.1: Summary of recommendations ............................................................................ 29

FIGURES

Figure 2.1: Rubber content (by mass of total binder) versus viscosity (Pa.s) ........................... 5 Figure 2.2: Viscosity (measured with Brookfield and Rion VT-06) versus

temperature ........................................................................................................... 7 Figure 2.3: Viscosity versus temperature with and without warm mix additive. ......................... 8 Figure 2.4: PSDs of Trials 1, 2 and 3. .................................................................................... 16 Figure 2.5: PSD of Trial 3 with CRM binder, no warm mix additive. ....................................... 16 Figure 2.6: Air voids between 50 and 150 gyrations at 7.5%, 8.0% and 8.5%

binder contents. ................................................................................................... 17 Figure 2.7: VMA between 50 and 150 gyrations at 7.5%, 8.0% and 8.5% binder

contents. .............................................................................................................. 18 Figure 2.8: Viscosity being measured in the laboratory at Hazelmere. ................................... 20 Figure 2.9: Milling of area to be paved and cleaned after milling. ........................................... 23 Figure 2.10: CRM GGA being paved at Hazelmere plant. ........................................................ 24 Figure 2.11: Rolling of SAMI seal. ............................................................................................ 25 Figure 2.12: Rollers on CRM GGA asphalt during compaction. ................................................ 27 Figure 2.13: Reported field core air voids data. ........................................................................ 28



- 1 - June 2019

1 INTRODUCTION

1.1 Background

Every year millions of tyres in Australia reach their functional end-of-life. The end-of-life tyres contain petroleum derivatives and significant embedded energy and are therefore a potentially valuable resource for recycling. The use of crumb rubber modified (CRM) binder in both asphalt and sprayed bituminous seals can provide increased durability and cracking resistance. In addition to improved performance, recycling ground tyre rubber reduces landfill volumes and preserves natural resources.

The use of CRM in high-performance sprayed seals has been routine practice in Western Australia (WA) for over 30 years. The use of CRM binders in asphalt is well established internationally, particularly in the USA since the 1990s when the Federal Highway Administration (FHWA) mandated the use of CRM binder in asphalt using the wet process (Ghabchi, Zaman & Arshadi 2016). There has since been a considerable number of studies into CRM binder in asphalt, largely originating from USA.

CRM binders are typically used in two types of asphalt, gap graded asphalt (GGA) and open graded asphalt (OGA) with the relatively less common use in stone mastic asphalt (SMA) (Deng et al. 2019). Extensive laboratory studies and field experience have shown that crumb rubber modification enhances the rutting and fatigue cracking resistance of asphalt mixes compared with mixes made with conventional bitumen. Other (less well documented) advantages include improved noise reduction and drainage when used in porous mix designs (Wu, Herrington & Neaylon 2015).

A previous study, WARRIP Project 2016-011: Transfer of Appropriate Crumb Rubber Modified Bitumen Technology to WA, focussed on facilitating the utilisation of CRM binder in OGA.

1.2 Purpose

The purpose of this project, WARRIP Project 2019-002: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 2, is to facilitate the use of CRM binder in GGA.

1.3 Approach

The use of CRM binder in GGA would be facilitated through the following tasks:

Develop sample and test plan for a CRM GGA demonstration trial. The mix design of the CRM GGA demonstration trial is to be undertaken by Fulton Hogan based on the Draft Main Roads Specification 517 Crumb Rubber Gap Graded Asphalt. The sample and test plan should enable testing by ARRB’s Melbourne laboratory as per the Main Roads draft specification.

Conduct emissions monitoring testing during the demonstration trial construction.

Conduct laboratory performance testing such as resilient modulus, flexural stiffness, flexural fatigue, Hamburg wheel tracking and Cooper wheel tracking.

Report the mix development based on the draft specification, laboratory results and any recommendations for specification improvement in a contract report.

This interim report documents the binder and mix design development of a CRM GGA mix by Fulton Hogan according to Draft Main Roads Specification 517.



- 2 - June 2019

Fulton Hogan was the industry partner selected for WARRIP Project 2019-002: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 2. Fulton Hogan was also the industry partner on WARRIP Project 2016-011: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 1. This project and the latter project reached the mix development phase simultaneously. The binder and mix design development took place between August 2018 and March 2019.

The remainder of the tasks will be executed late 2019 and is not reported on in this report.



- 3 - June 2019

2 DEVELOPING CRUMB RUBBER MODIFIED GAP GRADED ASPHALT

2.1 Specification 517 Crumb Rubber Gap Graded Asphalt

A new draft specification was developed in August 2018 (Main Roads 2018) that outlined the products and materials, mix design, manufacture and transport, placing of asphalt and as built and handover requirements of crumb rubber gap graded asphalt for pavement wearing courses.

The draft specification was based on the following documents:

Queensland Department of Transport and Main Roads (QTMR) 2016. Crumb rubber modified open graded asphalt surfacing, Supplementary Specification PSTS112, June 2016, Version 3.

Australian Asphalt Pavement Association (AAPA) 2018. Crumb Rubber Modified Open Graded and Gap Graded Asphalt Pilot Specification, Version 1.0, June 2018

Main Roads Western Australia 2017a. Specification 504 Asphalt Wearing Course

Main Roads Western Australia 2017b. Specification 511 Materials for Bituminous Treatments.

Draft Specification 517 was used by Fulton Hogan to develop a CRM binder and CRM GGA mix. Fulton Hogan opted to construct a 20 tonne trial section on their premises at Hazelmere, Perth, on 1 March 2019. The plant trial was conducted to evaluate the workability of the designed mix during production.

The development process is documented in this report by quoting the relevant section from the specification and then reporting or commenting on the process and results obtained.

2.2 Products and Materials

2.2.1 Crumb Rubber Modified Binder, Clause 517.06

1. The crumb rubber modified binder shall be designed to meet the

requirements of Table 517.1 without the inclusion of a warm mix

additive. The asphalt manufacturer shall submit test reports showing

compliance with Table 517.1 with its asphalt mix design submission.

A minimum quantity of 18% of crumb rubber by mass of total binder

shall be used in the crumb rubber modified binder.

2. Bitumen used in the manufacture of crumb rubber modified binder

shall conform to the requirements of Specification 511 MATERIALS

FOR BITUMINOUS TREATMENTS

Base bitumen

3. Crumb rubber, bitumen and as required oils shall be combined,

thoroughly mixed and digested for a minimum period of 60 minutes.

The manufacturing process shall not result in a reduction in the size

of the crumb rubber particles in the binder such as may occur

through a high shear mill. The temperature of the crumb rubber

modified binder during the digestion period shall not exceed 190°C.

Manufacture of

binder



- 4 - June 2019

Table 2.1: Binder design profile (Table 517.1)

Property Test Method

Digestion Time

60

min

120

min

240

min

360

min

Max

(Note 1)

Penetration at 4°C, 200g, 60s, pu

(minimum) AS 2341.12 15 - 15 - 15

Penetration at 25°C, 100g, 5s, pu

(minimum) AS 2341.12 Report - Report - Report

Resilience at 25°C,

% rebound (minimum) ASTM D5329 20 - 20 - 20

Torsional Recovery at 25°C, 30s, % AGPT/T122 Report - Report - Report

Softening Point, °C (minimum) AGPT/T131 55 - 55 - 55

Viscosity at 175°C

ASTM D7741/D7741M or

AGPT:T111

(Note 2)

1.5–4.0

Note 1 – The asphalt manufacturer is to nominate the maximum period of time it intends to store the crumb rubber modified

binder beyond 10 hours. The properties of the binder must comply with the table after this period of time.

Note 2 – For the ASTM method the viscometer used shall be a Rion Model VT-04 or VT-06 using the No. 1 rotor. The rotor

shall be immersed in the binder to the marked depth for a minimum of 60 seconds to achieve temperature equilibrium. Three

measurements shall be taken within a period of 1 minute with the three values not exceeding a range of 1.0 Pa.s.

Compliance to be taken as the average of three values. The base binder used for this project was a C170 class binder supplied by Puma (Fulton Hogan 2018). The rheological properties reported are summarised in Table 2.2.

Table 2.2: Base bitumen rheological properties

Property C170 Minimum Maximum Test method

Viscosity at 60 °C, Pa.s 190 160 230 AS/NZS 2341.2

Viscosity at 135 °C, Pa.s 0.367 0.3 0.5 AS 2341.2 or AS 2341.3 or

AS/NZS 2341.4

Penetration at 25 °C (100 g, 5 s), 0.1 mm 67 55 78 AS 2341.12

Density at 15 °C, kg/m³ 1053 1000 – AS 2341.7

Flash point, °C 340 250 – AS 2341.14

Matter insoluble in toluene, percent 0.2 – 1 AS/NZS 2341.8

Rolling Thin Film Oven Test Test conducted – – AS/NZS 2341.10

Viscosity of residue at 60 °C as percentage of original 176 – 300 AS/NZS 2341.2 or AS

2341.3

Ductility at 15 °C, mm Not reported 400 – AS 2341.11

Durability value, days 12.6 9 (Refer cl

511.06.03)

– AS/NZS 2341.13 or

WA 716.1

Softening point, °C 48(1) Not required – AGPT/T131

1. Softening point not required but tested for internal use by Fulton Hogan.

Source: Fulton Hogan (2018).



- 5 - June 2019

Although the specifications require a minimum of 18% of crumb rubber by mass of total binder for modification, Fulton Hogan (2018) conducted initial testing on the effect of rubber content on the viscosity of the crumb rubber modified (CRM) binder at 175 °C. Figure 2.1 shows a sharp increase in viscosity beyond 18% crumb rubber content.

Figure 2.1: Rubber content (by mass of total binder) versus viscosity (Pa.s)


Nonetheless, Fulton Hogan (2018) proceeded to develop both a binder with 18% and 20% crumb rubber by mass of the total binder. Both high shear and low shear blending in a Silverson Shear mixer was used to investigate the effect of the mixing process on the properties of the CRM binder. Table 2.3 summarises the 18% CRM binder results and Table 2.4 summarises the 20% CRM binder results.

It was also agreed that when determining the viscosity using AGPT/T111 (2006), the L series Brookfield together with spindle SC4-29 should be used to enable the rubber crumbs to pass through the opening between the spindle and the cup.

Table 2.3: 18% CRM binder results

Property Unit

Blending time (minutes) MRWA 517

High shear Low shear

60

min

240

min

360

min(2)

60

min

240

min

360

min(2)

Limits

Penetration at 4 °C, 100 g(1), 60 s 0.1 mm 15 13 16 12 15 15 Minimum 15

Penetration at 25 °C, 100 g, 5 s 0.1 mm 40 42 48 34 34 41 Report

Resilience at 25 °C % rebound 22 26 18 35 36 23 Minimum 20

Torsional recovery at 25 °C, 30 s % 51 44 46 49 51 51 Report

Softening point °C 72 69 72 72 70 72 Minimum 55

Viscosity at 175 °C Pa.s 3.13 3.17 6.13 2.53 3.17 5.51 1.5–4.0

1. Test method requires a 200 g weight. Results are expected to be higher with a 200 g weight. 2. Only viscosity limits after 360 minutes of blend applicable.


0

1000

2000

3000

4000

5000

6000

10 12 14 16 18 20 22

Vis

cosi

ty (

Pa.

s)

Crumb Rubber Content (%)



- 6 - June 2019

Table 2.4: 20% CRM binder results

Property Unit

Blending time (minutes) MRWA 517

High shear Low shear

60

min

240

min

360

min(2)

60

min

240

min

360

min(2)

Limits

Penetration at 4 °C, 100 g(1), 60 s 0.1 mm 17 12 14 17 8 21 Minimum 15

Penetration at 25 °C, 100 g, 5 s 0.1 mm 30 32 45 34 33 43 Report

Resilience at 25 °C % rebound 72 72 Not

Tested

72 87 71 Minimum 20

Torsional recovery at 25 °C, 30 s % 53 57 49 52 55 50 Report

Softening point °C 71 75 71 74 72 72 Minimum 55

Viscosity at 175 °C Pa.s 4.41 6.98 11.30 4.92 31.30 4.83 1.5–4.0

1. Test method requires a 200 g weight. Results are expected to be higher with a 200 g weight. 2. Only viscosity limits after 360 minutes of blend applicable.


The method of blending does not appear to influence the results significantly at 20% or 18% crumb rubber and high shear blending was used for the remainder of the project to blend CRM binder.

It was agreed that the 18% CRM binder blend would be used for this project.

The penetration test at 4 °C, with 200 g weight at 60 seconds was conducted on the selected 18% CRM binder blend after 60 minutes of digestion. The result was 25 mm, well above the minimum of 15 mm required.

The viscosity results reported thus far were determined using a Brookfield viscometer. However, Fulton Hogan conducted a comparison between the viscosity of the CRM binder determined by using the Brookfield viscometer (AGPT/T111) and the Rion VT-06 handheld viscometer (ASTM D7741/D7741M). This comparison was done since the use of both viscometers is allowed in Table 517.1. The results depicted in Figure 2.2 show the difference in measured viscosity at various temperatures.

The Rion handheld viscometer is normally used in the field during spray sealing operations. The Brookfield viscometer is normally standard equipment at an asphalt plant where blending of binder takes place. Temperature control during testing with the Rion viscometer was difficult. The comparison shows the Rion handheld viscometer results appearing less sensitive to temperature than the Brookfield viscometer. The difference in resulting viscosity is significant, although less so between 165 °C and 190 °C, which is general manufacture temperature. It is recommended that the Rion viscometer should be calibrated and correlated to the Brookfield measurement for field use (Way, Kaloush & Biligiri, 2011) or that only the use of the Brookfield viscometer should be specified. O’Connell, Anochie-Boateng & Marais (2010) noted that this observation is in line with previous experience and that the readings from the Brookfield viscometer display greater repeatability than the Rion viscometer.



- 7 - June 2019

Figure 2.2: Viscosity (measured with Brookfield and Rion VT-06) versus temperature

None of the results reported thus far contained any warm mix additive. The trial specification allows the use of warm mix additive and requires that the effect of adding a warm mix additive on the viscosity of the CRM binder should be evaluated.

4. To evaluate the effect of adding a warm mix additive on the viscosity

of the crumb rubber modified binder the asphalt supplier shall:

Viscosity with WMA

Prepare in the laboratory a sample of the crumb rubber

modified binder and split it into two portions.

Test the first portion for viscosity at 175 ºC to confirm the

viscosity conforms. If not make a new batch of binder.

Add the warm mix additive to the second portion at the

proposed proportion to be used and mix thoroughly with the

binder.

Test the second portion for viscosity at 175ºC, then 165ºC

and reducing by 10ºC steps until the viscosity of the second

portion is higher than the first portion.

Plot viscosity versus temperature and determine the

temperature at which the second portion has the same

viscosity of the first portion at 175ºC.

The nominated test temperature for the binder with the warm mix

additive shall be stated on the approved asphalt mix design and shall

be the temperature of the binder to achieve a viscosity of 1.5–4.0

Pa.s at the time of asphalt production.

Crumb rubber, bitumen and as required oils shall be combined,

thoroughly mixed and digested for a minimum period of 60 minutes.

The manufacturing process shall not result in a reduction in the size

of the crumb rubber particles in the binder such as may occur

through a high shear mill. The temperature of the crumb rubber

modified binder during the digestion period shall not exceed 190°C.

The results from the process outlined above are depicted in Figure 2.3 and show that at 155 °C the CRM binder with warm mix additive has the same viscosity, 3.1 Pa.s, as the CRM binder without warm mix additive at 175 °C.

y = 91933x-2.115

y = 9E+12x-5.685

0

1

2

3

4

5

6

7

8

9

10

11

1212

0

130

140

150

160

170

180

190

200

Vis

cosi

ty (

Pa.

s)

Temperature (°C)

Rion VT-06

Brookfield



- 8 - June 2019

Figure 2.3: Viscosity versus temperature with and without warm mix additive.

5. At the time of manufacture of the crumb rubber modified binder it

shall comply with the requirements of Table 517.2, without inclusion

of a warm mix additive, after a reaction time of 60 minutes. The

initial batch shall be tested for all properties and subsequent batches

shall be tested for all properties except loss on heating and flash

point. Loss on heating shall be tested once per month and flash

point every 12 months.

Binder

Testing Frequency

6. Prior to the use of the crumb rubber modified binder the

Contractor shall demonstrate compliance with the properties of

the binder for each batch used on the Contract.

HOLD POINT

Table 2.5: Binder properties at production (Table 517.2)

Property Test Method Limits

Penetration at 4 °C, 200 g, 60 s, pu AS 2341.12 Minimum 15

Penetration at 25 °C, 100 g, 5 s, pu AS 2341.12 Report

Resilience at 25 °C, % rebound ASTM D5329 Minimum 20

Torsional recovery at 25 °C, 30 s, % AGPT/T122 Report

Softening point, °C AGPT/T131 Minimum 55

Viscosity at 175 °C ASTM D7741/D7741M or AGPT:T111 1.5–4.0

Flash point, ºC AGPT/T112 Minimum 250

Loss on heating, % AGPT/T103 Maximum 0.6

Clause 517.06.5 states that at the time of manufacture of CRM binder, it shall comply with Table 517.2, without inclusion of a warm mix additive. When to test CRM binder with or without warm mix additive was debated during the design process. It is recommended that after the completion of Clause 517.06.4, the remainder of the binder design and mix design process should include the warm mix additive.

y = 9E+12x-5.685

R² = 0.9977

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

140 150 160 170 180 190 200

Vis

cosi

ty (

Pa.

s)

Temperature (°C)

CR - With warm mix additive

CR - No warm mix additive



- 9 - June 2019

2.2.2 Bitumen Emulsion, Clause 517.07

1. Bitumen emulsion to be used as the tack coat during the preparation

of the surface prior to the laying of open or dense graded asphalt

shall be Cationic Slow Setting emulsion grade CSS/170 60 or

Cationic Rapid Setting emulsion grade CRS/170 60, both conforming

to AS 1160, mixed 50:50 by volume with water.

Fulton Hogan used CRS/170 60 as tack coat at the Hazelmere Plant trial on 1 March 2019.

2.2.3 Aggregate, Clause 517.08

1. Crushed aggregate, including its source rock, shall meet the

requirements of Specification 511 MATERIALS FOR BITUMINOUS

TREATMENTS except for flakiness index. Coarse and fine

aggregate used in the manufacture of asphalt shall only consist of

crushed rock material.

2. Flakiness index shall be less than or equal to 25%. Table 2.6 contains the requirements as stated in Specification 511 (2017b), as well as the aggregate properties for 10 mm sized aggregate. Note that the flakiness index in Specification 511 (2017b) is replaced by the limit in Specification 517, which is 10% lower.

Table 2.6: Crushed aggregate properties for asphalt as required in Specification 511, Table 511.7

Property Results for 10 mm sized aggregate Requirement Test method

Los Angeles Abrasion Value (Note 2) 20

Granite and other rock types * 35% maximum WA 220.1

Basalt 25% maximum WA 220.1

Flakiness index (Note 2) 21 35% maximum (Note 3) WA 216.1

Water absorption 0.4 2% maximum AS 1141 6.1

Wet strength 182 100 kN minimum AS 1141.22

Wet/dry strength variation 14 35% maximum AS 1141.22

Stripping test value (Note 1)

Only applicable to regional plants

2 10% maximum AS 1141.50

Degradation factor 88 50 minimum AS 1141.25.2

Secondary mineral content (Note 4) 14 25% maximum AS 1141.26

Petrographic examination Suitable Statement of suitability for use as an asphalt aggregate

Note 1: The aggregate shall be tested in a clean dry condition without precoating. The binder shall include 0.5% by volume of

one of the approved adhesion agents at Clause 511.13.

Note 2: Only applicable to 10, 14 and 20 mm aggregate.

Note 3: Applicable to the mean of three results for each lot.

Note 4: This test is only applicable to basic igneous rock.

2.2.4 Mineral Filler, Clause 517.11

1. Mineral filler shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS. In addition the

combined filler being baghouse dust and hydrated lime shall comply

with the requirements of Table 517.3.

Mineral Filler



- 10 - June 2019

Table 2.7: Combined filler requirements (Table 517.3)

Property Test Method Requirement

Voids in dry compacted filler (%) AS/NZS 1141.17 ≥ 28 and ≤ 45

Apparent density of filler (t/m3) AS/NZS 1141.7 Report

2. Each added mineral filler shall meet the requirements for particle size

distribution shown in Table 517.4.

PSD

Table 2.8: Filler PSD (Table 517.4)

Sieve size (mm) Percentage passing (by mass)

0.600 100

0.300 95–100

0.075 75–100

The mineral filler that was used during this project conformed to the requirements and the results are presented in Table 2.9 and Table 2.10. The Methylene blue value (MBV) contained in the AAPA (2018) pilot specification was determined and is also reported. The MBV is a function of the amount and characteristics of clay minerals present in the test specimen. At this stage it is not recommended to align with AAPA (2018) and include MBV testing as a requirement, because Specification 517only allows granite rock to be used, which has historically had low clay mineral contents.

Table 2.9: Combined filler requirements (Table 517.3)

Property Result Test Method Requirement

Voids in dry compacted filler (%) 36.6 AS/NZS 1141.17 ≥ 28 and ≤ 45

Apparent density of filler (t/m3) 2.679 AS/NZS 1141.7 Report

Methylene blue value (mg/g) 2.5 AS/NZS 1141.66 ≤ 10

Table 2.10: Filler PSD (Table 517.4)

Sieve size (mm) Result Percentage passing (by mass)

0.600 100 100

0.300 99 95–100

0.075 86 75–100

2.2.5 Adhesion Agent, Clause 517.12

1. The adhesion agent shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS.

Adhesion Agent

Hydrated lime (1.5% by mass of total aggregate) was used in the mix design as per 517.26.as an adhesion agent. This is in line with Specification 511 (2017b).

The warm mix additive, EvoTherm, may enhance adhesion properties, but was not used for that purpose in the mix design.



- 11 - June 2019

2.2.6 Crumb Rubber, Clause 517.13

1. The crumb rubber shall be manufactured from end of life tyres from a

Tyre Stewardship Australia accredited tyre recycler. Uncured or

devulcanized rubber shall not be used as a source material. The

crumb rubber shall meet the requirements of Specification 511

MATERIALS FOR BITUMINOUS TREATMENTS.

Recycled crumb rubber was sourced from Tyrecycle. The supplied crumb rubber was not tested for conformance, as a certificate to state conformance was supplied. The rubber crumbs that were used during this project conformed to the requirements and the results are presented in Table 2.11.

Table 2.11: Properties of crumb rubber as required in Specification 511, Table 511.14

Property Result Requirement Test Method

Bulk Density 278 kg/m³ < 350 kg/m³ AG:PT/T144 or WA 235.1

Iron or steel content 0% ≤ 0.1% by mass AG:PT/T143 or WA 237.1

Particle shape Not reported Mean of measured particles

Maximum 3 mm

AG:PT/T143

Moisture content 0.4% Maximum 1% AG:PT/T143

Particle size distribution

Sieve size (mm)

Percentage passing (by mass) AG:PT/T143 or WA 237.1

2.36 100 100

1.18 100 100

0.60 68.9 60 minimum

0.30 17.9 20 maximum

0.075 Not reported 2 maximum

2.3 Asphalt Mix Design, Clause 517.26

2.3.1 General, Clause 517.26.01

Highlighted in this sub-clause are the following:

The asphalt mix design shall incorporate:

— aggregates

— crumb rubber modified binder and warm mix additive

— filler and hydrated lime.

Asphalt shall be resistant to segregation during handling and placing, shall have low permeability, shall have adequate workability to achieve the specified level of compaction on the road and shall have good field performance.

Asphalt for the Perth metropolitan area shall be produced using granite rock.

The mix design shall not include natural sand or RAP.

The mix design shall include 1.5% by mass of the total aggregate of hydrated lime as an adhesion agent.



- 12 - June 2019

2.3.2 Design Criteria, Clause 517.26.02

1. The mix design shall have a target particle size distribution (PSD)

complying with Table 517.5.

PSD

Table 2.12: PSD limits (Table 517.5)

Sieve size (mm) Percentage by mass passing

19.00 100

13.20 90–100

9.50 83–87

6.70 -

4.75 28–42

2.36 14–22

1.18 -

0.60 -

0.30 -

0.15 -

0.075 0–6.0

2. The mix design shall have a target binder content of a minimum of

7.5% and maximum of 9.0% by mass of the total mix.

Binder Content

3. The mix design shall comply with the requirements of Table 517.6.

The mix used to determine air voids for binder content, deformation,

moisture damage and moisture sensitivity shall not include a warm

mix additive.

Table 2.13: Design criteria (Table 517.6)


Binder Content

Air voids in laboratory compacted specimens

Number gyratory cycles (Note 1)

AS/NZS 2891.8 AS/NZS

2891.7.1 AS/NZS 2891.9.2

AS/NZS 2891.2.2

N design = 4.0

50–150

Voids in Mineral Aggregate AS/NZS 2891.8 18.0–23.0

Filler/Binder Ratio NA Report

Permanent Deformation – number of passes at 12mm rut depth

(Note 2)

Q325 Min. 20,000

Moisture Damage – number of passes at inflection point

(Note 2)

Q325 Min. 10,000

Stripping Potential of Asphalt – Tensile Strength Ratio (one

freeze thaw cycle required)

AGPT/T232 Min. 80%

Deformation Resistance (rut depth after 10,000 passes) AGPT/T231 Report

Number of gyrations to achieve 4% air voids at target binder

content

AS/NZS 2891.2.2 AS/NZS

2891.7.1 AS/NZS 2891.9.2

Report

Note 1 – test to comply with the following conditions:



- 13 - June 2019

Use 150 gyratory cycles where the asphalt is used in a very heavy traffic loading environment and a lesser

number of cycles for roads with lower traffic loadings.

the gyratory compactor shall be operated with an internal angle of 1.16°, 30 ± 0.5 gyrations per minute and 825

kPa loading pressure

Use 150mm diameter mould

finished specimen height to be 115 ± 5mm

Test temperature of 160 ± 3°C

At the completion of compaction the specimen may be held under pressure at constant height for a maximum of

90 minutes.

Note 2 – test to comply with the following conditions:

test specimens shall be prepared in accordance with AS/NZS 2891.2.2 as per Note 1

air void content of 7.0 ± 1.0% (AS/NZS 2891.8, AS/NZS 2891.7.1 and AS/NZS 2891.9.2)

specimen height 60 ± 1mm

two tests using four specimens, report each test result and not an average

test temperature 50°C

measurements to be taken at every 100 passes along the total length of the specimen

the inflection point is defined as the number of wheel passes at the intersection between the creep slope and

stripping slope

condition the specimens in water at the test temperature for 2 and 4 hours prior to testing

terminate the test after 25,000 passes.

4. The design binder content shall be determined in accordance with

the following process:

a) Select four different binder contents with the minimum being no

less than 7.5% by mass of crumb rubber modified binder in the

total mix and the maximum being 9.0%.

b) Compact three test specimens for each binder content in the

gyratory compactor, determine air void content and VMA for

each then average the air voids and VMA for the set of three

specimens.

c) Plot the average air voids for each set against the binder

content and draw a curve or line of best fit.

d) Plot the average VMA for each set against the binder content

and draw a curve or line of best fit.

e) Select an optimum binder content that complies with the

following criteria:

Air voids N design = 4.0%

VMA 18.0–23.0%

Binder content 7.5–9.0%.

5. Dry particle density of the combined aggregate and filler in

accordance with AS/NZS 2891.8 shall be reported.

6. A warm mix additive will be used at the time of manufacture of the

asphalt. To determine the temperature for compaction of gyratory

specimens to determine the air voids comparative testing shall be

done in accordance with Appendix B of AS/NZS 2891.2.2.

Specimens without the warm mix additive in the asphalt shall be

compacted at a temperature of 160ºC and specimens with the warm

mix additive in the asphalt shall be compacted to determine the

compaction temperature for the asphalt with the additive. The

temperature shall be nominated with the asphalt mix design

submission.



- 14 - June 2019

Transferring the technology into this sub-clause proved to be challenging for the following reasons:

1. Warm mix asphalt additive – AAPA (2018) states in clause 2.5.3 that the warm mix additive ‘must be included in the asphalt mix design’, but in clause 3.1 states ‘Where the proposed mix design incorporates additives listed under Clause 2.1, compliance shall be tested on the mix including these additives’. Clause 2.1 describes aggregate and mineral filler constituents and not warm mix additives. However, it may be inferred by the gyratory compaction temperature specified to be between 145 °C and 160 °C (Table 3-3, note 5).

The AAPA (2018) document builds on the Arizona Department of Transportation (ADOT) Standard Specifications for Road and Bridge Construction (2008) and the State of California Department of Transportation (Caltrans) Standard Specifications (2015). ADOT (2008) is silent on the use of warm mix additive during the asphalt mix design process, while Caltrans (2018) states in 39-2.01B(2)(c) ‘For HMA with WMA additive technology, produce HMA mix samples for your mix design using your methodology for inclusion of WMA admixture in laboratory-produced HMA.’

Clause 517.26.02.3 states that the mix used to determine air voids for binder content, deformation, moisture damage and moisture sensitivity shall not include a warm mix additive. Depending on the warm mix additive selected, it may influence all or some of these properties at the time of manufacture of the asphalt.

It is recommended that warm mix additive should be included in the mix used to determine air voids for binder content, deformation, moisture damage and moisture sensitivity.

2. Superpave Mix Design method - AAPA (2018) states that the volumetric design of GGA shall be performed in accordance with the Superpave Mix Design Method, similar to Caltrans requirements (Caltrans 2018). ADOT (2008) includes guidance on both the Superpave Mix Design Method and the Marshall Mix Design Method, but the Asphalt-Rubber Standard Practice Guide (RPA 2011) only details the Marshall Mix Design Method.

Specification 504: Asphalt wearing courses (MRWA 2017a) contains no guidance for GGA design, but states that for open graded asphalt mix design the Marshall method of design should be used. For dense graded wearing courses, the specification requires the air voids after 350 cycles of gyratory compaction to be no less than 2.5%.

Therefore, the Superpave Method being included in Clauses 517.26.02.3 and 4 was new to local industry in WA. It is recommended that this method be workshopped with industry when the Draft Specification 517 is published.

Also, note 1 to Table 517.6 states that where the asphalt is used in a very heavy traffic loading environment, 150 gyratory cycles should be used. This statement is in line with Austroads Part 4B (2014), which guides users that for routine mix design, the level of compaction depends on the traffic level, proposing 120 cycles under heavy traffic conditions. The note was misinterpreted, and it was understood that at 150 gyratory cycles an air void content of 4% should be obtained for the mix to be approved. In order to adhere to that criteria, the design grading and binder content would be skewed, and the mix would be almost impossible to compact during production.

Note 1 also states that the gyratory compactor shall be operated at 825 kPa loading pressure, where Caltrans (2018) states the ram pressure may be increased to a maximum of 825 kPa.

The mix design process commenced with Fulton Hogan selecting three gradations to obtain an understanding of the boundaries of the aggregate skeleton of locally available aggregates.



- 15 - June 2019

C320 grade binder was used for these initial tests with binder content between 7.5% and 7.8%. These binder contents aligned with that recommended by RPA (2011). Fibres were included in the Trial 3 mix, as some visible drain-off was noted on the Trial 2 mix. The fibres used were Topcel without any Sasobit.

The voids in mineral aggregate (VMA) results for the mixes did not clearly differentiate between the three trial mixes, all being within the 18% to 23% limit. Air voids at 150 gyrations (1.16 °, 825 kPa and 150 °C compaction temperature) were determined as an indicator to enable targeting 4.0% voids at 150 gyrations. However, as mentioned above, this interpretation of the Note 1 to Table 517.6 was incorrect.

After discussions the Trial 3 grading was selected to proceed with, for refinement and further testing.

The results of the three trials are summarised in Table 2.14 and the PSDs depicted in Figure 2.4.

Table 2.14: Trial 1, 2 and 3 gap graded mix results

Sieve size (mm) Trial 1 Trial 2 Trial 3 Limits*

19.00 100 100 100 100

13.20 99 99 98 90–100

9.50 87 81 90 83–87

6.70 63 56 64 –

4.75 35 25 41 28–42

2.36 19 13 22 14–22

1.18 13 9 19 –

0.60 10 7 11 –

0.30 7 5 8 –

0.15 6 4 6 –

0.075 4.3 3.0 4.6 0–6.0

Binder content (with C320) (%) 7.5 7.8 7.8 –

Fibres (%) – – 0.5 –

VMA (%) 21.6 22.8 19.2 18–23

Air voids at 150 gyrations (%) 6.1 6.9 1.8 –

Note: Limits as per Table 517.5.



- 16 - June 2019

Figure 2.4: PSDs of Trials 1, 2 and 3.

Note: Actual PSD after recovery of binder and other Marshall tests.

Figure 2.5 shows that there is a difference between the theoretical and actual (as determined after recovery of binder) PSD. This is notable on the sieve sizes 0.6 mm and smaller. Sabita Manual 19 (2016) notes that some fines, particularly material passing the 0.075 mm sieve, may be trapped in the rubber crumbs when carrying out the grading analysis after extracting the binder. Up to 1.5% of this fine material can be trapped in the crumbs that lead to lower than actual filler contents being measured. This phenomenon does not occur when the Ignition Furnace method is used.

Figure 2.5: PSD of Trial 3 with CRM binder, no warm mix additive.

The PSD of Trial 3 was refined to be in line with the limits contained in Table 2.12. The final design PSD (Trial 9) is summarised in Table 2.15.

0

10

20

30

40

50

60

70

80

90

100

0.07

5

0.15 0.

3

0.6

1.2

2.4

4.8

9.6

19.2

Per

cen

tag

e p

assi

ng

(%

)

Sieve size (mm)

Limit min

Limit max

T1 Actual

T2 Actual

T3 Actual

0

10

20

30

40

50

60

70

80

90

100

0.07

5

0.15 0.3

0.6

1.2

2.4

4.8

9.6

Per

cen

tag

e p

assi

ng

(%

)

Sieve size (mm)

Tol. min

Tol. max

T3 (Actual)

T3 (Theoretical)



- 17 - June 2019

Table 2.15: Design PSD for gap graded mix

Sieve size (mm) Trial 9 Limits*

19.00 100 100

13.20 99 90–100

9.50 83 83–87

6.70 61 –

4.75 39 28–42

2.36 20 14–22

1.18 14 –

0.60 10 –

0.30 8 –

0.15 6 –

0.075 4.4 0–6.0

Fibres (%) 0.5 –

Note: Limits as per Table 517.5.

The C320 binder was substituted with 7.5%, 8.0% and 8.5% CRM binder, including 0.5% of warm mix additive, EvoTherm, into the design PSD. The test specimens for each binder content were compacted in the gyratory compactor at 145 °C to determine the effect of gyrations on air voids and VMA for each binder content. The compaction temperature was lowered from the 155 °C determined in Clause 517.06.4 for equivalent binder viscosity with and without EvoTherm, to 145 °C based on Fulton Hogan’s experience in Queensland. Figure 2.6 depicts the results for air voids and Figure 2.7 depicts the results for VMA.

Figure 2.6: Air voids between 50 and 150 gyrations at 7.5%, 8.0% and 8.5% binder contents.

2

3

4

5

6

7

8

10 100

Air

vo

ids

(%)

Number of cycles (n)

CRM BC = 7.5%

CRM BC = 8.0%

CRM BC = 8.5%

15050



- 18 - June 2019

Figure 2.7: VMA between 50 and 150 gyrations at 7.5%, 8.0% and 8.5% binder contents.

Based on the results depicted in Figure 2.6, it can be concluded that a binder content of approximately 7.7% to 8.5% fulfils the Ndesign = 4.0% air voids between 50 and 150 gyrations criteria. A binder content of 7.5% crosses the 4.0% air voids line at approximately 180 cycles, outside of the number of gyrations requirement.

Figure 2.7 shows that all three binder contents yielded a VMA result between 18% and 23% for gyrations between 50 and 150, the results for VMA. Since 7.5% binder content does not fulfil the air void criteria, only 8.0% and 8.5% could be considered further.

It was decided that a CRM binder content of 8.0% would be trialled in a plant trial.

2.3.3 Approval of Asphalt Mix Design, Clause 517.26.03

This clause lists all the required test results for approval of the mix, lists information contained on the certificate to be issued upon approval, describes the requirements for renewal and limits of use of the approved mix.

The mix development did not proceed to approval of the asphalt mix design, as this will be completed later in 2019 and reported on separately.

2.4 Manufacture and Transport

2.4.1 Crumb Rubber Modified Binder, Clause 517.30

1. During manufacture of the crumb rubber modified binder the crumb

rubber and bitumen are to be thoroughly mixed prior to the beginning

of the reaction period. Mixing shall then continue with a reaction

period of at least 1 hour. Crumb rubber floating on the surface or

agglomeration of crumb rubber is evidence of insufficient mixing.

2. At the asphalt plant the crumb rubber modified binder shall be stored

in a vertical insulated binder tank incorporating circulation including a

continuous stirrer or may be stored in a mobile blending facility if the

binder has been batched at the asphalt plant.

18

19

20

21

22

23

10 100

VM

A (

%)

Number of cycles (n)

CRM BC = 7.5%

CRM BC = 8.0%

CRM BC = 8.5%

15050



- 19 - June 2019

3. The binder shall be stored at a temperature between 165ºC to 190ºC.

If during the first ten hours after completion of the reaction period the

temperature of the binder drops below 165ºC the binder may be

reheated to the required temperature of 165ºC to 190ºC. The binder

shall not be held at a temperature between 165ºC to 190ºC for more

than 10 hours after completion of the reaction period. Binder that is

to be used at a time beyond 10 hours after completion of the reaction

period shall be cooled to a temperature below 165ºC and reheated

when needed. Binder shall only be reheated once. Binder shall be

used within four days after completion of the reaction period.

4. For each batch of binder the Contractor shall provide the following

information:

The temperature of the bitumen prior to addition of the crumb

rubber

The source, grade and quantity of bitumen used

The crumb rubber content expressed as percent by weight of

total binder

Times and dates of addition of the crumb rubber

A continuous record of temperature of the binder against

time for each batch beginning at the time of addition of the

crumb rubber and until the load has been completely used.

5. Immediately prior to use of the crumb rubber modified binder for

asphalt production a sample shall be taken from the storage tank and

tested for viscosity at 175ºC. The viscosity shall be measured for

subsequent use of the binder in other shifts of asphalt production.

Where an alternative temperature has been proposed with the

approved asphalt mix design, as specified at 517.06, the viscosity

shall be measured at the alternative temperature. The viscosity shall

comply with the requirements of Table 517.8.

Table 2.16: Viscosity at production (Table 517.8)


Viscosity at 175 °C ASTM D7741/D7741M, or AGPT:T111 1.5–4.0 Pa.s

Fulton Hogan opted to construct a 20 tonne plant trial section on their premises at Hazelmere, Perth, on 1 March 2019. The CRM binder was mixed for one hour. After one hour a binder sample was taken and tested for compliance with the viscosity requirement. The binder did not include any warm mix additive at this stage. The viscosity was measured with the Rion handheld viscometer at approximately 175 °C, resulting in 1.6 Pa.s, which was between the required 1.5 to 4.0 Pa.s.

Since this viscosity was within the required limits, production of the trial mix proceeded.

Figure 2.8 illustrates the Rion handheld viscometer being used to determine the viscosity at Hazelmere in the laboratory.



- 20 - June 2019

Figure 2.8: Viscosity being measured in the laboratory at Hazelmere.

2.4.2 Mixing Plant, Clause 517.31

1. Asphalt shall be manufactured in a central mixing plant by either,

batch mixing, continuous mixing or drum mixing. All mixing plant and

equipment and associated facilities shall conform to the requirements

of AS 2150 and shall be such as to prevent segregation of the

asphalt at all stages.

Plant

2. A sampling cock shall be installed in the inlet pipe between the road

tanker and binder storage tanks. An additional sampling cock shall

be installed for sampling at the time of asphalt production between

the binder tank and the mixing chamber to facilitate the sampling of

any binder being used for asphalt production.

Binder sampling

cocks

3. For the verification of weights or proportions and character of

materials and determination of temperatures used in the preparation

of the asphalt, the Superintendent shall have access at any time to

all parts of the plant subject to safety considerations.

2.4.3 Manufacture of Asphalt, Clause 517.32

1. The quantities of coarse and fine aggregates, mineral filler, adhesion

agent and binder shall be accurately and positively controlled so as

to produce the asphalt specified for use in the Works. RAP shall not

be included in the production of asphalt.

Control

2. The mixing process shall be such as to produce a uniform distribution

of aggregate sizes and a uniform coating of binder on a minimum of

100% of aggregate particles when tested in accordance with AS/NZS

2891.11.

Mixing

3. The particle size distribution and the percentage of bitumen shall be

within the limits in the authorised asphalt mix design when tested in

accordance with WA 730.1 or AS/NZS 2891.3.1 using a dry

gradation.

Particle size

distribution



- 21 - June 2019

4. The air voids and VMA shall be in accordance with Tables 517.6 and

517.7 for asphalt and when tested in accordance with AS/NZS

2891.2.2, AS/NZS 2891.9.2 and AS/NZS 2891.8.

Volumetric

properties

5. The moisture content of the asphalt at the completion of the mixing

process shall not be greater than 0.15% by mass when measured in

accordance with AS/NZS 2891.10.

Moisture content

6. In a batch mixer the volume of material shall be limited to an amount

allowing the paddle tips to be seen when passing through the top

vertical position during mixing.

Volume of material

7. The temperature of the mixed asphalt shall be measured and

recorded at the discharge point of the pugmill or mixing drum. The

temperature of the asphalt shall not exceed 165°C.

Temperature at

discharge point

All of the testing listed in this clause was conducted on the mix produced during the plant trial. The results are reported in Appendix B.

2.4.4 Testing, Clause 517.35

1. The asphalt manufacturer shall provide and maintain at a suitable

location at the site of the mixing plant for the duration of the Contract

a suitably equipped air conditioned testing laboratory accredited by

the National Association of Testing Authorities of Australia (NATA) to

perform the following tests:

Testing Laboratory

WA 210.1, 212.1 or 212.2, 701.1, 705.1, 730.1, AS/NZS 2891.2.2,

AS/NZS 2891.7.1, AS/NZS 2891.8, AS/NZS 2891.9.1, AS/NZS

2891.9.2, AS/NZS 2891.10 and AS/NZS 2891.11.

2. The laboratory shall be equipped with all testing equipment

necessary to perform these tests. The asphalt producer shall

operate and maintain the equipment in good condition in accordance

with NATA requirements.

Testing equipment

3. Asphalt and mineral shall be tested for the properties and at the

testing frequency shown in Table 517.9.

Testing

requirements

Table 2.17: Asphalt and filler testing frequency (Table 517.9)

Property Test Method Minimum Testing Frequency

Binder content and PSD (Note 1) WA 730.1 or AS/NZS

2891.3.1 Up to 50 tonnes

Up to 150 tonnes

Up to 350 tonnes

Up to 550 tonnes

1 test

2 tests

3 tests

4 tests

Maximum Density AS/NZS 2891.7.1

Air Voids and VMA (Gyratory compaction)

AS/NZS 2891.2.2

AS/NZS 2891.9.2

AS/NZS 2891.8

Moisture Content AS/NZS 2891.10 1 test with initial production in first shift

and then once per week

Uniform Coating of Binder AS/NZS 2891.11 1 test with initial production in first shift

and then once per week

Stripping Potential of Asphalt - Tensile Strength

Ratio Test (one freeze/thaw cycle) AG:PT/T232

1 test with initial production in first shift

and then every 1500T

Voids in Dry Compacted Filler (%) AS 1141.17

1 test with initial production in first shift

and then once per week Apparent Density of Filler (t/m3) AS 1141.7

PSD of Filler AS 1141.11.1



- 22 - June 2019

Note 1 – when determining binder content the test shall be adjusted using the procedure described in Section 5 of Sabita

Manual 19 (Guidelines for the design, manufacture and construction of bitumen-rubber asphalt wearing courses published by

the South African Bitumen Association).

Note 1 of Table 517.9 was used to determine the correction factor to be used when determining the binder content after the extraction process. Some undigested rubber may not be accounted for during the extraction process and the correction factor was used to calculate the true binder content. A correction factor of 0.8 was calculated.

The results are contained in Appendix A.

4. Asphalt shall be sampled in accordance with WA 701.1 with samples

tested immediately they are taken. The number of tests undertaken

shall be evenly spread across the entire period of production for each

asphalt mix being tested within a shift.

Sample frequency

5. The first sample of asphalt in a shift shall be taken from the first 50

tonnes of asphalt manufactured in the shift for each type of mix being

manufactured.

First sample

6. If the result of a test sample does not conform to any specified

requirements another sample of asphalt shall be taken immediately

and tested immediately for a full test.

7. Results of testing shall be reported on a NATA endorsed test report

within 24 hours of a sample being taken. The testing laboratory shall

send all results directly to, amongst others, the Contractor, the

Superintendent and a nominated representative at the Main Roads

Materials Engineering Branch.

Reporting

2.4.5 Transport, Clause 517.37

1. The asphalt shall be transported from the asphalt plant to the Works

in metal bodied trucks or trailers previously cleaned of all foreign

materials. In long distance haul situations the asphalt should be

transported in insulated vehicles sufficient to ensure arrival of the

asphalt on site in a conforming condition.

Vehicle type

2. The temperature of the asphalt in each truck load and each trailer

load shall be measured using a calibrated digital probe thermometer

before the truck leaves the site of the asphalt manufacturing plant.

The thermometer shall have a digital display readable to 1°C and

have a measurement of uncertainty of not more than 3°C. Infrared

thermometers shall not be used to measure temperature. The

temperature shall comply with the requirements of Clause 517.32.7.

Temperature in

truck

3. The temperature of the asphalt shall be recorded on a printout

showing date, time and asphalt temperature for each truck load and

each trailer load of mix dispatched. The printout shall be provided

with the load delivery docket.

Temperature record

4. Each load shall be covered with suitable material of sufficient size to

prevent loss of heat from the mixture.

Heat loss

5. The asphalt shall be delivered at a uniform rate within the capacity of

the placing and compacting plant. Delivery rate

To simulate transporting of the asphalt, there was a delay of 30 minutes after being loaded before the mix was placed at the Hazelmere plant. The temperatures at loading were 160 °C.



- 23 - June 2019

2.5 Placing of asphalt

2.5.1 General, Clause 517.41

Clause 517.41.3 states that asphalt delivered to site shall be between 145 °C to 165 °C. Feedback from Fulton Hogan was that the lower limit of 145 °C delivery temperature, including a warm mix additive, was too high. It was proposed that the ambient temperature and base layer temperature should be specified. However, more data is required to establish acceptable limits for delivery temperature when warm mix additives are included in a mix.

2.5.2 Surface Preparation, Clause 517.42

The surface of the area at the Hazelmere plant was prepared according to requirements of this clause. The surface was milled and swept to remove any loose material. Figure 2.9 depicts the prepared surface.

Figure 2.9: Milling of area to be paved and cleaned after milling.

a) Milling in progress



- 24 - June 2019

b) Clean, prepared surface

2.5.3 Equipment, Clause 517.43

A self-propelled paver adhering to all the requirements was used during the paving on the trial at the Hazelmere plant. No material transfer vehicle (MTV) was used during the trial. Figure 2.10 depicts the paver in action.

Figure 2.10: CRM GGA being paved at Hazelmere plant.



- 25 - June 2019

2.5.4 Tack coat, Clause 517.44

A tack coat was not applied as per clause 517.44, but a Strain Alleviating Membrane Interlayer (SAMI) seal (1.6 l/m2 with 10 mm stone) was placed to simulate conditions on site. Figure 2.11 depicts rolling of the placed seal.

Figure 2.11: Rolling of SAMI seal.

2.5.5 Weather Conditions, Clause 517.46

1. Asphalt placement shall not commence or continue upon a surface

which is not clean and dry, and only when the pavement temperature

meets the requirements shown in Table 517.10 and rain is not

imminent.

Pavement

temperature

2. The Superintendent may, if the weather or surface conditions are

considered to be unsuitable, instruct the Contractor to cease laying

operations. Any materials laid after this instruction is given will not

be paid for and are to be removed at no cost to the Principal.

Table 2.18: Pavement temperatures for placement (Table 517.10)

Minimum pavement temperature when wind speed

< 20 km/h

Minimum pavement temperature when wind speed

≥ 20 km/h

15 °C 20 °C

The weather conditions were suitable for paving during the trial at Hazelmere plant.

2.5.6 Joints, Clause 517.47; Longitudinal Joints, Clause 517.48; Transverse Joints, Clause 517.49 and Terminal Joints, Clause 517.50

No additional comment on the clauses related to joints. During the trial, the requirements of the clauses were adhered to as much as practically applicable at the site.



- 26 - June 2019

2.5.7 Asphalt Construction Drawings, Clause 517.51

No additional comment on this standard clause.

2.5.8 Compaction, Clause 517.54

1. Self-propelled steel wheel rollers and meeting the requirements of

AS 2150 shall be used. Pneumatic tyred rollers shall not be used.

All rollers shall be fitted with reticulation to water wheels to prevent

pick up of asphalt and be fitted with scrapers to clean the wheels.

Equipment

2. Unless otherwise directed by the Superintendent rolling shall

commence immediately after placing and compacting with the

vibrating or tamping screed. The rolling shall start longitudinally at

the sides and proceed towards the centre of the pavement,

overlapping on successive passes by at least 150mm. Successive

passes of the roller shall be of slightly different lengths.

3. Roller speed shall be uniform. Stops and starts shall be controlled so

that displacement (shoving) of the asphalt mix does not occur when

changing direction. Any shoving occurring as a result of changing

direction, or from any other cause, shall be corrected at once by the

use of rakes and of fresh asphalt when required.

Roller stop/starts

4. To prevent adhesion of asphalt to the roller, all wheels shall be kept

properly moistened but excess of water shall be avoided.

Moistened wheels

5. Vibratory compaction shall be discontinued in areas where it is

considered such vibrations could cause damage to adjacent

buildings or structures. Under these conditions, initial compaction of

the asphalt shall be achieved using the self-propelled static steel

wheeled rollers of appropriate mass to meet the compaction

requirements in Clause 517.55.

Vibratory

compaction

6. The Contractor shall ensure the protection of services and property

from deterioration or damage due to the works.

Protection

7. Rollers shall be kept in continuous operation as much as practicable

and in such a manner that all parts of the pavement receive

substantially equal compaction. In the event of a delay in the laying

operation, rolling is to be carried out as close as practicable to the

paving machine. Rollers shall not be parked on work carried out the

same day.

Continuous

Operations

8. A sufficient number of rollers shall be available on site

commensurate with the rate of supply of asphalt and the output of the

paving machine.

Number of Rollers

9. All joints must be filled and edges adjacent to kerbing and such other

hand work as may be necessary must be rolled with a suitable

pedestrian type roller.

Joints

10. Finish rolling shall be carried out while the material is still warm

enough for the removal of tyre marks.

Finish Rolling

11. At places not accessible to the roller, thorough compaction must be

ensured by means of hot tampers and at all joints with structures the

surface mixture must be effectively sealed.

Hot Tampers

Figure 2.12 depicts rolling of the placed CRM GGA. Fulton Hogan tried different rolling sequences on the night of the trial. These and the resulting compaction will be reported on in the following section.



- 27 - June 2019

Figure 2.12: Rollers on CRM GGA asphalt during compaction.

2.5.9 Compaction Requirements, Clause 517.55

1. The Characteristic In situ Air Void content for any lot shall be deemed

to be conforming if it attains a maximum characteristic value of no

greater than 8.0% and a minimum characteristic value of no less than

3.0%. The Characteristic In-situ Air Voids shall be determined for the

asphalt in accordance with Clause 1.2.2 of Annexure 201A of

Specification 201 QUALITY SYSTEMS.

In-situ air voids

2. Air Voids shall be calculated on the basis of the results of tests of

core samples of asphalt sampled from an asphalt layer after laying

and compaction in accordance with WA 701.1 and prepared in

accordance with WA 705.1. The density of the core samples shall be

determined in accordance with AS/NZS 2891.9.1. The air voids shall

be calculated in accordance with AS/NZS 2891.8 using the mean

Maximum Density of all asphalt results from the same production

shift in accordance with AS/NZS 2891.7.1.

3. Core samples shall be taken within 24 hours of placement of a lot of

asphalt. Results of testing shall be reported on a NATA endorsed

test report within 48 hours of the core samples being taken. The

testing laboratory shall send all density results directly to, amongst

others, the Contractor, the Superintendent and a nominated

representative at the Main Roads Materials Engineering Branch.

Testing and

reporting of results



- 28 - June 2019

4. Where any lot of asphalt work is deemed non-conforming the

Contractor shall apply remedial action in accordance with the

procedures contained in Specification 201 QUALITY SYSTEMS, and

the lot shall be removed and replaced with fresh asphalt and

retested. Removal shall be carried out so as not to damage the

underlying layers or any road furniture such as gully gratings. Any

such damage shall be repaired at no cost to the Principal.

Non-conformance

Table 2.19 depicts the rolling sequences applied on the various sections constructed during the plant trial, as well as the characteristic in situ air void content achieved.

Table 2.19: Rolling sequence on different lanes and resulting compactions.

Run 1 2 3 4 5 6

No. of passes and

compaction setting

4 vibratory +

1 static

6 vibratory +

1 static

7 vibratory +

1 static

1 static +

6 oscillating

1 static +

6 oscillating 6 oscillating

Average thickness (mm) 45.5 44.9 39.1 39.3 - 38.5

Air voids (%) Upper

characteristic air voids 7.3 5.9 7.2 5.9 - 6.7

Air voids (%) Lower

characteristic air voids 6.6 4.8 5.7 4.8 - 5.3

Coring of the plant trial section did not take place within 24 hours of placement, but five days after. The compaction results from coring are summarised in Figure 2.13. The results indicate overall compliance to the density requirement of characteristic in situ air void content 3.0% and 8.0%. A combined mean of 6.0%, ranging between 4.1% and 8.2% was achieved. Reported results are also contained in Appendix A.

Figure 2.13: Reported field core air voids data.

2.5.10 Surface Requirements, Clause 517.56

This section contains requirements generally specified for wearing courses in terms of shape, level, thickness and compliance.

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

Run 1 Run 2 Run 3 Run 4 Run 6

Fie

ld c

ore

air

vo

ids

(%) 1

2

3

4

5

6

7

Core No.



- 29 - June 2019

2.5.11 Opening Finished Works to Traffic, Clause 517.57

A hold point applies before a section of road can be opened to traffic. No additional comment on this standard clause.



- 30 - June 2019

3 CONCLUSIONS AND RECOMMENDATIONS

3.1 Conclusions

WARRIP Project 2019-002: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 2, focussed on facilitating the use of CRM binder in GGA. This interim report documents the binder and mix design development of a CRM GGA mix by Fulton Hogan.

Fulton Hogan was the industry partner for WARRIP Project 2019-002, as well as WARRIP Project 2016-011: Transfer of appropriate crumb rubber modified bitumen technology to WA – Stage 1, which focussed on CRM in open graded asphalt.

A new draft specification was compiled in August 2018 (Main Roads 2018) that outlined the products and materials, mix design, manufacture and transport, placing of asphalt and as built and handover requirements of crumb rubber gap graded asphalt for pavement wearing courses. Draft Specification 517 was used by Fulton Hogan to develop a CRM binder and CRM GGA mix.

A 20 tonne trial section was constructed on 1 March 2019 at Hazelmere Plant. The plant trial was conducted to evaluate the workability of the designed mix during production and experiment with rolling sequence and roller setting.

The following was concluded during the binder and mix design process following Draft Specification 517:

Fulton Hogan (2018) developed and tested a 20% and 18% CRM binder. They commented that if a higher crumb rubber content than 18% is desired, a softer base binder may be required or the use of combining oils considered, as the 20% CRM blend did not comply with the viscosity requirements.

There are differences between the viscosity measured by the Brookfield viscometer (AGPT/T111) and the Rion VT-06 handheld viscometer (ASTM D7741/D7741M), but it appears to give the same result at 175 °C. The supplier of a CRM binder needs to be aware of this and that calibration of the Rion VT-06 handheld viscometer to the measurements of the Brookfield viscometer will be required.

Testing and adherence to requirements with or without warm mix additive lead to confusion during the design process.

The Superpave Mix Design method is specified in this draft specification. This method has not been widely used in WA and it led to a steep learning curve in using it.

The mix was more workable than expected during the construction of the trial section.

A demonstration trial is planned for late 2019 using full scale production of CRM GGA.

3.2 Recommendations

The recommended changes to Draft Specification 517 are summarised in Table 3.1:

Table 3.1: Summary of recommendations

Clause/Table/Note Recommendation

Table 517.1 Add ‘Note 3 – For the AGPT:T111 method the L series Brookfield is recommended together with spindle SC4-29’



- 31 - June 2019

Clause/Table/Note Recommendation

Figure 2.2 A Rion-Brookfield viscometer result comparison is recommended if both instruments will be used during design or

construction to ensure the reading is the same at 175 °C and to establish the relationship to be used during

production.

Alternatively, only the use of the Brookfield viscometer should be specified.

Clause 517.06.4 It is recommended that after the completion of Clause 517.06.4, the remainder of the binder design and mix

design process should include the warm mix additive and that all requirements should be met including the warm

mix additive.

Clause 517.26.02.3 & 4 It is recommended that the mix design should comply with Table 517.6 including the warm mix additive. This will

be representative of what is constructed in the field.

Note 1 of Table 517.6 and

Clause 517.26.02.4

It is recommended that the process be presented to industry in a workshop as training, as there has been limited

use of the Superpave Method of asphalt mix design in WA



- 32 - June 2019

REFERENCES

Arizona Department of Transportation 2008, Standard specifications for road and bridge construction, 31-

066, ADOT, Phoenix, AZ, USA.

Australian Asphalt Pavement Association 2018, Crumb rubber modified open graded and gap graded

asphalt pilot specification, AAPA, Melbourne, Vic.

Austroads 2014, Guide to pavement technology part 4B: asphalt, AGPT04B-14, Sydney, NSW.

Deng H, Ma X., Deng D and Tan L, 2019, ‘Fatigue Properties of Rubber Modified SMA Asphalt Mixture’,

MATEC Web Conf. 275 04001, DOI: 10.1051/matecconf/201927504001

Fulton Hogan 2018, ‘Transfer of crumb rubber modified asphalt to Western Australia’, progress report SR-

TS18013-2, Fulton Hogan, Dunedin, New Zealand.

Ghabchi, R, Zaman, M & Arshadi, A 2016, Use of ground tire rubber (GTR) in asphalt pavements: literature

review and DOT survey, Oklahoma Department of Environmental Quality, Oklahoma City, OK, USA.

Main Roads Western Australia 2017a, Asphalt wearing courses, specification 504, MRWA, Perth, WA.

Main Roads Western Australia 2017b, Materials for bituminous treatments, specification 511, MRWA, Perth,

WA.

Main Roads Western Australia 2018, Crumb Rubber Gap Graded Asphalt, draft specification 517, MRWA,

Perth, WA.

O’Connell J, Anochie-Boateng J and Marais H, 2010, ‘Evaluation of bitumen-rubber asphalt manufactured

from modified binder at lower viscosity, Southern African Transport Conference, 29th, 2010, Pretoria,

South Africa.

Queensland Department of Transport and Main Roads 2016, ‘Crumb rubber modified open graded asphalt

surfacing’, PSTS112, TMR, Brisbane, Qld.

Rubber Pavements Association 2011, Asphalt-rubber standard practice guide, RPA Technical Advisory

Board, Tempe, AZ, USA.

SABITA 2016, Guidelines for the design, manufacture and construction of bitumen-rubber asphalt wearing

courses, manual 19, 4th edn, SABITA, South Africa.

State of California Department of Transport 2015, Standard specifications, division V, section 39, Caltrans,

Sacramento, CA, USA.

State of California Department of Transport 2018, Standard specifications, division V, section 39, Caltrans,

Sacramento, CA, USA.

Way, GB, Kaloush, KE & Biligiri, KP 2011, Asphalt-rubber standard practice guide, Rubber Pavements

Association, Tempe, Arizona, USA.

Wu, JP, Herrington, PR & Neaylon, K 2015, Removing barriers to the use of crumb rubber in roads, research

report 578, NZ Transport Agency, Wellington, NZ.



- 33 - June 2019

Austroads methods

AGPT-T103-2006, Pre-treatment and loss on heating of bitumen multigrade and polymer binders (rolling thin

film oven [RTFO] test).

AGPT-T111-2006, Handling viscosity of polymer modified binders (brookfield thermosel).

AGPT-T112-2006, Flash point of polymer modified binders.

AGPT-T122-2006, Torsional recovery of polymer modified binders.

AGPT-T131-2006, Softening point of polymer modified binders.

AGPT-T143-2010, Particle size and properties of crumb rubber.

AGPT-T144-2006, Morphology of crumb rubber - bulk density test.

AGPT-T231-2006, Deformation resistance of asphalt mixtures by the wheel tracking test.

AGPT-T232-2007, Stripping potential of asphalt - tensile strength ratio.

Australian and New Zealand Standards

AS 1141 6.1-2000, Methods for sampling and testing aggregates: particle density and water absorption of

coarse aggregate: weighing-in-water method.

AS 1141.22-2008 amdt 1:2016, Methods for sampling and testing aggregates: wet/dry strength variation.

AS 1141.25.2-2003, Methods for sampling and testing aggregates: degradation factor: coarse aggregate.

AS 1141.26-1996, Methods for sampling and testing aggregates: secondary minerals content in basic

igneous rocks.

AS 1141.50-1998, Methods for sampling and testing aggregates: resistance to stripping of cover aggregates

from binders.

AS/NZS 1141.66:2012 amdt 1: 2018, Methods for sampling and testing aggregates Methylene blue

adsorption value of fine aggregate and mineral fillers.

AS 2341.3-1993, Methods of testing bitumen and related roadmaking products: determination of kinematic

viscosity by flow through a capillary tube.

AS 2341.7-1993, Methods of testing bitumen and related roadmaking products: determination of density

using a density bottle.

AS 2341.11-1994, Methods of testing bitumen and related roadmaking products: determination of ductility.

AS 2341.12-1993, Methods of testing bitumen and related roadmaking products: determination of

penetration.

AS 2341.14:2013, Methods of testing bitumen and related roadmaking products Determination of flashpoint

of bitumen.



- 34 - June 2019

AS/NZS 1141.7:2014, Methods for sampling and testing aggregates: apparent particle density of filler.

AS/NZS 1141.17:2014, Methods for sampling and testing aggregates: voids in dry compacted filler.

AS/NZS 2341.2:2015, Methods of testing bitumen and related roadmaking products: determination of

dynamic viscosity by vacuum capillary viscometer.

AS/NZS 2341.4:2015, Methods of testing bitumen and related roadmaking products: part 4: determination of

dynamic viscosity by rotational viscometer.

AS/NZS 2341.8:2016, Methods of testing bitumen and related roadmaking products: part 8: determination of

matter insoluble in toluene.

AS/NZS 2341.10:2015, Methods of testing bitumen and related roadmaking products.

AS/NZS 2341.13:1997 Rec:2013, Methods of testing bitumen and related roadmaking products: long-term

exposure to heat and air.

AS/NZS 2891.2.2:2014, Methods of sampling and testing asphalt: sample separation: compaction of asphalt

test specimens using a gyratory compactor.

AS/NZS 2891.3.1-2013, Methods of sampling and testing asphalt.

AS/NZS 2891.7.1:2015, Methods of sampling and testing asphalt: determination of maximum density of

asphalt: water displacement method.

AS/NZS 2891.8:2014, Methods of sampling and testing asphalt: voids and volumetric properties of

compacted asphalt mixes.

AS/NZS 2891.9.2:2014, Methods of sampling and testing asphalt: determination of bulk density of

compacted asphalt: presaturation method.

American Society for Testing and Materials (ASTM) Methods

ASTM D 5329:2016, Test methods for sealants and fillers, hot-applied, for joints and cracks in asphalt

pavements and portland cement concrete pavements.

ASTM D7741/D7741M:2018, Standard test method for measurement of apparent viscosity of asphalt-rubber

or other asphalt binders by using a rotational handheld viscometer.

Queensland Methods

Q325-2019, Stability of asphalt: Hamburg wheel tracking device (HWTD).

Western Australia Methods

WA 210.1-2013, Particle size distribution of aggregate.

WA 216.1-2016, Flakiness index.



- 35 - June 2019

WA 220.1-2012, Los Angeles abrasion value.

WA 235.1-2010, Bulk density of granulated rubber.

WA 237.1-2010, Steel content of granulated rubber.

WA 716.1-2018, Bitumen durability Dynamic Shear Rheometer method.

WA 730.1-2011, Bitumen content and particle size distribution of asphalt and stabilised soil: centrifuge

method.



- 36 - June 2019

APPENDIX A PLANT TRIAL RESULTS

A.1 Performance Testing of Proposed Mix

A.1.1 Hamburg Wheel Tracking Test



- 37 - June 2019

A.1.2 Wheel Tracking Test (Cooper)

National Pavement Materials Laboratory

25 Groves Avenue, McGraths Hill, N.S.W., 2756

Ph: (02) 4587 5131

ABN: 54 000 538 689

NATA Report Number: N190207

Project Description: GGA14 (CR)(S) Development for MRWA Request Number: 191009

Requested By: Laszlo Petho - Fulton Hogan, Geebung, QLD

AG:PT/T231: Deformation resistance of asphalt mixtures by the wheel tracking test.

Sample Description: GGA14 (CR)(S) Mix / Sample No.:

Sample Source: Fulton Hogan, Hazelmere Source Sample No.:

Mix Type: Lab Mix Mix Date:

CHK CHL

14/02/19 15/02/19

18/02/19 19/02/19

4 4

2.273 2.305

5.8 4.5

50.4 49.8

60 60

60 60

700 700

10,000 10,000

3.5 2.3

Note: 1 - Asphalt re-heated for compaction.

Approved Signatory:

Name: John Kozumplik

Position: Laboratory Supervisor

Date of Issue:

Laboratory Accreditation Number: 2291

Full Reproduction of this document must have approval from this laboratory. Corporate Site Number: 23668

Applied Load (N):

Number of Loading Passes:

Final Ave. Tracking Depth (mm):

The results of tests,

calibrations and or

measurements included in this

document are traceable to

Australian / national

standards.

Accredited for compliance with

ISO/IEC 17025 - Testing.

Mean Height (mm):

Initial Temperature (°C):

Final Temperature (°C):

MeanSpecimen ID:

Compaction Date:

5.2

Test Report - Deformation Resistance of Asphalt mixes by Wheel Tracking

Standards Reported:

ASTM D7981-15: Standard practice for compaction of prismatic asphalt specimens by means of the

shear box compactor

Test Date:

Age (days):

Bulk Density (t/m³):

Air Voids (%):

19009

LM880

12/02/2019

700

19/02/2019

10,000

2.9

0

1

2

3

4

5

6

7

8

9

- 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

Ave

rage

Rut

De

pth

(m

m)

Number of Passes

RN: 191009 - SN: 19009, GGA14 (CR)(S)

Slab ID: CHK

Slab ID: CHL

19009 GGA14 (CR) (S) WTr 60°-10,000 passes Page 1 of 1



- 38 - June 2019

A.1.3 Sensitivity of Asphalt to Water



- 39 - June 2019

A.2 Plant Trial Test Reports

A.2.1 Grading, Binder Content, Maximum Density and Marshall Air Voids

ASPHALT COMPLIANCE REPORT

Report Number : PER19W0317 05.03.2019

Client : Hazelmere Production

Location : Fulton Hogan-Hazelmere Yard Trial

Mix Type : 14mm Gap Graded Blows: 75

MRD Number: N/A

H2969 H2970

Sample Date 01.03.2019 01.03.2019

Test Date 01.03.2019 05.03.2019

Asphalt Temperature 160 160

BITUMEN CONTENT % 6.4% 6.7% 7.5 8.5

Bitumen Class CR(S) CR(S)

GRADING (%) PASSING:

100 100

100 100 100

97 100 96 100

87 81

70 66

52 48 34 48

24 25 16 26

16.1 17.8

11.6 13.5

7.7 8.8

5.0 5.4

3.7 3.3 1.3 4.3

MOISTURE CONTENT %

MARSHALL PROPERTIES:

Compaction Temperature0C 148.0 148.0

Bulk Density t/m3

2.305 2.302

Maximum Density - Rice t/m3

2.430 2.422

Air Voids % 5.2% 5.0%

Voids in Mineral Aggregate % 23.1% 23.7%

Voids Bitumen Filled % 77.6% 79.1%

Stability kN N/A N/A

Flow mm N/A N/A

Test Methods : MRD WA 210.1,701.1,705.1, 730.1, 731.1, 732.2, & 733.1

Note: CR(S) binder factor of 0.78 was established at the mix design stage

Accredited for compliance

with ISO 17025 - testing

Fulton Hogan Industries158 Talbot Road, PERTH AIRPORT WA 6105.

Phone No. : (08) 9454 0130 Fax No. : (08) 9352 8308

NATA Accreditation Number : 1979

Date of Report :

Lot Number :

13.20mm

SAMPLE NUMBER:

26.50mm

19.00mm

Approved Signatory:

Dilhani Jayasekara

Laboratory SupervisorTest results apply only to sample as tested

Specification

.150mm

9.50mm

6.70mm

.075mm

2.36mm

1.18mm

4.75mm

.600mm

.300mm

The tested binder content is 6.4% for sample H2969. Total CR(S) binder content is therefore 6.4/0.78=8.2%.

The tested binder content is 6.7% for sample H2970. Total CR(S) binder content is therefore 6.7/0.78=8.6%.



- 40 - June 2019

A.2.2 Asphalt Moisture Content

Report No. : PER19W0318 Date of Report: 05.03.2019

Client : Hazelmere Production Lot Number: -

Location: Fulton Hogan-Hazelmere Yard Trial Sample date: 01.03.2019

Mix Type: 14mm Gap Graded Test date: 01.03.2019

Sample Number: H2969

UOM Specification

% < 0.15

Test Method: RMS T660, Sampling Method:AS/NZS 2891.1.1

Notes :

Approved Signatory:



Laboratory Supervisor

Dilhani Jayasekara

Fulton Hogan Industries158 Talbot Road, Perth Airport WA 6105

Phone No. : (08) 9454 0130 Fax No. : (08) 9352 8308


ASPHALT MOISTURE CONTENT TEST REPORT

Test results apply only to sample as tested

Asphalt Moisture Content

Test Type Results

0.07



- 41 - June 2019

A.2.3 Degree of Particle Coating

Report No. : PER19W0319 Date of Report: 05.03.2019

Client : Hazelmere Production Lot Number: -

Location: Fulton Hogan-Hazelmere Yard Trial Sample date: 01.03.2019

Mix Type: 14mm Gap Graded Test date: 01.03.2019

Sample Number: H2969

UOM Specification

%

Test Method: AS/NZS 2891.11, Sampling Method: AS/NZS 2891.1.1

Notes :

Approved Signatory:



Laboratory Supervisor

Results

100

Test results apply only to sample as tested

Fulton Hogan Industries158 Talbot Road, Perth Airport WA 6105

Phone No. : (08) 9454 0130 Fax No. : (08) 9352 8308


DEGREE OF PARTICLE COATING TEST REPORT

Dilhani Jayasekara

Degree of Particle Coating

Test Type



- 42 - June 2019

A.2.4 Baghouse Dust



- 43 - June 2019

A.2.5 Core Results

transfer of appropriate crumb rubber modified bitumen ......transfer of appropriate crumb rubber...

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