An overview of the emerging warm mix asphalt technology

The asphalt industry is constantly attempting to reduce its emissions as concerns are growing on global warming. This is done by decreasing the mixing and compaction temperatures of asphalt mixtures without affecting the properties of the mix which is possible through numerous available technologies in the industry. The production of asphalt mix is done by warm mix asphalt (WMA) technology at considerably lower temperatures (120°C or lower). Less energy consumption, lower mixing and compaction temperatures, early site opening, reduced ageing, fewer emissions, cool weather paving, better workability and, finally, an extended paving window could be mentioned as some of the benefits obtained by using the WMA. This paper presents the WMA techniques and technologies such as foaming techniques, wax and chemical additives techniques. Additionally, the performance of WMA popular technologies such as Sasobit^®, WAM^®-Foam, Evotherm^®, Low energy asphalt, Rediset^® WMX and REVIX? are fully described.     

Black curves and creep behaviour of crumb rubber modified binders containing warm mix asphalt additives

Warm mix asphalt (WMA) is a new research topic in the field of road pavement materials. This technology allows lower energy consumption and greenhouse gas (GHG) emissions by reducing compaction and placement temperatures of the asphalt mixtures. However, this technology is still under study, and the influence of the WMA additives has yet to be investigated thoroughly and clearly identified, especially in the case of crumb rubber modified (CRM) binders.In order to study the effect that different types and quantities of organic waxes have on the high and intermediate temperature properties of 15 % and 20 % CRM binders, a dynamic shear rheometer (DSR) was used. Using Black diagrams, the rheological behaviour of the binders for the defined range of test temperature and frequency are summarised in a single diagram. In this way, a preliminary evaluation of the rheological behaviour in the extended domain of time and temperature can be attained as well as the effectiveness of the time–temperature superposition principle (TTSP) on the materials under study. Creep tests were also performed in order to evaluate the differences regarding mechanical response due to the addition of rubber and WMA additives, and particularly the ability to recover the strain at high temperatures.The results of this study reveal that these binders do not conform to the Time Temperature Superposition Principle (TTSP) and their rheological behaviour is strongly affected by the interaction of waxes and bituminous matrix and thus generally exhibited a higher elasticity compared to the corresponding control binder. The creep test results carried out proved the enhancement of elasticity and the resistance to permanent deformation produced by the addition of waxes. The WMA additives significantly lower the maximum deformation when compared to the control binders and slightly increased their elastic recovery.     

Rheological characterization of wax-modified asphalt binders at high service temperatures

The research reported herein focuses on the rheological characterization of wax-modified asphalt binders used in warm mix asphalt (WMA) technology. Wax-modified asphalt binders were produced by adding controlled quantities of different types of wax to a 50/70 unmodified bitumen. Five different kinds of wax were used, including synthetic hydrocarbons Fischer–Tropsch wax, Montan waxes and amidic-modified waxes. All the blends were subjected to different rheometric tests to assess their mechanical response at high service temperatures. The viscous deformation mechanism was analyzed with reference to static and repetitive creep loading; it was found that the viscous deformation is strongly affected by the presence of both hydrocarbons and amidic-modified waxes. Wax-modified binders exhibited an effective improvement in intrinsic resistance to non-reversible deformation, even in high applied stress and cyclic loading conditions. It was observed that the chemical composition and the consequent physical characteristics of the wax are the most important factors regulating the final behavior of wax-modified asphalt binders at high service temperatures. The final contribution of the experience performed is related to the technical evaluation of wax-modified asphalt binders and to the general development of WMA technologies for pavement applications.     

Performance evaluation of WMA plant and field trial mixes

Warm mix asphalt (WMA) technology is still in its infancy, with significant scope for further exploration of the benefits of incorporation of higher percentages of recycled asphalt RA as well as modified binders for performance enhancement. The objective of this study was to evaluate three different WMA technologies, namely chemical and organic additives as well as foamed technology, within different mix compositions. The variables in mix composition included 10–20 % RA in surfacing mixes and 20–40 % RA in base layer mixes. The binder variables included two base binders, control mixes (no modifier) and ethylene vinyl acetate (EVA) or styrene butadiene styrene (SBS) with or without WMA technologies. A partial factorial experimental design based on the above variables was developed. Full-scale plant mixes and field (construction) mixes were produced and beams were prepared from compacted slabs and tested under 4 point loading to provide master curves and fatigue relations. Comparative results show inconsistent trends between different technologies. control mixes (HMA) can provide both higher and lower flexural stiffness than their WMA counterparts. EVA or SBS modification can provide either superior or inferior mixes to their WMA counterparts depending on the WMA technology. Generally the fatigue results of both the HMA surfacing and base layer mixes at both RA contents are superior to their equivalent WMA counterparts. The implications of these differences are explored in the publication.     

Linear and nonlinear viscoelastic and viscoplastic analysis of asphalt binders with warm mix asphalt additives

Warm-Mix Asphalt (WMA) is a widely used product, which proved a contribution to the reduction in asphalt mixing and compaction temperatures. This reduction leads to lower fuel consumption and smoke emission in asphalt plants. Most of the characterisation of binders used in WMA has focused in the past on measuring linear viscoelastic properties and associated Superpave parameters. Several studies have shown that the average stresses and strains of the asphalt mixture remain mostly within the linear viscoelastic response. However, localised strains in the binder phase of the mixture could reach values high enough to induce nonlinear viscoelastic and viscoplastic deformations. Therefore, this study focuses on an experimental and analytical evaluation of linear, nonlinear viscoelastic and viscoplastic responses of selected binders modified for use in WMA. The first part of the paper analyses the linear viscoelastic material properties and their ability to evaluate permanent deformation resistance. Then, the non-recoverable creep compliance parameter obtained from the Multiple Stress Creep Recovery (MSCR) test is analysed to assess the nonlinear response and permanent deformation of asphalt binders. The paper utilises a nonlinear plasto-viscoelastic (NPVE) approach to assess and quantify the nonlinear plasto-viscoelastic response of binders by separating the recoverable and irrecoverable strains measured in the MSCR test. Two WMA additives were included in this study by mixing them with polymer-modified and unmodified asphalt binders. Analysis of results showed that the NPVE approach captured a higher percentage of recovery than the NLVE approach. However, binder’s performance evaluation and ranking did not change by adopting the NPVE approach. The nonlinear viscoelastic parameters provided insight on the behaviour of asphalt binders mixed with WMA additives during loading cycles. Sasobit showed higher influence than Advera on binders in resisting permanent deformation by increasing the recoverable strain during the unloading phase.     

Study on viscosity of conventional and polymer modified asphalt binders in steady and dynamic shear domain

This study focuses on evaluating the flow behavior of conventional and polymer modified asphalt binders in steady- and dynamic-shear domain, for a temperature range of 20–70 °C, using a Dynamic Shear Rheometer (DSR). Steady-shear viscosity and frequency sweep tests were carried out on two conventional (VG 10 and VG 30) and two polymer (SBS and EVA) modified asphalt binders. Applicability of the Cox–Merz principle was evaluated and complex viscosity master curves were analyzed at five different reference temperatures. Cross model was used to simulate the complex viscosity master curves at different temperatures.It was found that asphalt binders exhibited shear-thinning behavior at all the test temperatures. The critical shear rate increased with increase in temperature and was found to be lowest for plastomeric modified asphalt binder. The Cox–Merz principle was found to be valid in the zero-shear viscosity (ZSV) domain and deviated at higher frequency/shear rate for all the binders. Results from the study indicated that the ratio of ZSV can be successfully used as shift factors for construction of master curves at different reference temperatures. Cross model was found to be suitable in simulating the complex viscosity master curves at all the test temperatures. Analysis of model parameters indicated that a strong relationship exists between ZSV and the critical shear rate. ZSV and critical shear rate varied exponentially with temperature. This relationship was used to propose a simple equation for assessing the shift factors for construction of master curves.     

Effect of warm mix additives on the interfacial bonding characteristics of asphalt binders

The quality of the interfacial bonding between asphalt binder and aggregates plays a significant role in determining the durability of asphalt mixtures. Warm mix asphalt (WMA) modifiers have been used extensively in the last decade primarily to reduce production and compaction temperatures as well as to improve workability of asphalt mixtures. This study aimed to provide better understanding of the effects of these WMA modifiers on the interfacial bonding between asphalt binders and aggregates. The evaluation focused on measuring surface energy of binders in unaged and aged states and aggregates and then calculating energy parameters that describe the potential of a given asphalt-aggregate combination to resist fatigue cracking and moisture damage. Results show that the combination of asphalt-WMA additive, as well as the content applied of WMA additive has a significant impact on the fatigue cracking and moisture damage resistance. The results suggest that it is poor practice to use a given type and percentage of WMA modifier without regard for binder type. Instead, test methods are recommended to evaluate the compatibility of asphalt binder, WMA additive type/content, and aggregates for improved performance at different conditions.     

Evaluation of the performance of warm mix asphalt in Washington state

Warm mix asphalt (WMA) is a relatively new and emerging technology for the asphalt industry. It offers potential construction and environmental advantages over traditional hot mix asphalt (HMA). However, WMA must perform at least as well as HMA before it can be used extensively. This study evaluates the performance of WMA mixtures and their corresponding HMA control mixtures obtained from various field sites in the state of Washington. Four WMA technologies are examined, including Sasobit^® and three water-foaming technologies, Gencor^®, Aquablack? and ALmix Water Injection. Performance tests are conducted on the field cores to evaluate and compare the rutting, moisture susceptibility, fatigue and thermal resistance of WMA and HMA, respectively. Also, the extracted binders from the field cores are evaluated. In addition, the early-age field performance of WMA and HMA control pavements are compared.     

Use of waste high density polyethylene as bitumen modifier in asphalt concrete mix

The purpose of this study is to investigate the possibility of using various plastic wastes containing High Density Polyethylene as polymer additives to asphalt concrete. It was investigated that the influence of HDPE-modified binder obtained by various mixing time, mixing temperature and HDPE content on the Marshall Stability, flow and Marshall Quotient (Stability to flow ratio). The binders used in Hot Mix Asphalt (HMA) were prepared by mixing the HDPE in 4–6% and 8% (by the weight of optimum bitumen content) and AC-20 at temperatures of 145–155 and 165 °C and 5–15 and 30 min of mixing time. HDPE-modified asphalt concrete results in a considerable increase in the Marshall Stability (strength) value and a Marshall Quotient value (resistance to deformation). Four percent HDPE, 165°C of mixing temperature and 30 min of mixing time were determined as optimum conditions for Marshall Stability, flow and Marshall Quotient (MQ). MQ increased 50% compared to control mix. It can be said that waste HDPE-modified bituminous binders provide better resistance against permanent deformations due to their high stability and high Marshall Quotient and it contributes to recirculation of plastic wastes as well as to protection of the environment.     

Effect of waste plastic bottles on the stiffness and fatigue properties of modified asphalt mixes

Nowadays, the use of recycled waste materials as modifier additives in asphalt mixes could have several economic and environmental benefits. The main purpose of this research was to investigate the effect of waste plastic bottles (Polyethylene Terephthalate (PET)) on the stiffness and specially fatigue properties of asphalt mixes at two different temperatures of 5 and 20 °C. Likewise, the effect of PET was compared to styrene butadiene styrene (SBS) which is a conventional polymer additive which has been vastly used to modify asphalt mixes. Different PET contents (2–10% by weight of bitumen) were added directly to mixture as the method of dry process. Then the resilient modulus and fatigue tests were performed on cylindrical specimens with indirect tensile loading procedure. Overall, the mix stiffness reduced by increasing the PET content. Although stiffness of asphalt mix initially increased by adding lower amount of PET. Based on the results of resilient modulus test, the stiffness of PET modified mix was acceptable and warranted the proper deformation characteristics of these mixes at heavy loading conditions. At both temperatures, PET improved the fatigue behavior of studied mixes. PET modified mixes revealed comparable stiffness and fatigue behavior to SBS at 20 °C. However, at 5 °C the fatigue life of SBS modified mixes was to some extent higher than that of PET modified ones especially at higher strain levels of 200 microstrain.     

Effect of aggregate types on the performance of neat and EVA-modified asphalt mixtures

The objective of this study is to determine the effect of bitumen modification with varying percentage of ethylene vinyl acetate (EVA) for preparing the hot-mix asphalt containing various aggregates (marble, granite and quartzite) and compare the results with mixes prepared with neat viscosity grade 30. The selection of aggregates has been done based on their acidic and basic nature. The physical and mechanical properties of EVA-modified bitumen and neat bitumen aggregate mixes were evaluated. Moisture susceptibility tests and wheel tracking test were carried out on the samples. Brookfield viscometer and dynamic shear rheometer were used to determine the mixing and compacting temperatures of neat and modified bitumen. The results indicate that mixes prepared with aggregates that are basic in nature, i.e. with higher calciumcontent, show better bonding with both neat bitumen and EVA-modified bitumen compared with acidic aggregates, i.e. aggregates with higher silica content.     

Influence of selected WMA additives on viscoelastic behaviour of asphalt mixes and pavements

Warm mix asphalt additives are effective in decreasing production, laying and compaction temperatures of asphalt mixes. However, there are still questions concerning influence of warm mix additives on properties of asphalt mixes and pavement performance. This paper presents results of the comprehensive research of viscoelastic behaviour of asphalt mixes and pavement structures with layers made with warm mix asphalt additives at high temperatures. Two additives of significantly different effects on mixes at higher temperatures were selected for analysis, namely aliphatic synthetic wax produced with the use of Fisher–Tropsch method and formulation of surfactant- based molecules (ionic and non-ionic). Viscoelastic properties of mixes with these two additives and, as a reference mix, with neat unmodified asphalt binder were determined in uniaxial compression with sinusoidal loading using Asphalt Mixture Performance Test. The viscoelastic analysis of pavement structures was performed with use of the VEROAD software and data from laboratory testing. Two different pavement structures were analysed, for light and heavy traffic. The temperature distribution in pavement structure during the hottest summer day in northern Poland in 2012 was taken into account. The model of pavement was loaded with moving wheel at different speeds. The analysis has shown that two tested warm mix additives had different effect on viscoelastic transient response at high temperatures. One of them (Fischer–Tropsch wax) evidently caused an increase in resistance of asphalt mix and pavement structure to loading at high temperature. The second additive (formulation of surfactant-based molecules) slightly reduced resistance of asphalt mix and pavement to loading at high temperatures as compared with the reference mix.     

Laboratory investigation of the properties of epoxy asphalt rubber (EAR)

Crumb rubber is preliminarily mixed with asphalt in wet process to produce ductile and elastic asphalt rubber (AR), which has been extensively used in high performance bituminous mixtures for road pavement. Epoxy asphalt is a thermosetting polymer modified asphalt with excellent performance and has been widely applied on the pavement of steel bridge decks. Epoxy asphalt rubber (EAR) was prepared by mixing AR with the epoxy (EP). The effect of AR concentration on the phase-separated morphology, viscosity, thermal stability and mechanical properties of the neat EP were compared with that of asphalt. Laser scanning confocal microscopy observations revealed that AR particles disperse in the continuous epoxy phase with co-continuous phase-separated structures in EARs with 40 and 50 wt% AR. However, the phase inverts to continuous asphalt structures with dispersed spherical and co-continuous epoxy phase as AR concentration reaches 60 wt%. The addition of AR increases the viscosity of the neat EP. The thermal stability of the neat EP is improved with the incorporation of AR. The presence of AR decreases the tensile strength of the neat EP, while the elongation at break of the neat EP increases with the increase of AR concentration. The viscosity and mechanical properties of EAR with 50 wt% AR completely satisfy the technical requirement of hot-mix epoxy asphalt binder for steel bridge deck pavements.     

Dynamic mechanical characterization of asphalt concrete mixes with modified asphalt binders

The primary objective of this work is to characterize and compare the dynamic mechanical behavior of asphalt concrete mixes with styrene butadiene styrene (SBS) polymer and crumb rubber modified asphalt binders with the behavior of mixes with unmodified viscosity grade asphalt binders. Asphalt binders are characterized for their physical and rheological properties. Simple performance tests like dynamic modulus, dynamic and static creep tests are carried out at varying temperatures and time. Dynamic modulus master curves constructed using numerical optimization technique is used to explain the time and temperature dependency of modified and unmodified asphalt binder mixes. Creep parameters estimated through regression analysis explained the permanent deformation characteristics of asphalt concrete mixes. From the dynamic mechanical characterization studies, it is found that asphalt concrete mixes with SBS polymer modified asphalt binder showed significantly higher values of dynamic modulus and reduced rate of deformation at higher temperatures when compared to asphalt concrete mixes with crumb rubber and unmodified asphalt binders. From the concept of energy dissipation, it is found that SBS polymer modification substantially reduces the energy loss at higher temperatures. Multi-factorial analysis of variance carried out using generalized liner model showed that temperature, frequency and asphalt binder type significant influences the mechanical response of asphalt concrete mixes. The mechanical response of SBS polymer modified asphalt binders are significantly correlated with the rutting resistance of asphalt concrete mixes.     

Comparison between the fatigue response of hot and warm mix asphalts based on the dissipated energy approach

This study focused on the fatigue behaviour of warm mix asphalt (WMA) based on the dissipated energy (DE) approach. Two conventional binders consisting of 60/70 and 85/100 penetration-grade bitumens were used to prepare the control mix. WMA was prepared by incorporating 2% Sasobit by weight of bitumen. First, the basic properties of WMA containing optimum bitumen content were compared with those of control hot mix asphalt (HMA). The main laboratory programme included four-point flexural fatigue test that was accomplished at different strain levels of 250, 500, 750 and 1000 microstrain. The studied WMA had comparable Marshall stability and indirect tensile strength to those of control HMA. Furthermore, based on the resilient modulus test results, the temperature susceptibility of WMA was slightly more than that of the control mix. Fatigue lives of studied mixes were evaluated using the conventional fatigue curves that were developed based on the initial strain level. Comparison between these curves revealed the predominant fatigue behaviour of WMAs at different examined strain levels. The initial DE and the cumulative DE of WMAs were lower than those of HMAs. The latter issue justifies the predominant fatigue response of WMA. By considering the DE curve, the ratio of dissipated energy change (RDEC) was calculated. Afterward, the plateau value (PV) was determined using the moving average of fatigue data in the plateau stage of the RDEC curve. Finally, PV-based fatigue models were developed which could precisely estimate the fatigue life regardless of the mix type and testing condition.     

Cracking of asphalt at low temperature as related to bitumen rheology

A laboratory investigation of the influence of bitumen rheology on low temperature behaviour of asphalt mixtures is described. Five bitumens from four sources and three different mixture types were studied. Rheological characteristics of the binders were measured using conventional methods (penetration, softening point and viscosity) as well as dynamic mechanical analysis (DMA). Low temperature properties of asphalt characterized by the fracture temperature were measured using thermal stress restrained specimen test (TSRST). Statistically significant relations between rheological characteristics of bitumens and TSRST fracture temperatures of asphalt specimens were established. © 1998 Chapman & Hall     

Performance evaluation of warm mix asphalt containing reclaimed asphalt mixtures

The objective of this study is to expose the effect of a variety of variables including three reclaimed asphalt pavement (RAP) contents, two warm mix asphalt (WMA) additives and a rejuvenating agent (or lack of) on the performance of WMA containing (WMA–RAP) materials. A laboratory study was conducted to evaluate the performance of WMA–RAP mixtures through rutting, bending and freeze-thaw splitting tests. Analysis of variance (ANOVA) was performed to analyse the significant effect of the variables on the performance. The tests results showed that the increased RAP content led to an increased rutting resistance and the decreased resistance to low-temperature cracking and moisture damage. The addition of the rejuvenating agent into the WMA–RAP mixtures can significantly improve the low-temperature cracking and moisture resistance. The ANOVA results showed that the RAP content had a significant effect on the rutting and low-temperature cracking resistance, and moreover, the rejuvenating agent (or lack of) had a large effect on the low-temperature cracking and moisture resistance.     

The use of asphalt low shear viscosity to predict permanent deformation performance of asphalt concrete

The permanent deformation performance of asphalt concrete is strongly dependent on the rheological properties of the asphalt binder. It has been recognized that the asphalt’s low shear viscosity (LSV) characterizes the mixture’s rutting resistance. At the same time, the pavement temperature is one of the main factors that significantly affect the mixture performance. In this work the rutting performance of mixtures prepared with the same aggregate gradation and different binders [conventional (C), multigrade (M) and polymer modified (PM) asphalts] were evaluated by using wheel tracking tests (WTT) performed at 50, 60, 70 and 80°C; in parallel, the LSV of asphalts were measured at the same temperatures. The relationship between the asphalt’s LSV and rutting, to predict asphalt mixture performance, was discussed and a criterion to consider the effect of LSV is proposed.     

Field performance of top-down fatigue cracking for warm mix asphalt pavements

As a result of repeated rehabilitation efforts over the past few decades, often asphalt pavements have become deep-strength pavements. Consequently, top-down cracking has become a primary distress type. In particular, the top-down cracking performance of warm mix asphalt (WMA) pavements, i.e. how does it compare with similar hot mix asphalt (HMA) pavements is largely unclear mainly due to the lack of field performance data. This paper presents an effort of monitoring the top-down cracking performance of 28 pavement projects including WMA pavements and their corresponding HMA control pavements with service lives ranging between 4 and 10 years. These pavements cover different climate zones, WMA technologies, service years, pavement structures and traffic volume levels. Two rounds of distress surveys were conducted at a two-year interval, and the material (asphalt binder and mixture) properties of the pavements were determined using field cores. The top-down cracking performance of the HMA and WMA pavements was compared based on the first and second round distress surveys. It was found that the HMA and WMA pavement in general exhibited comparable performance. The significant determinants (material properties) for top-down cracking were determined, which were vertical failure deformation of mixes measured at 20 °C from indirect tension test.     

Towards an optimised lab procedure for long-term oxidative ageing of asphalt mix specimen

Ageing of bitumen leads to increased stiffness and brittleness. Thus, bituminous bound pavements become more prone to failure by low-temperature and fatigue cracking. Therefore, the ageing behaviour of bitumen has a crucial impact on durability, as well as recyclability of pavements. To assess ageing of bitumen, the rolling thin film oven test and pressure ageing vessel are standardised methods for short-term and long-term ageing in the lab. For lab-ageing of hot mix asphalt (HMA), various methods have been developed in the last decades. This paper presents a study on the potential of employing a highly oxidant gas for simulating the long-term oxidative ageing of asphalt mix specimens in the lab. Based on the results, an optimised lab-ageing procedure (Viennese Ageing Procedure – VAPro) for compacted HMA specimens to assess mix performance of long-term lab-aged specimens is developed. Thus, it is possible to optimise mix design not only for short-term performance but to take into account effects of oxidative ageing during its in-service life. VAPro is based on a triaxial cell with forced flow of a gaseous oxidant agent through the specimen. The oxidant agent is enriched in ozone and nitric oxides to increase the rate of oxidation. It is shown by stiffness tests of unaged and lab-aged specimens, as well as by Dynamic Shear Rheometer tests of recovered binder from aged specimens that asphalt mixes can be long-term aged at moderate temperatures (+60°C) and within 4 days and a flow rate of 1 l/min by applying VAPro. Thus, an ageing procedure is at hand that can simulate long-term ageing at conditions that are representative of conditions that occur in the field within an efficient amount of time.