CONTENTS ‘SINo. Description Page No. Disclaimer - ‘Acknowledgements z | Ust of Tables - - - List of Figures - 1.0 INTRODUCTION 1 20 BACKGROUND OF THE STUDY 1 3.0 LABORATORY EVALUATION 2 40 MATERIAL CHARACTERIZATION 2 al ‘Aggregates 2 42 RAP Characterization 3 43 Fresh Bitumen Characterization — 4 44 Proportioning of Fresh Aggregates and RAM 5 5.0 MIX PREPARATION 7 60 JOB MIX FORMULA 10LIST OF TABLES Table No. Description Page No. Table 1 | Physical requirements for coarse aggregates for Dense 3 Bituminous Macadam Table 2 | Aggregate Specific Gravity ry 3 Table 3 | Gradation of RAP Material Ts Table 4 | Properties of Binder extracted from RAP 4 Table 5 | Physical properties of VG-30 and VG-40 Binder 4 Table 6 | Gradation of blended material for DBM-1 (15 % RAP) 5 Table 7 | Gradation of blended material for DBM-II (15 % RAP) 6 Table 8 | Marshall Test ResultsforDBM1 8 Table 9 | Marshall Test Results for DBM-II 9 Table 10 | Job Mix Formula for DBM-1 by weight of total mix 10 Table 11 | Job Mix Formula for DBM-Il by weight of total mix 10LIST OF FIGURES Figure No. Description Page No. Figure 1 _| Flow Chart for Design of RAP Mixes 2 Figure 2 | Proposed Gradation for DBM-| 6 Figure 3 | Proposed Gradation for DBM-II 7 Figure 6 _| Plots of Marshall Test Results for DBM-! with 15 % RAP 8 Figure,7 _| Plots of Marshall Test Results for DBM-ii with 15 % RAP 9—_.. 1. INTRODUCTION Bitumen (Asphalt) is a dark brown to black, highly viscous, hydrocarbon produced from petroleum distillation residue. Bitumen is generally used to prepare bituminous mixtures. Bitumen is classified into two categories namely, unmodified and modified bitumen. Further unmodified bitumen is classified into four types based on viscosity, namely VG-10, VG-20, VG- 30, and VG-40. Modified bitumen is further classified into crumb rubber-modified and polymer-modified bitumen, Reclaimed asphalt pavement (RAP) is the term given to removed and/or reprocessed pavement materials containing asphalt and aggregates, These materials are generated when asphalt pavements are removed for reconstruction, resurfacing, or to obtain access to buried utilities. When properly crushed and screened, RAP consists of high-quality, well-graded aggregates coated by asphalt cement. Asphalt pavement is gegerally removed either by milling or full-depth removal. illing entails the removal of the pavement surface using a milling machine, which can remove up to 50 mm (2 in) thickness in a single pass. Full-depth removal involves ripping and breaking the pavement using a rhino horn on a bulldozer and/or pneumatic pavement breakers, 2. BACKGROUND OF THE STUDY CEIGALL India Ltd, A-898, Tagore Nagar, Ludhiana, Punjab-141001, vide their letter .No.CIL/QA/QC/DK-07/01/2023/1195, Dated-16/01/2023 requested CSIR-CRRI to provide the Evaluation of RAP Material and Mix Design of DBM Grade-l (90 mm Thickness) and Grade I! (70 mm Thickness) for construction of 4-lane greenfield Delhi-Amritsar-Katra expressway from the junction with Patiala-Bathinda road(NH-7) near Bhawai rh to the junction with Ludhiana-Malerkotla road (SH-11) near Bhogiwal village (km 188+830 to 2254770) (total Project length 36.940 km) on EPC mode under Bharat mala Pariyojna in the state of Punjab. CSIR-CRRI agreed to take up the work. This technical report presents laboratory evaluation done on reci ied asphalt pavement (RAP) aggregates, RAP binder, fresh aggregate, and fresh VG 40 binder. Mix designs were carried out as per Asphalt Institute Manual MS-20 and MS-2 Asphalt Mix Design Methods (7th edition). Ministry of Road Transport (2013) specifications for DBM-I & DBIM-Il_ gixes were Fesible Povernent Division, CSIR-CRR, New Delhi + See——— SSSSSSSSSSSsSSSSSSSSsSsSseess followed in finalizing the mix design. Detailed investigations carried out in this study are discussed in the following sections. 3. LABORATORY EVALUATION The objective of the material evaluation is to sample, test, and determine the important properties of the asphalt materials to come up with an optimum blend of materials to meet the final mix requirement. The task consists of sampling and evaluation of aged mix (RAP mix), the rejuvenator/recycling agent, and the proposed virgin aggregate and bitumen. The flowchart for the design of RAP mixes is given in Figure 1 and it shows the general steps followed for the RAP mixes. “Aggregate gradation and binder content from. Reclaimed Asphalt Pavement (RAP), properties of extracted binder a Gradation of New Aggregates aL Determine combined gradation in recyeled mix ‘Determine approximate binder demand of combined agaregates t ‘Estimate virgin agaregate in recycled mix z ‘Estimate Peccent of New binder in the Mix a ‘Select Grade of the New binder/Rejuvenator (Grom Viscosity/Complex Modulus Blending Chart) v ‘Trial Mix designs by Marshall Method a eee Select Job Mix!Formula igure 1: Flow Chart for Design of RAP Mixes 4, MATERIAL CHARACTERIZATION 4.1 Aggregates The milled material and fresh aggregate (40 mm, 26.5 mm, 20 mm, 10 mm and stone dust) were sent by the client. The materials were evaluated for their physical properties as per Flexible Pavement Division, CSIR-CRRI, New Delhi 2relevant IS codes. The physical-properties of fresh aggregate and recovered aggregates from the RAP are given in Table 1. The specific gravity of fresh aggregate (40 mm, 26.5 mm, 20 mm, 10 mm and stone dust) is given in Table 2. Table 1: Physical requirements for coarse aggregate for Dense Bituminous Macadam Property "Test Fresh RAP Aggregate | Recommended Aggregate | (RAM) Test Value | Limits as per Test Value (%) (%) MORTH 2013 Particle | Combined Flakiness and 29 Fra 35 Max. shape Elongation Index Strength | Aggregate impact Value 10.06 15.23 27 Max. Water Water absorption Value 0:50 053 2 Max. absorption _| (%) Stripping | Coating and stripping of 38 98 95 Min, bitumen aggregate mix Table 2: Aggregate Specific Gravity ‘Aggregate Sample ‘Specific Gravity 40 mm Aggregate 2.650, 26.5 mm Aggregate | 2.623 20mm Aggregate 2.662 10 mm Aggregates 2.590 Stone Dust 2565 4,2. RAP Characterization Gradation of the reclaimed asphalt pavement (RAP) material for DBM | grading and DBM Il grading (as per MORTH section 500) is shown in Table 3. Bitumen was recovered from the milled material using distillation and Abson recovery method as per ASTM D 1856. The average binder conten} the RAP was found to be 3.8% by weight of RAP. << iy LaF a Flexible Pavement Division, CSIR-CRRI, New Delhi 3HS Table 3: Gradation of RAP material IS Sieve Size (mm) '% passing from the specified IS sieve 375 100.0 265 100.0 19 100.0 _ 13.2 88.3 35 655 475 wag 236 345 118 25. 06 204 03 169 015 87 0.075 43 RAP Binder content (%) 38 The proper of the bitumen binder extracted fr: Table 4: Properties of Binder extracted from RAP ‘om RAP are shown in Table 4, Parameter Value Penetration at (25°C), 0.1mm 8 Softening Point (°C) 88 ‘Specific Gravity 1.03 4.3 Fresh Bitumen Characterization The Physical Properties of the fresh bitumen are sI shown in Table 5. Table 5: Physical properties of VG-30 and VG-40 Binder Parameter VG-30 6-40 Penetration at (25°C), 0.1mm 56 44.8 Viscosity (60 °C) Poise | 3504 4728 ‘Softening Point (‘C) 1 51 54 Specific Gravity 1.02 1.02 5 sity Flexible Pavement Division, CSIR-CRRI, New Deihi4.4 Proportioning of Fresh Aggregates and RAM A blending exercise was carried out to identify the proportion in which RAM and different sizes of fresh aggregates are to be mixed to achieve the gradation specified by MORTH for DBM-1& DBM-2, The following aggregates/RAM were available for blending. 1. 40 mm Aggregates 2. 26.5 mm Aggregates 3. 20 mm Aggregates 4. 10 mm Aggregates 5, Stone Dust 6. RAM Different sizes of fresh aggregate and RAM were proportioned to achieve the target gradation specified by the Ministry of Road Transport and Highways (2013). The proportioning for DBM- 1 in indicated in Table 6 & for DBM-2 is indicated in Table 7. Table 6: Gradation of blended material for DBM-I (15 % RAP) (14.43 % RAM) Sieve ee DeM-1 (mm) ‘Aggregate Fractions used Combined | Specified Limit | Mid | Grading as per Value (40 | 20 | 10 | Stone | RAM MORT&H, [mm | mm | mm | dust 2013 45 | 100 | 100 | 1000 | 1000 | 1000 | 100.0 100 |_100 375 | 99 | 100 | 1000 | 1000 | 1000 9972 | 95-100 975 265 | 46 | 100 | 100.0 | 1000 | 99.6 693 | 78 | [-132 [0 | 11 | 100.0 | 100.0 | 844 55-75 65 [47s [0 | 0 | 209 | 985 | 496 3854 46 z36 {| o | o | 42 | 932 | 402 [28-42 35 o3 | 0 | 0 | 06 | 454 | 244 721 4 oo | 0 | 0 | 03 | 65 | 109 28 5 used | 27 | 10 | 14 34 15 | From the blending exercise, 15 % RAP material was blended with fresh aggregates to achieve the target gradation consideration shown in Figure 2 CE Flexible Pavement Division, CSIR-CRRI, New Delhi a < ote, Eviegeateei DBM-I with 15% RAP 100 90 20 70 60 50 40 30 20 10 % PASSING 001 Is SIEVE MO-LOWER RANGE —-@—UPPER RANGE -5--MO VALUE PASSING Figure 2 : Proposed Gradation for DBM-1 Figure 3 shows the aggregate gradation with 15 % RAP for DBM-Il. Table 7: Gradation of blended material for DBIM-II (15% RAP) (14.43 % RAM) DBM II Aggregate Fractions used Specified Mid Limit as per Value 20 | 10 | Stone | RAM ‘MORT&H, mm | mm | dust 2013 100 | 100 | 100 | 1000 | 100.00 1000 | 400 too | 100 | 100 99.6 | 98.83 90-100 95 * 91.81} 100 100 97.6 82.15 71-95 83 10.85) 100 100 84.4 66.11 56-80 68 1.43 | 20.93 | 98.47 49.6 43.14 38-54 46 oO 4.17 | 83.21 40.2 33.49 28-42 35 { 0 | 063 | 4537] 244 18300 | 7-21 15 ) 0.27 651 10.9 3.77 28 5 12 | 20 Ee eC ee) | | | | ot hey oe ey” Flenble Pavernent Division, CSIR-CRRIDBM - Il with 15% RAP 100 %0 20 2 g 60 a gS 0 Ps 20 10 ° oot GM teen 0 100 ®-LOWER RANGE SUPPER RANGE —@-MIDVALUE PASSING Figure 3: Proposed Gradation for’ DBM 5. MIX PREPARATION The mixing protocol is based on the most recent standard (MS 2 2015) and laboratory mixing experiences. The mixing method consists of the following stages: + Dry and heat the virgin aggregates above the mixing temperature (160-165°C) by a certain amount. Although actual mixing temperatures vary, a good rule of thumb is to increase the temperature of virgin aggregates by 0.5°C for every percent of RAP used in the mix. Thus, for a mix with 15,0% RAP, the mixing temperature of the virgin aggregate should be raised by7.5°C. © Heat the virgin binder at the ing temperature (160-170°C) * Put the RAP material in the mixer. The mixing was done for 20-30 seconds to get the uniform RAP mix. * Add the virgin aggregates and then add the hot virgin binder and mix it well to get a homogeneous asphalt mix and to achieve a complete coating of the aggregate. ‘The Marshall Test results for DBM- | & DBM-II are given in Table 8 and Table 9.Table 8 : Marshalll Test results for DBM-1 Total Binder | Gm» | AirVoids| VMA | VFB | Stability | Flow Content, % (By | (g/cc) | (%) (%) (%) (kn) (rum) Weight of Mix) 35 2.287 65 15.28 57.49 23.62 47 4.0 2.313 46 14.76 67.33 25.14 53 4s 2.332 3.6 14.51 75.31 26.21 6.1 5.0 2.294 24 16.34 84.14 25.55, 6.7 STABILITY DENSITY _7 234 7 = Ba gan Bm Bos =a 2.28 3035 4 45 5 55 Sous a Gs al ‘% Bitumen % AIR VOIDS vMA we? 20 ge et ais Sa gi6 2 Zu ee Fo 2 335 4 455 2544S 8S % Bitumen % Bitumen veB FLOW VALUE 100.00 .? 30.00 ® 30.00 g§ Se ee @ 70.00 BS > 60.00 22 50.00 ° 2035 4 45 555 3035 4 45 555 % Bitumen % Bitumen Flexible Pavement Division, CSIR-CRRI, New Delhi Figure 4 : Plots of Marshall Test results for DBM-I with 15 % RAPTable 9 : Marshall Test results for DBM-It Total Binder Gmo VMA | VFB | Stability] Flow Content, % (By (g/cc) | (%) (%) (%) (kN) (mm) Weight of Mix) 40 2313 5.16 1557 | 6630 | 14.86 18 | 45 2.357 441 1441 | 6843 | 15.67 29 | 50 2380 | 329 1403 | 7753 | 16.89 36 35 2.361 263 15.17 | 8369 | 15.61 45 Note : Gny = Bulk density of the bituminous mixture STABILITY DENSITY v B65 8 a zw E236 2, 234 Buss = é % 22 m3 B23 aun 145 eas 4 45 5 55 6 3504 45S % Bitumen % BITUMEN % AIR VOIDS VMA x 25 ge 2 3 8D ga) 28 — 2g? 9 ° Ps i a5 #4 SSO % Bitumen % BITUMEN VFB FLOW VALUE 100.00 .° ® = B 50.00 ge ae £ B20 0.00 Zoo 3504 45 Ss 3504 a5 55S % BITUMEN % BITUMEN Figure 5: Plot of Marshall Test results for DBM-II with 15% RAP Flexible Pavement Division, CSIR-CRRI, New Delhi6. JOB MIX FORMULA, The optimum total binder content (with 15 % RAP) corresponding to a median air void content of 4.0 % is obtained as 4.20 % and 4.70 % for DBM - | & DBM - Il by weight of the total mix, respectively. The Marshall properties obtained at Optimum Binder Content (OBC) and other details of the Job Mix Formula, by weight of total mix, are given in Table 10 & Table 11. Table 10 : Job Mix Formula for DBM-I by weight of total mix . RAP Aggregate (RAM) = 14.43% a) Total RAP to be added = 15.0% b)_RAP binder = 0.57 % p. Fresh Aggregates= 81.37 % (40 mm +20 mm + 10 mm + stone dust) a) 40 mm Aggregates = 25.85 % b) 20mm =9.57% ¢) 10mm = 13.40% d) stone dust = 32.55 % inder by weight of total mix= 4.2% a) Fresh bitumen (VG-40) = 3.63 % b)_RAP binder = 0.57% Table 11 : Job Mix Formula for DBM-II by weight of total mix . RAP Aggregate (RAM) = 14.43% a) Total RAP to be added = 15.0% b) RAP binder = 0:57 % D. Fresh Aggregates = 80.87 % (26.5 mm + 20 mm + 10 mm ¢ stone dust) a) 26.5 mm Aggregates = 19.98 % b) 20mm = 11.42% ) 10mm =19.03 % d) stone dust = 30.45 9% . Binder by weight of total mix = 4.7 % a) Fresh bitumen (VG-40) 13% b) RAP binder = 0.57 %