French Instituteof Science and Technology for Transport, Developmentand Networks

BioRePavation: Innovation in bio-recycling of old asphalt pavements

Emmanuel CHAILLEUX

Consortium

• IFSTTAR (France - coordination – will evaluate durability at full scale)

• EIFFAGE Infrastructures (EI - France – will produce an alternative binder & carry mix design test )

• Iowa State university (ISU-USA – will produce a bioasphalt & carry mix design test)

• KRATON chemical (former Arizona Chemical )(AZCHEM-Netherlands – will produce a bio-based performance additive)

• Western Research Institute (WRI-USA – will carry non-destructive in-situ evaluation and binder test)

• University of Nottingham (UNOTT-UK - will conduct life cycle and risk assessment and binder test)

Main objectives

• Towards safe cost effective renewable pavement– Aims to evaluate innovations in pavement recycling

techniques using alternative binders from renewable biomass.

– From a societal point of view, the target is to save natural resources by reducing consumption of virgin materials

• virgin petroleum bitumen• virgin aggregate from quarries

– In line with international movement towards less hydrocarbon consumption

• 3 alternative materials used to reuse asphaltic pavement :

• bio-based rejuvenator designed to increase RA content up to 100%• bioasphalt designed to increase RA compatibility with virgin materials• bio-binder designed for total replacement of bitumen in recycling

technique

• An innovative non destructive method, based onphysico/chemical analysis from in-situ micro samples

ScopeTo promote innovations

Experimental demonstrator built on the IFSTTAR APT (Accelerated pavement testing) facility:

• Macroscopic evaluation of distress mechanism• Non destructive ageing evaluation• Analysed in terms of life cycle and risk assessment

ScopeTo validate innovations

Today presentationFocus on:

• Lab assessment of innovative pavement materials with high reclaim asphalt content using three alternative binders

• Full scale experiment on the IFSTTAR facility

• Non destructive method

• Life cycle and risk assessment

Experimental plan - Materials

• BM-1: SylvaroadTM (rejuvenator), Arizona Chemical/Kraton Polymers

• BM-2: Biophalt® (vegetable binder), Eiffage

• BM-3: Epoxidized methyl soyate, Adventus & ADM/ISU

• FB: Fresh binder, 50/70 Pen grade• AB: Aged binder, extracted from

RAP• RAP: RAP 8/12mm, RAP 0/8mm,

Eiffage plant• Aggregates: 10/14mm, 0/2mm,

filler, Eiffage plant

Experimental plan - MaterialsBM-1: SYLVAROAD™ RP1000

• Patented by Kraton/Arizona Chemical • Bio-based additive from Pine chemistry• Developed for the reuse of Reclaimed Asphalt

– Increase RA content to 70%, even 100% in theory– Reverse RA quality (very hard aged binder)– Facilitate asphalt mix manufacturing

Experimental plan - MaterialsBM-2: Biophalt®• Patented 3rd generation of Eiffage Bio-binder • Designed for HMA and WMA• Composed by pitch, rosin and elastomers• Made with >90% of bio raw materials

• Pitch is composed by fatty acids that help for the rejuvenation of the old binder

• Elastomers improve ductility and resistance to ageing

• Lowers the high & low temperature stiffness of bitumen.• Lower energy consumption due to lower viscosity & lower mixing/compaction

temperatures.• No concern with mass loss compared to other bio-renewable additives.• Moisture content < 0.15%.• Highly competitive in terms of cost relative to petroleum-based additives.

Soybean oilEsterificationMethyl soyate

Determine optimal additive dosage

EpoxidationEpoxidized

methyl soyate

Binder grading and rheology

Blend with virgin binder

and recovered RAP binder

Experimental plan - MaterialsBM-3: Epoxidized Methyl Soyate

• Patented by Adventus & ADM/ISU

Experimental plan - Mix designGB5® type mixes

• A new type of base course mix has been designed : GB5 type mix (50 % RAP and 70% RAP) using aggregate packing concept (by maximizing their interlock)

– Designed according to:» Aggregate availability on the plant» Lab studies of blends with virgin binder and recovered RAP binder

in order to determine optimal dosage

0102030405060708090

100

0 0 1 10 100

Pass

ing

( % )

Sieve

50% RAP

70% RAP

• Main mix properties:• Very dense mix• High modulus with a

relatively equivalent « soft binder »

• Low binder content 4.5%

Experimental plan - Tests

– Comparison between US and EU mix performance evaluation systems

– Structural design using both EU and US methodologies

EU - CEN US - Superpave

Binders:(AB, FB)Blends:(AB+FB)(BM-1+AB+FB)(BM-2+AB)(BM-3+AB+FB)

Pen/R&B/Fraass PG grading system

Mixes (50% RAP):MIX1= (BM-1+FB+AB)MIX2= (BM-2+AB)MIX3= (BM-3+FB+AB)

Gyratory / Water sensitivity / Rutting / Stiffness / Fatigue

Volumetric / Stiffness / Rutting / Low Temp. Perf. / Fatigue

ResultsBinder properties following EU specification system and US one

EU binder specification US binder specification

Binders and blends

Penetration at 25°C (dm

m)

Softening point (⁰C)

Softening point after RTFOT (⁰C)

Fraass breaking point (⁰C)

DSR failure temperature (°C)

BBR failure temperature (°C)

PGOriginal (25mm)

RTFOT aged

(25mm)

Low pass temp

(m-value)

Low pass temp (S)

AB 7 81.0 +14 99.4 > 0° 94 >-16

FB 55 49.0 -7 68.1 67.3 -12.6 -15.6 64-22

FB+AB 25 61.8 +1 80.6 81.9 -7.5 -11.4 76-16

BM1+FB+AB 33 57.2 61 -4 77.2 76.9 -12.1 -14.2 76-22

BM2+AB 80 68.8 54.6 -7 79.6 61.5 -15.9 -15.3 58-22

BM3+FB+AB 71.9 73.8 -12.3 -14.5 70-22

FB: Fresh binder

AB: Aged binder, extracted from RAP

ResultsMix Performances using the European/French specification system

Mixes

Volumetric data

Water sensitivity

%

(NF EN 12697-12)

Rut depth at 30000 cycles

(NF EN 12697-22+A1)

Complex modulus

at 15°C, 10 Hz

(NF EN 12697-26 -A)

Fatigue performance at 10°C, 25 Hz

Strain at half of the initial

modulus at 106

cycles

(NF EN 12697-24 -A)

Richness modulus

Void content after 100 gyrations

(gyratory compactor)

(NF EN 12697-31)

Requirements for a EM2 (AC14

base)> 3.5 <6% >0.75 < 7.5 % >14000 MPa > 130 µdef

Requirements for a GB4 (AC14

base)< 9% >0.70 < 10% >11000 MPa >100 µdef

MIX1(BM1+FB+AB) 3.0 4.2% 85% 5.6%

(void = 4.4%)12860 MPa(void = 3.2%) ε6=113 µdef

MIX2(BM2+AB) 3.0 3.0% 86% 4.3%

(void = 3.5%)14620 MPa(void = 3.0%) ε6=84 µdef

MIX3(BM3+FB+AB) 3.0 4.2% 90% 3.7%

(Void = 5.5%)12100 MPa(Void = 4.3%) ε6=107 µdef

ResultsMix Performances using the US specification system

Mixes

Volumetric dataStiffness

(MPa)

at 15°C, 10 Hz

AASHTO TP-79

Rutting resistance

(flow number)

At 7% air void

T=54°CAASHTO TP-79

(Cycles)

DCT (N/m)

Low temp.

cracking resistanceAt 7% air void

At -12°CASTM D7313

Fatigue life(4-point bending mode)

Fatigue line

N=K1*ε-K2

AASHTO T-321

VMA VFA DP %Va%Gmm@ Nini

Requirementmedium

traffic level> 13.0 [65 – 78] [0.6 –

1.2] 4 < 90.5 >190 >400

MIX1(BM1+FB+AB) 13.9 71.0 0.6 4 88.8 13002 609 625 ε5=338 µdef

MIX2(BM2+AB) 14.2 71.6 0.6 4 90.1 12213 578 581 ε5=339 µdef

MIX3 (EMS+FB+AB) 14.2 71.8 0.6 4 87.9 11321 668 639 ε5=393 µdef

Main findings from lab study

• Measurements on the blends:– Biomaterials restore most physical properties of the

aged bitumen: • Penetration value increased, softening point

temperature, DSR high temperature criteria decreased while Fraass and BBR critical temperature decreased

– EU and US systems give the same overall behavior in the high and low temperature domains

• Levels of regeneration measured by both methods are not strictly comparable.

Main findings from lab study

• Measurements on the mixes:– All alternative mixes ensured excellent rutting

resistance at high temperatures while providing superior fracture resistance at low temperatures and good fatigue life at intermediate temperatures.

• Rejuvenating effect of the biomaterials (as demonstrated at the binder level)

– High amount of RA can be incorporated in hot mix asphalt

• Appropriately selected additives/binders to reactivate the aged RA binder

Progress of the projectFull scale test

• Summer 2017 → Winter 2018: full scale evaluation (rutting + fatigue)

• April 2018: end of the project

Next steps

Construction of the demonstration test strip was done in May 2017

Main outcomes

Proof of concept done:

It is possible to manufacture (in a conventional plant) and to lay (at full scale) a mix with 50%RA while reducing the part of petroleum bitumen (up to full replacement)

Prior to definitive conclusion we need the results from full scale accelerated loading and LCA

EU and US design methodologies in lab have been applied as well as physico-chemical studies useful for implementation under other climates and/or local technical regulations

• Emmanuel Chailleux, Erik Bessmann, Pierre Hornych, Gaudefroy Vincent, & Juliette Blanc - IFSTTAR (FR)

• Zahra Sotoodeh-Nia, Nick Manke, Chris Williams, Eric Cochran - ISU (US)

• Davide Lo Presti and Ana Jimenez - University of Nottingham (UK)

• Laurent Porot - Kraton Chemicals (NL)• Jean-Pascal Planche and Ryan Boysen - Western Research

Institute (US)• Simon Pouget and François Oland - EIFFAGE Infrastructures

(FR)

Thank you for your attention

http://biorepavation.ifsttar.fr/

Emmanuel.chaileux@ifsttar.fr