1. Mix Designs with RAS Dr. Richard Willis National Center for Asphalt Technology at Auburn University Asphalt Shingle Recycling Forum November 8 th, 2013 1

2. Background Mix design considerations – Binder Quantity and quality – Aggregate Quantity and quality – Volumetrics Air voids Voids in mineral aggregate Voids filled with asphalt Dust 2

3. Things to Consider RAP 3 – 6 % asphalt binder 94 – 97% stone RAS 19 – 36% asphalt 2 – 15% fibers 20 – 38% mineral aggregate 8 – 40% mineral filler 3

4. What Affects Mix Design and Mixture Quality? Shingle type Shingle gradation Shingle quantity Deleterious materials 4

5. Shingle Type Manufacturer’s Waste New shingles with less oxidation No contaminants No asbestos Post-Consumer Commonly 20-40 years old Oxidized asphalt Nails and other deleterious materials Might contain asbestos – Must conform to EPA’s NESHAP and other local requirements 5

6. Shingle Gradation Oversized shingles affect – Asphalt mobilized – Mixture consistency 6 StatePercent Passing ½”3/8”#4No. 100No. 200 Texas100%95%-- Missouri--100%-- GA/VA/AASHTO100%-- Iowa100%98%90%-- Oregon100%90%-- South Carolina100%--70.0 – 95.0%15% Max7% Max Minnesota100%--90%--

7. Shingle Aggregate Gradation Sieve Size% Passing 3/8 in (9.5 mm)100 No. 4 (4.75 mm)95 No. 8 (2.36 mm)85 No. 16 (1.18 mm)70 No. 30 (600 μm)50 No. 50 (300 μm)45 No. 100 (150 μm)35 No. 200 (75 μm)25 RAS Aggregate must be accounted for in new mix design AASHTO – Assumes gradation Does it matter if your RAS has a different gradation? 7

8. RAS Quantity Most states use between 3 – 5 percent RAS AASHTO Recommendations – If greater than 30 percent is shingle binder, must evaluate the blended binder to ensure performance grade (MP 15-09) – Possibly effected by grind size 8

9. Deleterious Materials Material retained on #4 sieve AASHTO – Total deleterious < 3% – Lightweight < 1.5% Some states < 0.5% Cleaner stockpiles = better mixtures 9

10. Deleterious Materials Example specification (TEX-217-F Part III) – Oven dry sample – Sample 1000 g = W T – Weigh Pan and pour sample over pan – Magnet on pan catches metal pieces in shingle – Weigh metal pieces = M

11. Deleterious Materials Sieves Used: 3/8”, No. 4, No. 8, No. 30 Shake sample for 10 minutes Discard – No. 30 material Test material retained on each sieve for deleterious materials (wood, paper, plastic, felt paper) – Manual separation Weigh material removed from RAS for each sieve – Deleterious materials on 3/8” sieve =N 3/8

12. Deleterious Materials P = percent of deleterious matter by weight M = weight of material retained by magnet, g N # = weight of deleterious substance on sieve, g

13. Design Considerations How do I determine the specific gravity of the RAS? How much binder is in the RAS? How much of that binder am I actually getting? 13

14. Shingle Specific Gravity 14 Peregrine et al., 2011

15. How Much Binder is in the RAS? Chemical extraction vs. Ignition Oven – Chemical Extraction: Do I get all of the RAS? – Ignition oven: Do I burn off other organic matter? AASHTO – Must use chemical extraction Virginia – Developed ignition oven correction factor 15

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17. Shingle Binder Contribution 17 Organization How Much RAS Binder Is Available for Mix? AASHTOShingle Binder Availability Alabama Department of Transportation100 of RAS binder Iowa Department of Transportation66.7 percent of RAS binder Missouri Department of Transportation100 Percent of RAS Binder Texas Department of Transportation100 Percent of RAS Binder Oregon Department of Transportation100 Percent of RAS Binder What’s the truth?

18. What Can Affect Binder Availability? Size of RAS Where is the RAS introduced Aggregate temperature Binder temperature Mixing time Moisture content! 18 Schroer 2009

19. AASHTO Methodology 1.Perform volumetric mix design on a mix which contains all components but RAS 2.Perform a second mix design on a RAS mixture 1.RAS added at ambient temperature to aggregate 1.Should I heat the RAS overnight at 140F and then preheat for two hours at mix temp? 3.Determine the difference between the optimum asphalt content of virgin and RAS mixtures, Δ 19

20. AASHTO Methodology 4.If Δ is positive, RAS is contributing binder 5.Multiply the percentage of shingle binder in the RAS by the percent RAS in the mix = total available binder 6.Divide Δ by total binder available 7.Correct shingle asphalt binder availability factor 20

21. Limitations of Methodology Assumes – Differences in virgin and RAS mix is only due to shingle binder and not Fibers Aggregate 21 Townsend et al., 2007

22. Performance Grade When using high amounts of reclaimed binder, do I need to use a softer virgin binder? Blending charts 22

23. Performance Grade Challenge: – How do I determine the Performance Grade? – Too stiff for water controlled DSRs – BBRs can be difficult to make 23

24. Are Volumetrics Enough? Rutting – Flow number – Hamburg – Asphalt Pavement Analyzer Cracking – Energy ratio – Semi-circular bend (low and intermediate) – TSRST or IDT Creep Compliance – Overlay Tester – Beam fatigue or S-VECD 24

25. Thank you! NCAT report 13-07: RAS Characterization: Best Practices www.ncat.us J. Richard Willis (334) 844-7301 willi59@auburn.edu 25