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Foam Bitumen Mixes for Base Layers-Laboratory and Field Study

Dr. Sunil Bose, Head Flexible Pavements Division, CRRI-New Delhi Shri Arun Gaur, Lecturer Civil Engineering Deportment, MNIT-Jaipur G Narendra Goud, Student M.Tech Transportation Engineering MNIT-Jaipur

Abstract
In the dense populated cities like Delhi, where environmental pollution and Land fill problems are of prime concerns in the recent years. In rapid developing countries like India, where conservation and optimum utilization of the road building materials specially petroleum and mineral products are an important issue. There is an immediate attention requirement towards the development and implementation of Eco-friendly and cost effective pavement construction technologies. Through application of these technologies the efficient use of existing and waste materials can be made with out creating problems to the environment and at the same time meeting the quality requirements of the pavements. Advances in technology and techniques in the in recent years have made cold recycling an increasingly popular and cost-effective pavement construction and maintenance technique. In the present study an effort is made to study the laboratory and field behavior of recycled cold mixes with binder as foamed bitumen. The Marshall specimens were cast using foamed bitumen in combination with cement. The specimens were tested for Density, Indirect Tensile Strength, Resilient modulus and dynamic creep. Benkelman Beam deflection study was carried out on the pavement constructed with recycled foamed bituminous mix after a period of three months from construction and field cores were cut from the pavement and were investigated in the Laboratory. It was found that the pavement constructed with foamed bitumen treated RAP was structurally sound and cores cut from that pavement have shown higher ITS and MR values when compared with Laboratory cast cores but they shown less creep stiffness and densities.

1.0 Introduction
In the dense populated cities like Delhi, where environmental pollution and Land fill problems are of prime concerns in the recent years. In rapid developing countries like India, where conservation and optimum utilization of the road building materials specially petroleum and mineral products and energy are an important issues. The rehabilitation and up gradation of existing badly distressed Pavements due to rapidly growing heavy vehicular traffic are attracting the concentration. There is an immediate attention requirement towards the development and implementation of Eco-friendly pavement construction technologies. Through application of these technologies the efficient use of existing and waste materials can be made with out creating problems to the environment and at the same time meeting the quality requirements of the pavements. Advances in technology and techniques in the in recent years have made cold recycling an increasingly popular and cost-effective pavement construction and maintenance technique. It has been proved in abroad that cold recycling with foamed bitumen is one of the best alternatives to be considered as a rehabilitation option. Cold recycling technology can be an option which has the potential to address the above mentioned issues. In the present study an effort is made to study the laboratory and field behaviour of recycled cold mixes with binder as foamed bitumen. The Marshall specimens were cast using foamed bitumen in combination with cement. The specimens were tested for density, Indirect

Tensile Strength, Resilient modulus and dynamic creep. Benkelman Beam deflection study was carried out on the pavement constructed with recycled foamed bituminous mix after a period of three months from construction and field cores were cut from the pavement and were investigated in the Laboratory.

2.0 Literature review


2.1 Foam bitumen
In order to mix bitumen with road-building aggregates, you first need to considerably reduce the viscosity of the cold hard binder. Traditionally, this was done by heating the bitumen and mixing it with heated aggregates to produce hot mix asphalt. Other methods of reducing the bitumen viscosity include dissolving the bitumen in solvents and emulsification. Prof. Csanyi came up with the idea of introducing moisture into a stream of hot bitumen, which effects a spontaneous foaming of the bitumen (similar to spilling water into hot oil). The potential of foamed bitumen for use as a binder was first realised in 1956 by Dr. Ladis H. Csanyi, at the Engineering Experiment Station in Iowa State University. Since then, foamed asphalt technology has been used successfully in many countries, with corresponding evolution of the original bitumen foaming process as experience was gained in its use.

Figure 1: schematic diagram of foamed bitumen production The foamed bitumen, or expanded bitumen, is produced by a process in which pressurized water and compressed air is injected into the hot bitumen (155-180 0c), resulting in spontaneous foaming. The physical properties of the bitumen are temporarily altered when the injected water, on contact with the hot bitumen, is turned into vapour which is trapped in thousands of tiny bitumen bubbles. In the foam state the bitumen has a very large surface area and extremely low viscosity making it ideal for mixing with aggregates however the foam dissipates in less than a minute and the bitumen resumes its original properties. In order to produce foamed asphalt mix, the bitumen has to be incorporated into the aggregates while still in its foamed state. A distinct difference between foamed asphalt mixes and conventional asphalt stabilised mixes is the way in which the bitumen is dispersed through the aggregate. In the later case the bitumen tends to coat all particles whilst in the foamed mixes the larger particles are not fully coated. The foamed bitumen disperses itself among the finer particles forming a mortar which binds the mix together.

2.2 Characterization of Foam bitumen


Foamed bitumen is characterized by two primary properties:

1. Expansion Ratio that is a measure of the viscosity of the foam and will determine how well it will disperse in the mix. It is calculated as the ratio of the maximum volume of foam relative to its original volume 2. Half-Life is a measure of the stability of the foam and provides an indication of the rate of collapse of the foam. It is calculated as the time taken in seconds for the foam to collapse to half of its maximum volume. The best foam is generally considered to be the one that optimizes both expansion and half-life.

Figure 2: Bitumen Foam characterization

2.3 Action of Foamix


Unlike hot-mix asphalt, material stabilised with foamed bitumen does not appear black. This result from the coarser particles of aggregate not was being coated with bitumen. When foamed bitumen comes into contact with aggregate, the bitumen bubbles burst into millions of tiny bitumen droplets that seek out and adhere to the fine particles, specifically the fraction smaller than 0.075 mm. The bitumen droplets can exchange heat only with the filler fraction and still have sufficiently low viscosity to coat the particles. The foamed mix results in a bitumenbound filler that acts as a mortar between the coarse particles, as shown in Figure 3. There is therefore only a slight darkening in the color of the material after treatment. The addition of cement, lime or other such fine cementitious material (100 % passing the 0.075 mm sieve) assists the bitumen to disperse, in particular where the recycled material is deficient in fines.

Figure 3: Foamed bitumen dispersion and binding in the treated mix

2.4 Material suitability for foamed bitumen treatment


The foamed bitumen process is suitable for treating a wide range of materials, ranging from sands, through weathered gravels to crushed stone and RAP. Aggregates of sound and marginal quality, from both virgin and recycled sources have been successfully utilized in the process in the past. As depicted in Figure 4, the minimum requirement is 5% passing the 0.075 mm (No. 200) sieve. When a material has insufficient fines, the foamed bitumen does not disperse properly and tends to form what are known as stringers (bitumen rich agglomerations of fine material) throughout the recycled material. These stringers vary in size according to the fines deficiency, a large deficiency will result in many large stringers which will tend to act as a lubricant in the mix and lead to a reduction in strength and stability.

Figure 4: Material gradation envelops Material that is deficient in fines can be improved by the addition of cement, lime or other such material with 100 % passing the 0.075 mm sieve. However, the use of cement in excess of 1.5 % by mass should be avoided due to the negative effect on the flexibility of the stabilised layer. The envelopes provided in Figure 4 are broad and can be refined by targeting a grading that provides the lowest voids in the mineral aggregate. This produces foamed bitumen mixes with the most desirable mix properties. A unique relationship for achieving the minimum voids, with an allowance for variation in the filler content, is shown in equation. This relationship is useful as it provides flexibility with the filler content of a mixture. A value of n = 0.45 is utilised to achieve the minimum voids.

Where: d = selected sieve size (mm) P = percentage by mass passing a sieve of size d (mm) D = maximum aggregate size (mm)

F = percentage filler content (inert and active) n = variable dependent on aggregate packing characteristics (0.45) Achieving a continuous grading on the fraction less than 2 mm is important for the proper dispersion of the foamed bitumen and easier compaction, thereby reducing voids and the materials susceptibility to water ingress. Where necessary, therefore, consideration should be given to blending two materials to improve the critical grading characteristics. Moisture Conditions: The moisture content during mixing and compaction is considered by many researchers to be the most important mix design criteria for foamed asphalt mixes. Moisture is required to soften and breakdown agglomerations in the aggregates, to aid in bitumen dispersion during mixing and for field compaction. Insufficient water reduces the workability of the mix and results in inadequate dispersion of the binder, while too much water lengthens the curing time, reduces the strength and density of the compacted mix and may reduce the coating of the aggregates. The optimum moisture content (OMC) varies, depending on the mix property that is being optimized (strength, density, water absorption, swelling). However, since moisture is critical for mixing and compaction, these operations should be considered when optimizing the moisture content. The optimum mixing moisture content occurs in the range of 65 - 85 per cent of the modified AASHTO OMC for the aggregates. Curing Conditions: Studies have shown that foamed asphalt mixes do not develop their full strength after compaction until a large percentage of the mixing moisture is lost. This process is termed curing. Curing is the process whereby the foamed asphalt gradually gains strength over time accompanied by a reduction in the moisture content. A laboratory mix design procedure would need to simulate the field curing process in order to correlate the properties of laboratoryprepared mixes with those of field mixes. Since the curing of foamed asphalt mixes in the field occurs over several months, it is impractical to reproduce actual field curing conditions in the laboratory. Most of the previous investigations have adopted the laboratory curing procedure proposed by Bowering (1970), i.e. 3 days oven curing at a temperature of 60 C. This procedure results in the moisture content stabilizing at about 0 to 4 per cent, which represents the driest state achievable in the field. In the present study the specimen are cured for 72 hours at 40 0C temperature only.

3.0 Laboratory and Field studies


3.1 Material evaluation
Representative sample of pulverized and air dried Reclaimed Asphalt Product (RAP) and Crusher stone dust were collected from stock piles and then sieved through a set of sieves for gradation. The details of sieve analysis are presented in tables 1 and 2. Bitumen content and moisture content of air dried RAP found to be 5.2% and 0.12% respectively. Moisture content and specific gravity of air dried Stone Dust found to be 0.40% and 2.68 respectively. Based on pulverized RAP and stone dust gradation their proportions were fixed (RAP:Stone dust::55%:45%) to meet the gradation requirements for Foamed bitumen treatment. Figure 5 shows the gradation envelops.

1 0 0

lowerlimit upperlimit combined achieved RAP stone dust

2 0
0.01

Percentage passing 8 6 4

0.1sieve size, mm (log scale) 10 1

100

Figure 5: Gradation envelops Table 1: Sieve analysis of pulverized and air-dried RAP
sieve size, mm cumulative % passing 37.5 100.0 26.5 99.2 19 95.0 13.2 74.7 9.5 52.1 6.7 39.1 4.75 29.1 2.36 16.6 1.18 7.5 0.6 5.3 0.425 3.4 0.3 2.0 0.075 0.2 pan 0.0

Table 2: Sieve analysis of Stone Dust


sieve size, mm cumulative % passing 6.7 100.00 4.75 93.40 2.36 72.00 1.18 50.60 0.6 43.60 0.425 35.80 0.3 26.20 0.075 9.00 pan 0.00

OMC Determination for Foamed Bitumen Treatment: The pulverized and air dried RAP is separated in to three different fractions (i.e. P-19mm & R-13.2mm, P-13.2mm & R4.75mm and P-4.75). The proportioned and un-treated material was used to find Optimum Moisture Content with modified Proctor compaction effort for foamed bitumen treatment. The Optimum Moisture Content found to be 8.75% with a Maximum Dry Density of 2.09 g/cc. The mixing moisture content of proportioned material was decided based on optimum moisture content and air dried field sample moisture content to prepare foamix. Foamed Bitumen Characterization: The Study of foamed bitumen and its characterization wais carried out using Wirtgen Foam bitumen Laboratory plant, WLB-10. The Foamability and the variation of foam characteristics viz. expansion ratio and half life time were observed at different air pressures, temperatures and Bitumen water contents. The bitumen used was of 80/100 penetration grade. The figure xx shows variation of Half life time and Expansion ratio with Bitumen water at 4.5 bars air pressure and 165 oC bitumen temperature. Optimum foam producing bitumen water found to be 3.3% by weight of bitumen.
12 11 10 9 8 7 6 5 4 3 2.0 2.5 3.0 3.5 4.0 Bitumen water content, % 9 8 7 6 5 4 3 2 1 0 Expansion ratio
Half life, seconds

exp ratio half life

4.5

Figure 5: Bitumen water content Influence on expansion ratio and half life time of Foamed bitumen

3.2 Foamix preparation and specimens casting


The graded material and filler cement was mixed using pug-mill type mixer Initially dry mixing of proportioned material was carried out for 10 to 15 seconds then additional water was added and then in to that mix foamed bitumen was sprayed using WLB-10, after setting the calculated and determined parameters on the laboratory plant. Foam bitumen quantity varied from 2 to 5% with 1% interval and cement varied from 0 to 3% with 1% interval. The Marshall Specimens were cast with the mixture,

the number of blows applied were 75 on each side.

3.3 Specimens conditioning and testing


The Marshall specimen prepared with formulated material have been tested for Bulk Density, Resilient modulus (MR) and Indirect Tensile Strength (ITS) after a curing period of 24 hours at room temperature in mold and 72 hours at 40 0C after taken out of mold. And testing was carried out at room temperature only. Duplicate samples were tested for soaked Indirect Tensile Strength after a soaking period of 24 hours in water bath at ambient temperature. Indirect Tension Test for Resilient Modulus was carried out at a repetitive load 100 N, frequency 0.1 Hertz and at a temperature of 25 0C. The test results of bulk density, indirect tensile strength and Indirect Tension test for Resilient Modulus are presented in table 3. Field cores cut from the Foamed bitumen treated recycled pavement layer were tested for Bulk Density, Resilient modulus (MR), Indirect Tensile Strength (soaked and un-soaked) and dynamic creep resistance. Some Laboratory cast specimens were also tested for dynamic creep resistance since the uniaxial unconfined creep test is effective in identifying the sensitivity of asphalt mixtures to permanent deformation or rutting. Dynamic creep test was conducted under unconfined conditions at a temperature of 40 0 C. The Specimens were placed in the temperature control cabinet for a minimum period of two hours for conditioning the specimen to achieve test temperature before testing. The contact stress of 3 kPa was applied for 0.1 second and rest period of 0.9 second at a frequency of 1 Hz. The load was applied for a maximum of 3600 cycles. The results of Dynamic creep test on lab and field cores presented below in table 4. The values of Resilient modulus were plotted in graphs (Figure 6) and then linear trend lines were drawn to observe the variation in MR with foam bitumen and active filler. It was observed from the graphs that the increase in foam bitumen and increase in cement increased the MR but at higher cement contents and at higher foam bitumen contents increase in MR was not much significant. The optimum cement content ranges from 1 to 2% and optimum foam bitumen content ranges from 3 to 4%. The maximum MR values observed was 2372 MPa at 1% cement and 5% foam bitumen and 2350 MPa at 3% cement and 3% foam bitumen. The ITS values were increased and then decreased with increase in foam bitumen. The addition of cement increased the ITS values significantly. Maximum ITS observed was 510 kPa at 3% cement and 4% foam bitumen (Figure 7). The specimens with cement were observed to be very less susceptible to moisture as it was observed from soaked ITS of the specimens. Table 3: Test results of Marshall Specimens of Foamix
Mold ID 0/2/1 0/2/2 0/3/1 0/3/2 Filler type Filler, % 0% Foamed Bitumen, % Bulk Density, g/cc 2.107 2.063 2.114 2.182 Average Bulk Density, g/cc Resilient Modulus, MPa 1211 1425 2090 800 Mean Resilient Modulus, MPa ITS, kPa Dry 1318 1445 316.74 183.41 353.89 259.87 Soaked 58 73 TSR, %

2 3

2.085 2.148

0/4/1 0/4/2 0/5/1 0/5/2 1c/2/1 1c/2/2 1c/3/1 1c/3/2 1c/4/1 1c/4/2 1c/5/1 1c/5/2 2c/2/1 2c/2/2 2c/3/1 2c/3/2 2c/4/1 2c/4/2 2c/5/1 2c/5/2 3c/2/1 3c/2/2 3c/3/1 3c/3/2 3c/4/1 3c/4/2 3c/5/1 3c/5/2 1 2 3 4 Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement Cement 1.5% 1.5% 1.5% 1.5% 3% 2% 1%

4 5 2 3 4 5 2 3 4 5 2 3 4 5

2.134 2.132 2.129 2.131 2.340 1.964 2.188 2.127 2.126 2.125 2.148 2.074 2.144 2.140 2.161 2.139 2.152 2.155 2.126 2.077 2.163 2.120 2.117 2.121 2.114 2.118 2.110 2.095 2.110 2.090 2.108 2.035

2.133 2.130 2.152 2.158 2.125 2.111 2.142 2.150 2.153 2.101 2.141 2.119 2.116 2.102

1845 1528 2544 1765 2519 1517 2585 2250 2132 2362 2335 2464 2094 2244 2188 2201 2278 2286 2300 2253 1957 2028 2494 1802 2058 2287 2258 2390 3350

1687 2155 2018 2417 2247 2399 2169 2195 2282 2277 1993 2148 2173 2324

372.66 322.41 402.01 318.31 329.83 292.94 390.23 405.37 437.23 387.04 450.46 343.44 435.79 305.23 448.34 403.76 519.35 376.00 359.33 301.16 484.19 433.83 494.21 426.57 512.92 402.82 500.38 382.34 525.8072

87 79 89 104 89 76 70 90 72 84 90 86 79 76

Field cores 3.5% 3.5% 3.5% 3.5% 2374 3416 2302 403.3839 342.1538 258.0461

2.090

2861

155

Table 4: Dynamic creep Test results of Foamix


S.NO 1 2 Mold description 1.5% Cement, 3.5% Foamed bitumen Field core of 1.5% cement, 3.5% Foamed bitumen Creep stiffness, MPa 464.7 30.5 Total accumulated axial strain at 1 hour of loading, % 0.015 0.222 Remarks No failure No failure

Variation of MR w ith Foam ed Bitum en and Cem ent 3500 3250 3000 Resilient modulus, MPa 2750 2500 2250 2000 1750 1500 1250 1000 750 500 1.5 2.0 2.5 3.0 3.5 4.0 Foam ed bitumen, % 4.5 0% Filler 1% Cement 2% Cement 3% Cement 5.0 5.5

Figure 6: variation of Resilient modulus with foamed bitumen and cement


Variation of Dry ITS with Foamed bitumen and cement
550 500 450 400 Dry ITS, KPa 350 300 250 200 150 100 50 0 1.5 2 2.5 3 3.5 4 Foam ed bitum en, % 4.5 0% Filler 1% Cement 2% Cement 3% Cement 5 5.5

Figure 7: variation of ITS with foamed bitumen and cement

3.4 BBD study on RAP Foamix pavement


Benkelman beam deflection study has been carried out on the pavement constructed with Recycled mix of Foamed bitumen in Kumbalgodu industrial area, Bangalore after three months of construction i.e. in the month of March 2006. The interval of deflection measurement points was selected as 30 meters and initial point was marked at a distance of 10 meters from the zero Chainage of the Road (i.e. SH-17 Junction). The pavement temperature observed was 37 0 C, The PI value and moisture content of sub-grade soil found to be 14% and 17% respectively. The temperature correction factor and moisture correction factor applied were -0.02 and 1.1 respectively. The average characteristic rebound deflection of the pavement found to be 1.17mm. Table 5: Deflection data (LHS, towards Karnataka cold Storage Pvt. ltd)
Chainage, km & m Distance, m Corrected Rebound Deflection, mm 00+010 10 0.89 00+040 40 0.66 00+070 70 1.18 00+100 100 0.37 00+130 130 0.62 00+160 160 0.65 00+190 190 0.31 00+220 220 0.62 00+250 250 0.37 00+280 280 1.03 00+310 310 1.31

Table 6: Deflection data (RHS, towards Karnataka cold Storage Pvt. ltd)
Chainage, km & m Distance, m Corrected Rebound Deflection, mm 00+010 10 1.2 00+040 40 0.99 00+070 70 1.01 00+100 100 1.16 00+130 130 0.33 00+160 160 0.62 00+190 190 1.06 00+220 220 1.32 00+250 250 1.23 00+280 280 1.14 00+310 310 0.57

4.0 Conclusions
The following conclusions were drawn based on the studies performed on foamed bitumen treated RAP in laboratory and Field. When recycling with foam bitumen mixing moisture content should be around 60% of OMC as per Wirtgen Cold Recycling Manual, however observing the material it can be varied from 50 to 65% to reduce problems in compacting the mix Loss of strength on soaking is very less with foamed bitumen and cement treated material, in most of the cases the tensile strength ratio ranges from 70 to 100% and it is 155% in case of field cores Cores cut from the foamed bitumen treated pavement have shown higher ITS and MR values in comparison with laboratory cast cores Dynamic creep stiffness of Cores from the field was very less in comparison with laboratory cast cores but they were comparable to HMA cores, which needs to be further examined before any conclusions are drawn. Benkelman beam deflection study on foamed bitumen treated pavement shows that it was structurally sound with an average characteristic rebound deflection of 1.17mm and no functional failure was observed even in the absence of surface course Foam bitumen treated mixes can be one of the considerable options for base courses in a flexible pavement structure since it requires a surface course

Acknowledgements
The authors are grateful to the director for granting permission to publish this paper. Thanks are also due to M/S Wirtgen India Pvt. Ltd. For supporting during foamix study and Nagarjuna Construction Company for the help rendered during field study.

References
Websites www.asphalt.csir.co.za www.arra.org www.infratech.com www.wirtgen.com www.betterroads.com www.asphaltwa.com/wapa www.trb.org Reports and papers

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