THE USE OF CONVERSION RESIDUE AS A COMPONENT...

SHRP-ID/UFR-92-610

The Use of Conversion Residue

as a Component in Asphalt Cement

Richard E. Root, P.E.Chicago Testing Laboratory, Inc.

3360 Commercial Avenue

Northbrook, IL

Richard B. Moore

Shell Development CompanyP.O. Box 1380

Houston, TX

Strategic Highway Research ProgramNational Research Council

Washington, DC 1992

SHRP-ID/UFR-92-610Contract ID-020

Program Manager: Edward HarriganProject Manager: Rita LeahyProduction Editor: Amy Gray Light

Program Area Secretary: Juliet Narsiah

June 1992

Reprint December 1993

key words:asphaltic concreteconversion residue

thermal cracked residues

thermal cracking

Strategic Highway Research Program2101 Constitution Avenue, N.W.Washington, D.C. 20418

(202) 334-3774

The publication of this report does not necessarily indicate approval or endorsement of the findings, opinions,conclusions, or recommendations either inferred or specifically expressed herein by the National Academy ofSciences, the United States Government, or the American Association of State Highway and TransportationOfficials or its member states.

© 1993 National Academy of Sciences

50/NAP/1293

Acknowledgments

The research described herein was supported by the Strategic Highway ResearchProgram (SHRP). SHRP is a unit of the National Research Council that was authorizedby section 128 of the Surface Transportation and Uniform Relocation Assistance Act of1987.

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Contents

Abstract ............................................. 1

Executive Summary .......................................... 2

Related Research ........................................... 4

Binder Preparation .......................................... 4

Binder Evaluation ........................................... 5

Methodology of Binder Evaluation ............................... 5

Arabian Heavy ............................................. 7

California Heavy ............................................ 7

Binder Evaluation in Bituminous Mixture .......................... 8

Arabian Heavy ............................................. 9Georgia Aggregate ....................................... 9Maryland Limestone ...................................... 10Texas Chert ............................................ 10Comments ............................................. 10

California Valley ............................................ 10

Conclusions and Recommendations .............................. 11

Appendix AList of Figures .......................................... 12

Appendix BList of Tables ........................................... 24

References ............................................ 104

V

Abstract

Thermal cracking of distilled residues was a popular refining practice in the 1920s thathelped double the production of gasoline from a given quantity of crude oil from 1919to 1935. Thermal cracked residues, a by-product of thermal cracking, were used aspaving materials in the 1920s and '30s, although they ultimately proved unsatisfactory forthis purpose.

A conversion residue generally used as a blending component in heavy fuel oils or as arefinery fuel, was discovered to successfully blend into paving grade asphalt to providesuperior resistance to moisture-induced damage, and to provide similar hardeningcharacteristics as conventional specification asphalt.

Although conversion residue is seldom used in the United States, the preliminaryfindings of this material compared to conventional asphalt form the basis of this SHRPIDEA study.

Executive Summary

Thermal cracking of distilled residues became a popular refining practice in the 1920s.The primary benefit of thermal cracking was to increase the production of gasoline andother light products from a given quantity of crude, and decrease the volume ofasphaltic residue. As a result of the introduction of thermal cracking, the production ofgasoline from a given quantity of crude oil was practically doubled during the period of1919 to 1935 (ref 1).

Thermal cracked residues (TCR), a by-product of thermal cracking, were used as pavingmaterials in the 1920s and '30s. Most of the TCR, however, was volatile (not highlyvacuum distilled), and proved to be unsatisfactory in terms of age hardening (partiallydue to high volatility losses during the hot mix process to make asphaltic concrete). Thisled to some premature failures (primarily thermal and fatigue cracking) of pavements.

The Oliensis spot test (ref 2), developed in 1933 as a means of identifying TCR, waslater used as a specification standard to ensure that TCRs were not used in pavingasphalts. (This test is still mandatory in eight states and optionally enforced in 21 states--AASHTO M226, Table 2) (ref 3). The thin film oven test (TFOT), developed in 1941,gave a more accurate prediction of age hardening during plant mixing to produce hotmix asphaltic concrete (ref 4). A majority of states today no longer run the spot test,while all use the TFOT, or rolling thin film oven test.

Conversion Residue (CR) is a visbroken material (lightly thermal cracked, typicallyexposed to temperatures between 420C and 480C) that is subjected to a high vacuum toremove volatile materials (ref 5). CR is produced according to the scheme illustrated inFigure 1, page 13. If the material exiting the visbreaking reactor is not exposed to a highvacuum unit, the resulting residue would be volatile, a poor aging material, and wouldbe classified as visbroken residue--not CR.

CR is generally used as a blending component in heavy fuel oils or as a refinery fuel,and it has a relatively low value when compared to other refinery streams. If CR were tobe blended into paving grade asphalts, it would not increase the overall cost of theasphalt. Presently, CR is seldom (if ever), used in paving grade asphalts in the UnitedStates. However, previous preliminary findings (ref 6) show that when CR is used insmall percentages, (< 20 percent) with the remainder being a conventional distilledasphalt, the resultant material in limited testing displayed superior resistance tomoisture-induced damage (Modified Lottman Test) and similar hardening characteristics

2

(TFOT) when compared to conventional specification asphalts. These preliminaryfindings are the basis of this SHRP IDEA study.

For this study, two different CR materials, two sources of vacuum distilled asphalt, andthree sources of aggregate were evaluated. The asphalts and their blends were testedusing standard specification binder tests, and the asphalt-aggregate mixtures were testedusing ASTM-D-4867 (ref 7) to assess moisture-induced damage.

RELATED RESEARCH

The reduction of moisture-induced damage by using CR or TCR is not widely knownor practiced in the United States. However, in the 1955 Proceedings of theAssociation of Asphalt Paving Technologists (AAPT) there is a paper entitled"Waterproofing Aggregates with Cracked Road Oils" (ref 8). The authorsconcluded "that certain cracked road oils are better waterproofing agents thanany other commonly used asphalt products".

In the 1988 Proceedings of AAPT a paper entitled "Hydrocracking Residues--ThePotential Source of Road Binders" by Zanzotto et al (ref 9) showed dramaticimprovement in percent of retained Marshall stability after a 24-hour soak withas little as 3_ hydrocracked residue. Zanzotto also showed lower aging indexvalues with 20_ or less hydrocracked residue in the blend when compared to thestraight run asphalt. At percentages above 30_ the hydrocracked residueincreased the aging index significantly.

In work done at Shell Development (ref 6) findings similar to Zanzotto's werereached when CR was used. A blend containing 17.6_ CR had a lower aging indexthan the original vacuum distilled AC-5 blending base. Also, a blend having 20%CR had a higher Tensile Strength Ratio (51.2I vs. 36.1_) when compared to thecontrol (using the Modified Lottman Test procedure as run by the Texas StateDepartment of Highways and Public Transportation).

BINDER PREPARATION

Two CR materials were chosen. One sample (W-834) is a Tia Juana Pesado (TJP) CR.TJP is Venezuelan crude. The other (W-840) is a Middle East CR. Asphalt sourceschosen from the SHRP Materials Reference Library (SHRP MRL) were Arabian Heavy(AAS) and California Valley (AAG). West Texas Intermediate (solvent deasphalted)(AAM) was originally chosen, but proved to be incompatible with both CRmaterials. This was determined by viewing thin films of the blends under amicroscope at 200X. Instead of being a homogenous honey color (compatible),these blends contained a network of visible black structures (flocculated

asphaltenes). All subsequent blends used in this study were compatible using the200X microscopic technique.

It was the aim of the study to have CR blended at O, 5, 10, 20 and 40% by weightof the total binder with the base asphalt; and the resultant blends have a

consistency of AC-20. The AC-20 blends (18 in all) were then tested using commonasphalt specification tests along with a minimum of other tests that have shownsome correlation to field performance.

Because both CR materials were more viscous than AC-20, it was necessary to usea soft asphalt to give the resultant blends the proper consistency. The softestCalifornia Valley available from the SHRP MRL was an AR-2000 and for the ArabianHeavy an AC-IO. In a few of the higher Z CR blends, soft asphalts were notsufficient, and a heavy non-volatile distillate from a Mexican/West Texas Sourcrude was used to attain AC-20 consistency.

BINDER EVALUATION

Binder tests results are found in Tables IA through 4A. Calculated propertiesof the binders are found in Tables IB through 4B. It should be noted that allblends did meet AASHTO M-226 specifications for either AC-20 Table I or Table 2,except (in some cases) for the optionally specified Spot Test.

METHODOLOGY OF BINDER EVALUATION

The following calculated properties and test data are considered important inpredicting binder performance:

Bitumen Temperature Susceptibility (BTS)Estimated Thermal Cracking Temperature (ETCT)Penetration at 4C (60 seconds, 200 _rams)Viscosity at 60C

of Original penetrationAging IndexExudation 0roplet Tests (EDT)

It is more meaningful to evaluate these properties or data on TFOT residue (whereapplicable), because TFOT residue closely matches the short-term aging thatoccurs during construction of a hot mix asphalt pavement (ref I0). Unfortu-nately, at the time of this study there was no standard long-term aging testavailable (Pressure Air Vessel test under development in SHRP). Each of theabove properties and test data in relation to performance are discussed below.

BTS is identical to the Penetration Index (PI) as developed by Pfeiffer and VanDoormaal (ref 11) when penetrations are used. Heukelom (ref 12 & 13) extendedthe PI concept to include viscosities. However, PI based on viscosities is acontradiction in terms, and authors de Bats and van Gooswilligen (ref 14)developed the term BTSwwhi_h will be used in this report. From a rheologicalstandpoint it would be advantageous to have a relatively stiff binder at highservice temperatures (high viscosity at 60C) and a relatively soft binder at lowtemperatures (high penetration at 4C). This type of material would have a highBTS value. BTS can be represented graphically using the Bitumen Test Data Chart(BTDC) developed by Heukelom (ref 12). An example of the BTDC is given in Figure2. Three classes of asphalt are shown: Type W (waxy), Type S (straight line) andType B (blown). The slope of the line in the performance region (typically 60Cand below) is of most concern. Viscosities (and BTS) at temperatures above theperformance region are important during the construction of the pavement, butonce properly constructed, they have no correlation to performance.

ETCT is based on findings of low temperature thermal cracking from the ST. Anne'sTest Road (ref 15). A relatively simple chart (see Figure 3) and penetrationsat 5C and 25C are all that is needed to determine the ETCT. Penetrations ( 5seconds and 100 3rams) were run at4C and 25C in this study. The penetration at5C was interpolated (using BTDC) and used in calculation of the ETCT.

The Pacific Coast Conference on Asphalt Specifications has adopted the 60 second-

200 gram penetration test at 4C on Rolling Thin Film Oven Residue in their 1990Performance Based Asphalt Specifications. It is felt that this test is better

5

from a precision standpoint than the 5 second -100 gram test at 4C. The apparentproblemwith the 5 second test at low temperatures is the depth of penetrationis small, and it is on the highly tapered portion of the needle. Goodrich (ref16) evaluated the 60 second penetration test at 4C as a performance based test,and found that it correlated with low temperature creep testing on mixtures(limiting stiffness temperature) better than any other binder test in his study.

Viscosity at 60C is the basis of our country's present Viscosity Graded AsphaltCement Specifications. It is intuitively obvious that the higher the viscosityof the asphalt cement--the stiffer the mixture, and the more resistance the mixis to permanent deformation (rutting). The Shell Pavement Design Manual (ref 17)has input parameters for asphalt cement stiffness, and this factor directlyaffects predicted mix stiffness and rutting.

Percentage of original penetration (25C) after the TFOT is a specificationrequirement for Penetration Graded Asphalt Cements (ref 18). AASHTO M-20requires a minimum of 58X, 54_ and 50_ for 40-50, 60-?0, and 85-100 penetrationgrades. If the % is less than these minimums, then it is inferred that thematerial is prone to excessive aging and the resulting pavement will prematurelycrack.

Aging index is the ratio of TFOT viscosity • 60c / viscosity e 60c. AASHTOM-226limits this ratio to a maximum of 4.0. If the aging index is above 4.0, then(similar to I of original penetration) it is inferred that the material is proneto excessive hardening during aging and the resulting pavement will prematurelycrack. However, pavements do notcrack at BOCmthey crack at lower temperatures;and the fallacy of the aging index was discussed by Moore (ref 19). In this

• discussion it was pointed out •that some aged asphalts develop high 60Cviscosities, but they have excellent low temperature properties (high 4Cpenetrations--soft and resistant to cracking}. It was concluded that judging howan asphalt will perform after age hardening cannot be adequately assessed by onlycomparing relative aging indexes based on viscosities at 60C.

The exudation droplet test (EDT) was proposed by van Gooswilligen, de Bats andHarrison (ref 20). It has been found that exudative hardening may contribute topremature fracture of pavements, which occurs more frequently with lean mixes.Exudative hardening is the loss of oily material that exudes from the binder intothe mineral aggregate. Shell Method Series 2697 was the test procedure followed.Weighed quantities of asphalt are placed in drilled recesses of a marble plateof a specific Italian origin. The plates are heated to 60C for four days undera nitrogen blanket. During this period oily rings develop which are measuredwith a microscope under ultraviolet light. For AC-20 materials a ring width ofless than 2.0mm is an indicator_9ood performance. All blends in this study were1.2mm or less.

The following two sections will discuss how the two CRs affected the ArabianHeavy and California Valley asphalts.

6

ARABIAN HEAVY

Arabian Heavy is recognized as an asphalt with low temperature susceptibility,and because of this is generally considered a gocx_ performer. It easily exceedsAASHTON-226 Table 2 require_nts for temperature susceptibility (minimum 60penetration at 25C and 1600 to 2400 poise at 600). The ArebianHesvy AC-20 hasa 25C penetration of 81 and a 60C viscosity of 2041 poise (Table 1A) and a BTSof -0.73 (Table 1B). It can be seen that both CRs had little effect on the BTS(25C pen. & 60C visc.) for original properties (Table 1B & 2B). However, in allcases CR improved the BTS after the TFOT when compared to the control AC-20.

BTS (4C pen & 60C visc.) for the control AC-20 (Table 1B & 2B) were slightlybetter than the CR blends. However, after the TFOT the higher percentages (20& 40_ CR) exhibited better BTS. Similar trends are evident in the EstimatedThermal Cracking Temperature (ETCT) on TFOT residue--which show lower ETCT (moreresistant to theFmal cracking) for high _ CR blends.

The aging index increased with increased amounts of CR (Figure 4), however, per-cent of original penetration at 25C showed no significant change with increasedCR (Table 1A & 2A). TFOT penetrations at 4C generally increased with increasingamounts of CR (Figure 5)uwhich is beneficial for low temperature properties ofthe pavement.

Based on binder evaluation of the two CRs in Arabian Heavy, there is littleevidence of reduced performance. With the exception of spot test results, allArabian Heavy-CR blends tested meet current AASHTOH-226 Table 2 requirements.

CALIFORNIA VALLEY

California Valley is recognized as an asphalt with high temperature suscepti-bility, and because of this is generally considered a marginal perfomer in areaswith large seasonal temperature changes. It easily exceeds AASHTOt4-226 Table1 requirements for temPerature susceptibility (minimum 40penetration at 25C and1600 to 2400 poise at 60C), but fails to meet more stringent requirements foundin Table 2. The California Valley AC-20 control has a 25C penetration of 50 anda 60C viscosity of 2059 poise, (Table 3A) and a BTS of -1.51 (Table 3B).

It can be seen that both CRs had a positive effect on the BTS (25C pen. & 60Cvisc.) for original properties and TFOT properties (Tables 3B & 4B). The 20 and40%TJP and the 40_ Middle East CR blends improved the temperature susceptibilityto the point that these blends meet AASHTOM-226 Table 2 (Tables 3A & 4A).

Low temperature properties were improved significantly with CR. For example, theETCT for the control after TFOT was -21C while the 40_ TJP and Middle East CRSwere -28 and -33C respectively (Table 3B & 4B).

The aging index did not increase with increased amounts of CR untii 40_ CR wasused (Figure 6). Percent of original penetration at 25C did decrease withincreasing CR, but this is probably a function of increased penetration (Table3A & 4A). As previously discussed AASHTON-20 allows for a lower percent of

original for a high penetration grade. Penetrations at 4C on the TFOT agedmaterial in both cases increased with the higher amounts of conversion residue

(Figure 7).

The improvement in BTS was primarily a function of the two CR crude sources ascompared to the California Valley. However, Giavarini (ref 21) shows an increasein asphaltenes during the CR process. In this study six different residues fromdistillation and their corresponding CRs were analyzed for asphaltenes. In allcases the • weight asphaltenes increased. The average asphaltene content for thesix distilled residues was 11.0_, and for the corresponding CRs it was 15.0_ Twomain reactions occur in visbreaking (ref 5 & 21). The primary reaction is theremoval of Alkyl side chains (paraffins) from the molecules of the distilledresidue. The secondary reaction is condensation of ring structures--increasedmolecular weight. Simpson et al (ref 22) found that the temperature suscepti-bility of an asphalt decreases with increasing molecular weight; and Corbett (ref23) found that asphaltenes decrease the temperature susceptibility and are adesirable component of asphalt. Thus based on the above, a possible benefit fromthe CR process appears to be an improved BTS.

Based on binder evaluation of the two CRs in California Valley, there is strongevidence of improved performance (BTS). With the exception of some spot testresults, all California Valley-OR blends tested meet current AASHTO M-226 TableI requirements; and the higher • of CR improved the resultant blends so theycould meet Table 2.

BINDER EVALUATION IN BITUMINOUS MIXTURE

Three sources of aggregate were chosen from the SHRP Library in order toevaluate the effect of the various CR binders in the performance of mixtures inthe presence of moisture. The aggregates selected for this phase of theevaluation were:

RA Lithonia GraniteVulcan Materials Co.

Grayson, Georgia

RD LimestoneGenstar Stone ProductFrederick, Maryland

RL Golf Coast GravelFordyce Inc.Sullivan City, Texas

It was known from previous studies that the RA was prone to severestripping, the RL to moderate stripping and the RD to little stripping.

Preliminary supplies of each aggregate were obtained from the SHRP Libraryand evaluated for gradation. Calculations indicated that satisfactory mixture

8

designs could not be prepared without additional fine aggregate. A supply ofnatural sand (FA-2) was obtained from SHRP source:

RF Glacial GravelVulcan Material

Crystal Lake, Illinois

Marshall Mixture designs were prepared with each aggregate (RA, RD and RL)incorporating 301 of the natural sand (RF) using Arabian Heavy AC-20 (W 831).The designs were prepared in essential conformity with the procedures in theAsphalt Institute Manual MS-2. Optimum asphalt content was chosen at 4.0% airvoids. This design data and blends are shown on Tables 5-7.

In order to evaluate the effect of the conversion residue to reduce

moisture damage a series of fifty-four moisture induced evaluations wereconducted. Each of the three aggregates were tested with two control asphaltsAC-20 Arabian Heavy and AR-4000 California Valley. Each aggregate was alsotested with blends of the above control asphalts and each conversion residue inconcentrations of 5, 10, 20 and 40%.

The testing was conducted in accordance with ASTM Method D-4867. The dataon these tests is summarized in Tables IC through 4C. Individual Data on eachtest is in the Appendix.

ARABIAN HEAVY

The test results for the ori9inal Arabian Heavy AC-20 indicate that all threeaggregates have moisture damage potential (Table IC & 2C). The data indicatesthat the Georgia aggregate (RA) has the greatest damage potential as expected.However, the order of the Texas and Maryland aggregate was reversed from theexpected performance. Both Tensile Strength Ratio (TSR) and the visualevaluation of stripping confirmed the ranking of the laboratory performance ofthe aggregates. The fact that the high percentage of natural sand (RF) fromIllinois was needed for the mixture design could have confused the comparisonof the laboratory versus field performance of the aggregates.

Georqia AQqregate (RA) - The test results for the Georgia Granite showed the

greatest improvement of the study when the Arabian Heavy was blended with theMiddle East CR. The TSR values increased from 20 with 0 percent CR to 69 with

40 percent CR. This is a statistically significant increase when testingprecision reported in the ASTM Method is considered. When the Tia Juana PesadoCR was used, an increase in the TSR values was noted as the percentage of CR wasincreased. The blend of 40 percent Middle East CR with the Arabian Heavy bringsthe TSR values up to a marginal area. All other blends as well as the mixturewithout CR would need some additive to inhance the moisture damage potential of

the mixtures. However, for all blends with this asphalt the TSR properties wereequal to or better than the results on the mixtures without CR. The test resultsfor the three aggregates and two CRs are shown on Figures 8&9. Visual evaluationconfirmed that the stripping for the control and eight blends in this part of thestudy occurred in the coarse aggregate fraction.

Maryland Limestone (RD) - The test results on Tables IC & 2C indicate that the40 percent blends of both CRs brought the retained strengths for the Marylandlimestone up to a value which would meet most state specifications. Both resultsare significantly different than the control results according to the ASTMprecision statement.

In all cases, the CR blends were again equal to or better than the control testswith this aggregate. These results are in Figures 8&9.

Visual examinations of the moisture treated specimens again confirmed that thecoarse aggregate fraction was the cause for the loss of strength.

Texas Chert (RL) - The test results given in Tables IC & 2C show a generalincrease in the TSR values for increased percentages of CR. These results arecompared on Figures 8&9 for all three aggregates. None of the values aresignificantly different from the control tests. However, they are equal to andthere appears to be a trend of better performance with more CR.

Visual evaluation of the moisture treated specimens confirmed that the strengthloss was a result of coarse aggregate stripping.

Comments - The test results for the Arabian Heavy indicate in some cases asignificant improvement in the moisture damage properties of the three aggregatesstudied. No detrimental performance was indicated with regard to moisture damageby this data. In all cases, the visual evaluation confirmed that the moisturedamage occurred in the coarse aggregate fraction. This indicates that thenatural sand (RF) used in the mix design did not have a detrimental effect on theperformance of the aggregate blends. This is confirmed by the reasonableagreement between the laboratory data and the field performance history of theaggregates.

CALIFORNIA VALLEY

The moisture damage test results with the control asphalt indicate that theGeorgia aggregate was approximately equal to if not better than the Marylandmaterial and the Texas aggregate showed to be the worst. As previouslyindicated, this does not agree with previous field or laboratory experience. TheGeorgia material is a known stripper with TSR values expected to be in the 20 to30 range if the material doesn't fall apart durin9 testing.

A further factor which confused this issue is the fact that none of the CR blends

showed any significant benefit as experienced with the Arabian Heavy Study.

The visual evaluation of all the mixtures with the California Valley asphaltindicated that the vast majority of the stripping occurred in the fine aggregatefraction. This is totally different from the Arabian Heavy data and indicatesthat instead of evaluating three aggregates, only the natural sand RF fromIllinois was studied.

Because of the concern over the major switch in data in this part of the study,an independent sample of California Valley asphalt was obtained (Not part of SHRP

10

MRL). The results of a new set of TSR tests on the Georgia aggregate are shownon Table 8. With this sample of asphalt, the TSR values decreased from 70percent to the more common value of 28 percent with the coarse aggregate showingthe stripping.

A study was undertaken to determine the differences in the asphalts which couldcause such a major change. The results of a X-Ray fluorescence indicated thatthe SHRP MRL sample of California Valley asphalt contained 2400 parts per millionof calcium compared to less than 50 parts per million for the check sampleobtained independently. Other elements were present in virtually the same con-centrations in each sample. Following is the data obtained on the two CaliforniaValley asphalts.

SHRP IndependentElement I Wt. % Wt.

_T

Al 0.06 0.08Si 0.03 0.03S 1.2 1.2Ca < 50 PPM 0.24Fe < 0.010 PPM < 0.010 PPM

Based on this information, it appears that a form of processing was used in themanufacturing of the SHRPMRLasphalt which introduced calcium into the material.

It appears that the calcium benefitted this asphalt such that when tested withthe aggregates and CR in this study it masked the results. For this reason, theresults of the California Valley asphalt moisture damage tests were not used toderive the conclusions to this study.

CONCLUSIONS

All the tests conducted in this study showed that conversion residue can be usedin limited quantities with current asphalts. The data indicates a significantimprovement in asphalt properties and moisture performance for a number ofconditions. None of the tests indicated any adverse effect of the CR on theasphalt except for the spot test.

RECOMMENDATIONS

Based on the results of this study, it is recommended that several of the CRblends be shipped to other SHRP contractors for evaluation under the new bindertests being developed. If those results prove satisfactory, it is recommendedthat several test sections be built as part of the Long Term Pavement PerformanceStudies.

11

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23

Appendix B

24

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36

CONSULTING

TESTING

GENE ABSON, P.E. (1897-1963) _ RESEARCH

CONWAY C. BURTON,P.E.

(CONSULTANT)RICHARD E. ROOT, P.E. 3360 COMMERCIAL AVENUEINORTHBROOK, ILLINOIS 60062 FOUNDED 1912GEORGE J. GIROLIX,B.S

EROL UNER, C.E.T. (708) 498-6400 FAX: (708) 498-7232

TABLE 5A

Report September 28, 1990No. 006039

National Research CouncilStrategic Highway Research ProgramAttention: Mr. Robert R. Kelley818 Connecticut Avenue, N.W.

Washington, DC 20006

SHRP IDEAS - Georqia Granite (RA)Contract No. SHRP 87-ID020

Samples of aggregate were received from SHRP-Reference Laboratory fortesting. A Marshall mix design was conducted in essential conformity with theprocedures in the Asphalt Institute Manual MS-2.

Specimens were prepared from multiple batches and held at compactiontemperature for 1.5 hours to simulate field conditions. Compaction wasaccomplished with a mechanical hammer and the maximum density was determined inaccordance with ASTM Method D-2041.

The test data is summarized on the attached Report of Bituminous Mix Designand has been plotted on the Marshall data curves.

The following data summarizes the recommended mix design for the materialssubmitted.

Aqqreqate Proportions (Cold Feed):

Quantity Material Source

20_; No. 7 Georgia Granite (RA)15_; No. 890 Georgia Granite (RA)35_ No. 810 Georgia Granite (RA)30_; FA-2 Crystal Lake (RF)

Optimum Asphalt Content for 75 Blow Desiqn:(Percent by Total Weight of Mix)

Grade Amount

AC-20 6.0

_-T,_....-..__,. (W831 )

37AS A MUTUAL PROTECTION TOCLIENTS, THE PUBLIC AND OURSELVES, ALL REPORTS ARE SUBMITTED AS THE CONFIDENTIAL PROPERTY OF OUR CLIENTS, AND AUTHORIZATIONFOR PUBLICATION OF STATEMENTS, CONCLUSIONS OR EXTRACTS FROM OR REGARDING OUR REPORTS IS RESERVED PENDING OUR WRITTEN APPROVAL. SAMPLES WILL BEDISPOSED OF 21 DAYS AFTER TESTING IS COMPLETED UNLESS OTHER ARRANGEMENTS ARE AGREEDTO IN WRITING. ALL TESTSARE CONDUCTED IN ACCORDANCE WITH THELATEST ASTM OR AASHTO TEST METHODS WHERE APPLICABLE.

TABLE _B

CHICAGO TESTING LABORATORY, INC

Report 006039

Marshall Properties at Optimum Asphalt Content:

Stability, at 140F, Ib .... 2770

Flow, at 14OF, 0.0_" . .... 10.5Unit Weight, Ib/ft" 145.4

Voids Analysis, %:Air Voids .......... 4.0

Voids Mineral Aggregate . . 16.4Voids Filled ........ 76

Job Mix Formula:

Sieve Size percent Pas_inR

3/4" . ............ 1001/2" . ............ g53/8" . ............ 67No. 4 ............. _5No. 8 ............. 54NO. 16 ............ 42No. 30 ............ 30No. 50 ............ 15No. 100 ............ 7NO. 200 ............ 3.8

Asphalt Content, % ...... 6.0

RespectfulIy submitted,

CHICAGO TESTING LABORATORY, INC.

iJ."....'_,._.,C.;'..r_[!._'_L.._Richard E. RooSt,PiE.

38

T%BI,F SC

2.50 ,,i ....... ' .... i , il " i , ,

......... _;_ I _ ;_'!: if::; i : i -li 7i _i_i i : ;,::

}17i: ;i iiiTii';! ii ili i _ "'!: ;71111:ii _: _;; _ i :_ :"i' i:'7!2.4o if! :::: :: ,;_ i:;, ii! i! _;_ ::'i: 8 !"_i!I . i:i !"ii 'i,

,i ii ' ;,i ii :i! iii :iiif i i _, ;...... { ,ii iiiii{i{i i <_ : i :i ' _ ......!lii_"i! ,_:i;iiii{ iT'!!!iiiir_ _"'_ii!!!iTiTi_ _ ' 'i ,," _i,, ;,

!!! i _ !_.,.4---.: _-, ,!l!i ,; :',i: 0.... . , . I-- 6 f' ' I "_ , _, 17:

..... ',, :;,; :!:Iii!i ! r.il! I_ 0 _]:_ . . :'. i_

'" ' 7;! iii { ........:_I" ,I i ;i7 7_ _ !i!l] :: :! i_: ,i7; > 4 "l .... 1 : , 7_ :-__ ,

..... : !i ,!,i iii! i -ii!_ :; _i,_ ::. i ii !_i! I,, i ;I_ z ' ' i ";[:l; i:l]_;l_: O I lii ' i ' Ii : _ :

= i]i _ !i7 7 ilii }! 'iii'l :iiiii ii;ili _ "' ';; _ '{ i:7 i ;i:1;_ !; l :,i <,;: ! I : I II!; I!<I ! i!'2.10 ]!7[' '7:. { ' ii Ii' ! . i;ii: _," i 77i: 2 _ !!..:,:,,,, ,, ,,,' :.ill ii", , :

zoo I:_ _ _' _ ,,i_;:; i!i_, :!! 'i'i _ '' _ " ,:;': :............ 1.i ....... , ....... 0,,, ' ' ''

4.0 4.5 5.0 5.5 6.0 6.5 i.0 a_ 5.0 5.5 6.0 6.5PERCENT ASPHALT CEMENT PERCENT ASPHALT CEMENT

, , , L , I ,* !$I'

i _',i;;__' " ; i _ i,iiii!!i::i_

..... • - ' ..... ,,, 17I , ' _0 ! ' i I !

,i": i : I 1 " ;'_ _,I, ,!t!! I-- iii:_i ;"'_-;-----_.,,,, ,_ . _ 'l

2500 !: ' :_-,-""-_;:: :_i . '.",';T'_,..i- , V,-.......... _ _ : :,,,.1 • "- ' ; _°_' : ' " ;_;_iil i _i : " 80 : _

, iII

- 2000 !::.,;:i:_,i.'.I i:: ....,!'.: r'._, _:.. : _. ,_.: 15< ! _' !! ;i :: i, , _ " 70 I ,, , ' ", 'i-- uJ r _ : , i!'

i,:,, ,;; I i i;! ' !':,i ' ,I _,i,,,i i!: "_ _i,;i;! .... i .... ;

1500 ..... i_;; :, ii,_{,!:i ; i'.._........ _ _.._' " '; ' " ': ......: 14!_I,...., i,,..... ....!i ;i:['i >5 so ..;.;: ..', ": ....i _i_.i ii:,,_;,'!!'.!i i :! i !i_i,;iii, :., . , , ,,<i!i i

4.0 4.5 5.0 5.5 6.0 6.5 4.0 4.5 5.0 5.5 6.0 6.5PERCENT ASPHALT CEMENT PERCENT ASPHALT CEMENT

25i .... i .....'_:7i !''' i:_ i# ......:.i

20 , :' I " "" ",i ;i';::::i BITUMINOUS MIXTURE DESIGN

' : :<:;ii_ By The MARSHALL METHODtJ) ' L' "

':: !"i ';:ii I 28/90,; ....i ': 006039 Date 9/

z i_i ',, _,: .i_T l_b. No.O 15 '::; ': , .

z t! !" ; i Materi-',ls Used

- _:,_ ..... _ ' Georgia Granite_, , , +:. !: " !!_,.I lO , : ;' !

o _ ! ': _ _!: ........ 20% No. 7

i :! ; ;ii 'i ;il;i!i,I,. i

_' i: _: :,' 15% No. 890s " ' ' _.... _ !!_ 35% No. 810

! ' i II; '!,, ! , "

_ ,_ , :i : ',_'!! 30 No. FA-2

o , ' ' CHICAGO TESTING LABORATORY. INC.4.0 4.5 5.0 5.5 6.0 6.5 33_ COMMERCIAL AVENUE

PERCENT ASPHALT CEMENT NORTHBROOK. ILLINOIS oo662

39

TABLE 5D

REPORT OF BITUMINOUS MIX DESIGNLAB. NO. 006039

DATE 9/28/90

TO: SHRP Ideas - Georgia Granite (RA) TYPE: Surface

MATERIALS SUBMITTED

CTL No Agg Source004102 No. 7 Georgia Granite (RA)004104 890 Georgia Granite (RA)004103 810 Georgia Granite (RA)007131 FA 2 Crystal Lake, Illinois (RF)

AGGREGATE GRADATION - PERCENT PASSINGNo. 7 890 810 FA 2 Blend

Sieve

3/4" 100,0 100.0 1OO.0 100.0 100.01/2" 75.7 100,0 1OO.0 100.0 95.13/8" 37.0 97,5 100.0 100.0 87.0

No 4 3.4 20.0 90.7 99.8 65.4No 8 2.0 2,6 77.2 85.9 53,6No 16 1,7 1.6 65.3 62.1 42.1No 30 1.4 1,2 50.2 39.1 29.8No 50 1,0 0.7 32.1 11.0 14.8No 100 0.7 0.5 18.0 2.1 7.1No 200 0.4 0.2 9.6 1,2 3.8

Agg BSG 2.627 2.613 2.634 2.629 2.628

AGGREGATE BLENDPercent 20.0 15.0 35.0 30.0 100.0

BITUMEN DATA

Type : AC-20 Source: '004208 SG :1.034

MARSHALL MIXTURE DATATEMP. MIX- 315 COMP.- 290 BLOWS- 75

Bitumen BSG MSG Voids VMA Vf Flow Stab4.5 2.291 2.488 7.9 16.7 52.8 9.7 26205.0 2.306 2.469 6.6 16.6 60.2 9.8 25955.5 2.318 2.451 5.4 16.6 67.3 10.2 28006.0 2.339 2.434 3.9 16.3 76.2 10.2 28206.5 2.344 2.416 3.0 16.6 82.0 10.8 2470

Agg ESG 2.664 Asphalt Abs, % 0.5

COMMENTS:

40 CHICAGO TESTING LABORATORY, INC.

TABLE 6A

Report September 29, 1990No. 006040

National Research Council

Strategic Highway Research ProgramAttention: Mr. Robert R. Kelley818 Connecticut Avenue, N.W.Washington, DC 20006

SHRP IDEAS - Maryland Limestone (RD)Contract No. SHRP 87-ID020


Specimens were prepared from multiple batches and held at compactiontemperature for 1.5 hours to simulate field conditions. Compaction wasaccomplished with a mechanical hammer and the maximum density was determined inaccordance with ASTM Method D-2041.



Aqqreqate Proportions (Cold Feed):

quantity Material Source

15% No. 7 Maryland Limestone (RD)10% I/2-4 Maryland Limestone (RD)10% Birdeye Maryland Limestone (RD)35% 10 Sceenin9 Maryland Limestone (RD)30% FA-2 Crystal Lake (RF)

Optimum Asphalt Content for 75 Blow Design:(Percent by Total Weight of Mix)

Grade Amount

AC-20 5.5

(ws31)

41

TABLE 6B


Report 006040


Stability, at 140F, Ib .... 2550

Flow, at 140F, 0.0_" . .... 10.8Unit Weight, Ib/ft" . 149.8

Voids Analysis, _:Air Voids .......... 4.0Voids Mineral Aggregate . . 15.0Voids Filled ........ 75

Job Mix Formula:

Sieve Size Percent Passinq

3/4" . ............ 100i/2" . ............ gs3/8" . ............ 93No. 4 ............. 73No. 8 ............. 52No. 16 ............ 35No. 30 ............ 22No. 50 ............ 10No. 100 ........... 6No. 200 ............ 4.B

Asphalt Content, % ...... 5.5

Respectfu IIy submitted,


Richard E. Root, P.E.

42

TABLE 6C

t50 10

,;_...... i .... !; :::_;,:_ " :_= !"!i i!t' '" ' ';!"

i _,, x Jl

, ,, _ ,,_, ,, ,_ t,i ' _ _..:"" ........ ._,: ..... !!t,_ _'ii!iii!ii:! i ,,i i '_ J ,q

2.30 ii il i i:{! i : ! I ........ • ! ,

;!i: ,::' :_ii: ii! _i_i:i. ...........'_: !iiii;!!; " ::, :_: _'_:: iii!!{: .i; ;;I:::

2.10 !!!' ' i! i: ;i; _ ;iiil;' ': :i;;;l; _ o.. 2 il t: ;i:! I :I,, . _"_.;

,, " , , i_;_;_,:, ,,;, .... : .... , .... :;i_i{'!ii! _; :i:i!!;:!_!;ii II :i .;:;,: ,,,,_,:,: ......• ' " ..... iiii!!:': I, i,

2.00 .......i!!!: ;:i :_! { _-:!i,!i;, :; !"_:; :_,_,_,i: 0 .... ',; ...... '4.0 4.5 5.0 5.5 6.0 6.5 4.0 4.5 5.0 5.5 6.0 6.5

PERCENT ASPHALT CEMENT PERCENT ASPHALT CEMENT

3500 too

i,i,;,_:_,:'r',::,'_ ':',i:i;i;_i:__;,i i I _:"" _; '_' 'i!;!'':' :',';i ,!I'''_;_,,::' '_" ': iii, ii_....... ':, : , • ,,if, , , . ,i', !t,, .... ,ii,,

3000 :!: _;'=l'i ; ! ' ' ' ). ': !:_,;_, _ I ; ..... ;_: ",!I _' _, .= 90 ' li' " I ' ,' .' '_ii! !:1''', i: r, ,t

!i ...... Iii 'I > i' ! 'I ,ii' "1_ ; i".i : ii,:i i i _ ,_ , -- ; ' !I; ' _ :i _: i • '.,I

,' ;,,',', ,,,', '. ', ,!',_I, _ ,:,,' ;: ,l] I_,- ,• " '" < " ",_j,,_,'ri, :, ; :!ii>- ' ' "r .

( _;_[I: ' .::Ii : ;',: : : ! ! !T _ 70 - ,x I I

:,,_,.,, ,,_ :i:'i: ,::,,: !_I ' "" ,"" ':1 '_; _ '"1500 ',!'i':,! '" ' ::' 'i ,-, ,!,,:, .;.. ,,' , , ,, ' i,I " I' " " _:' "' ',';:I',!;! '_ "

1000 :,, ], , ': , , : : i , ' ':', ..... ' 50 ,4.0 4.5 5.0 5.5 6.0 6.5 4.0 4.5 5.0 5.5 6.0 6.5

PERCENT ASPHALT CEMENT PERCENT ASPHALT CEMENT

25i ::_ ; ' :;_i:!! =_ ', "'!!_i

_: ' ,ii!i!i'

....... iii_i' , ,,_ i_ iii20 ' , , , _;, i , BITUMINOUS MIXTURE DESIGN• ii

:: :;i :_ ;!':_ i By The MARSHALL METHOD

'" I-,- ..... ......... 9/29/90O 15 :'" ' I' [; I , ; }!: !. iiiii_i_, Lab.No. 006040 Date

!: : ,,:. , ,. ;:: . ;i:,_-": Materials Used

I 10 "." . i ':: _ : i;ii:, 15% NO. 7o _; :: ',;_i: !, ':_ : iii,: _ -;_ .i_i:i:,_ 10% 1/2-4

,[ i, .: ::-,. 10% Birdeve

,:; i .... ] ,,I ' ! ; _ ',',', , 35% 10 Screening...... ;,,, ,, 50% FA-2

I _ ' " I ''O: _ I ;' ' ' ;'' " CHICAGO TESTING LABORATORY. INC.4.0 4.5 5.0 5.5 6.0 6.5 3300 COMMERCIAL AVENUE

PERCENT ASPHALT CEMENT NORTHBROOK LLINOIS __062, 43

TABLE 6DREPORT OF BITUMINOUS h_IX DESIGN

LAB. NO. 6040DATE 9/29/90

TO: SHRP Icleas - Maryland Limestone (RD) TYPE: Surface

MATERIALS SUBMITTEDCTL No Agg Source4111 No. 7 Maryland Limestone (RD)4109 1/2-4 Maryland Limestone (RD)4107 Birdeye Maryland Limestone (RD)4.112 10 Scrn Maryland Limestone (RD)7131 FA-2 Crystal Lake, Illinois (RF)

AGGREGATE GRADATION- PERCENT PASSINGNo. 7 1/2-4 Bird 10 Scrn FA 2 Blend

Sieve

3/4" 10,3.0 100.0 100.0 100.0 100.0 100.01/2" 83.3 100.0 100.0 100.0 100.0 98.43/8" 57.6 91.1 100.0 100.0 100.0 92.8

No 4 8.5 14.0 67.6 95.7 99.8 72.9No 8 2.2 3.0 22.7 68.0 85.9 52.5No 16 1.3 1.2 6.6 43.1 62.1 34.7No 30 :.1 1.0 4.0 28.0 39.1 22.2NO 50 1.1 0.8 3.1 19.0 11.0 10.5

No 100 1.0 0.7 2.7 14.0 2.1 6.0No 200 0.9 0.7 2.6 11.4 1.2 4.8

Ago BSG 2.710 2.691 2.699 2,683 2.629 2,673

AGGREGATE BLENDPercent 15.0 10.0 10.0 35.0 30.0 100.0

BITUMEN DATA

Type : AC-20 Source: '004208 SG :1.034


Bitumen BSG MSG Voi ds VMA Vf Flow Stab4.5 2.273 2.537 ,6.5 15.2 57.4 9.7 26255.0 2.387 2.518 5.2 15.2 65.6 10.3 24905.5 2.410 2,499 3.6 14.8 75.8 10.2 25906.0 2.414 2.481 2.7 15.1 82.2 12.2 23706.5 2,420 2.462 1.7 15.3 88.8 17.0 2050

Ag9 ESG 2.724 Asphalt Abs, • 0.7

COMMENTS:

44

CONSULTING

TESTING

GENE ARSON, P.E. (1887-1963) _ RESEARCH

WARDPARRPE,,,,2,'=, VN VD[ ® B @O

CONWAY C. BURTON, P,E.

(CONSULTANT)RICHARDE.ROOT,P.E. 3360COMMERCIALAVENUE/NORTHBROOK,ILLINOIS60062 FOUNDED1912GEORGE J. GIROUX, B.S.

EROL UNER, C.E.T. (708) 498-6400 FAX: (708) 498-7232

TABLE 7A

Report February 5, 1991No. 006041-A

National Research CouncilStrategic Highway Research ProgramAttention: Mr. Robert R. Kelley818 Connecticut Avenue, N.W.Washington, DC 20006

SHRP IDEAS - Texas Chert (RL)Contract No, SHRP 89-ID020


Specimens were prepared from multiple batches and held at compactiontemperature for 1.5 hours to simulate field conditions. Compaction wasaccomplished with a mechanical hammer and the maximum density was determined inaccordance with ASTM Method i)-2041.



Aqqreqate Proportions (Cold F¢ed):

Quantity Haterial Source301; No. 4 Texas Chert (RL)15Z No. 6 Texas Chert (RL)24_ 8-200 Texas Chert (RL)304 FA-2 Crystal Lake (RF)

11; Dust Texas Chert (RL)

Optimum Asphalt Content for 75 Blow Desi,qn:(Percent by Total Weight of Mix)

S}_: Grade Nnount

_ AC-20 6.2 _;_"_ (we31)

4S

AS k MUTUAL PROTECTION TO CLIENTS, THE PUBLIC AND OURSELVES, ALL REPORTS ARE SUBMITTED AS THE CONFIDENTIAL PROPERTY OF OUR CLIENTS, AND AUTHORIZATIONFOR PUBLICATION OF STATEMENTS, CONCLUSIONS OR EXTRACTS FROM OR REGARDING OUR REPORTS IS RESERVED PENDING OUR WRITrEN APPROVAL. SAMPLES WILL BEDISPOSED OF 21 DAYS AFTER TESTING IS COMPLETED UNLESS OTHER ARRANGEMENTS ARE AGREED TO IN WRITING, ALL TESTS ARE CONDUCTED IN ACCORDANCE WITH THELATEST ASTM OR AASHTO TEST METHODS WHERE APPLICABLE.

TABLE 7B


Report 006041-A


Stability, at 140F, lb .... 1860Flow, at 140F, 0.01" . .... 9.1Unit Weight, Ib/ft3 143.3

Voids Analysis, ¢:Air Voids .......... 4.0Voids Mineral Aggregate . . . 16.0Voids Filled ........ 75

Job Mix Formula:

Sieve Size Percent PassinR

1/2" . ............ 1003/8" . ............ 90No. 4 ............ 67No. 8 ............. 51No. 16 ............ 38No. 30 ............ 28No. 50 ............ 17No. 100 ............ 4No. 200 ............ 2.4

Asphalt Content, ¢ ...... 6.2

Respectfu 1ly submitted,


Richard E. Root, P.E.

46

• !!,

8 ;:"

iii::

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m w iiii!_10 2 !!!::i!ii_

!;iii!i: "

_00 O

5.0 S.5 6.0 6_5 7.0 7.5 5.0 5.5 6.0 6.5 7.0 7.5PERCENT ASPHALT CEMENT PERCENT ASPHALT CEMENT

_oo 18

_ -,t-

o 70 u,1000 w zp- .,J

U_

r_ ¢

0

5.0 5.5 6.0 6.5 7._0 7_5 5.0 5.5 6.0 6.5 7.0 7.5PERCENT ASPHALT CEMENT PERCENT ASPHALT CEMENT

25

20 BITUMINOUS MIXTURE DESIGNBy The MARSHALL METHOD

IJJ•_- Lab. No. 006041-A Date 2/5/91o 15 MateriaLs UsedZ

30% No. 4 (RL)_- 15% No. 6 (RL)I lo 24% 8-200 (RL)

30% FA-2 (RF).J

_- 1% Dust5

AC-20

0 CHICAGO TESTING LABORATORY, INC.

s.o J.o AvENuENORTHBROOK. ILLINOIS 60062

47

TABLE 7D

REPORT OF BITUMINOUS MIX DESIGNLAB. NO. 306041A

DATE 1/22/91

TO: SHRP Ideas - Texas Chert (RL) TYPE: Surface

MATERIALS SUBMITTEDCTL No Agg Source4115 No. 4 Texas Chert (RL)4116 No. 6 Texas Chert (RL)2109 8-200 Texas Chert (RL)7131 FA-2 Crystal Lake, Illinois (RF)4117 Dust Screened from -200 Material

AGGREGATE GRADATION - PERCENT PASSINGNo. 4 No, 6 8-200 FA-2 Dust Blend

Sieve

3/4" 100.0 100.0 100,0 100.0 100,0 100.01/2" 99.4 100.0 100.0 100.0 100.0 99,83/8" 67.0 99.8 100.0 100.0 100.0 90.1

No 4 1.7 79.1 99.9 99.8 100,0 67,3No 8 0.3 7.8 94.5 85.9 100.0 50.7No 16 0.2 0,6 76.4 62.1 100.0 38.1No 30 0,1 0.2 65.6 39.1 100,0 28.5No 50 0.1 0.1 51,7 11.0 100.0 16,8No 100 0.1 0.1 10.9 2.1 100,0 4.3No 200 0.0 0.0 4.3 1.2 100.0 2.4

Agg BSG 2.597 2.578 2.485 2.629 2.562 2,575

AGGREGATE BLENDPercent 30.0 15.0 24.0 30.0 1.0 100.0

BITUMEN DATA

Type : AC-20 Source: 004208 SG :1.034


Bitumen BSG MSG Voids VNA Vf Flow Stab5.0 2.275 2.447 7.0 16.1 56.2 8.7 18505.5 2.283 2.430 6.0 16.2 62.8 9.7 18006.0 2.295 2.413 4.9 16.2 70.0 8.8 18406.5 2.311 2.396 3.5 16.1 78.1 9.0 18707.0 2.316 2.379 2.6 16.4 83.9 10.2 1710

A99 ESG 2.637 Asphalt Abs, % 0.9

COMMENTS:

CM!CAGO TESTING LABORATORY, INC.48

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References

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104

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