WARM ASPHALT PLANT #91 COLUMBUS OHIO - Flexible … · 2011-10-12 · WARM ASPHALT PLANT #91...
Transcript of WARM ASPHALT PLANT #91 COLUMBUS OHIO - Flexible … · 2011-10-12 · WARM ASPHALT PLANT #91...
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WARM ASPHALT WARM ASPHALT PLANT #91 PLANT #91
COLUMBUS OHIOCOLUMBUS OHIOFLEXIBLE PAVEMENTS FLEXIBLE PAVEMENTS
ANNUAL MEETINGANNUAL MEETINGMARCH 29, 2006MARCH 29, 2006
Larry Shively
The Shelly Company
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WHAT IS WARM ASPHALT?WHAT IS WARM ASPHALT?
•• PROCESS BY HMA: PROCESS BY HMA: CAN BE PRODUCED AND CAN BE PRODUCED AND PLACED AT LOWER PLACED AT LOWER TEMPERATURES TEMPERATURES
•• SOME ROAD FOREMEN SAY THE SOME ROAD FOREMEN SAY THE INDUSTRY HAS BEEN INDUSTRY HAS BEEN PRODUCING THIS TYPE OF MIX PRODUCING THIS TYPE OF MIX FOR YEARS!!FOR YEARS!!
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Why Warm Asphalt?Why Warm Asphalt?
•• Reduce production and laydown Reduce production and laydown temperaturestemperatures
•• Reduce emissionsReduce emissions•• Reduce energy costsReduce energy costs•• Reduce aging of binderReduce aging of binder•• Other Possible Benefits:Other Possible Benefits:
–– Cool weather paving (extend season)Cool weather paving (extend season)–– Compaction aid for stiff mixesCompaction aid for stiff mixes
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Why Warm Asphalt?Why Warm Asphalt?
Research by Stroup-Gardiner and Lange at AUIndicates increased emissions with increased temp.
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Comparison of Visible EmissionsComparison of Visible Emissions
311 °F 230 °F
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What are Warm Asphalt Mixes?What are Warm Asphalt Mixes?
Several process have been developed to Several process have been developed to improve mixture workability allowing improve mixture workability allowing lower production and laydown lower production and laydown temperaturestemperatures–– WAM Foam WAM Foam –– Shell/Kolo VeidekkeShell/Kolo Veidekke–– ZeoliteZeolite –– Eurovia/Hubbard ConstructionEurovia/Hubbard Construction–– Sasobit Sasobit –– Sasol Int./Moore and MungerSasol Int./Moore and Munger–– New processesNew processes
•• MeadWetvacoMeadWetvaco
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ZeoliteZeolite
•• Zeolites are crystalline hydrated aluminum Zeolites are crystalline hydrated aluminum silicatessilicates
•• AsphaAspha--minmin®®, is a special Zeolite added to the , is a special Zeolite added to the hot mix asphalt in the temperature range of hot mix asphalt in the temperature range of 100 to 200 100 to 200 °°C (212 to 392 C (212 to 392 °°F)F)
•• When the Zeolite is heated; it gives up itWhen the Zeolite is heated; it gives up it’’s s internal moisture, approximately 21% by internal moisture, approximately 21% by weight, weight, microscopicallymicroscopically foaming the asphaltfoaming the asphalt
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Above 100°C the water is slowly released providing a workable mix at a lower
temperature.
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AsphaAspha--minmin
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Granulated asphaGranulated aspha--minmin®®
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Addition of Addition of asphaaspha--minmin®®
•• AsphaAspha--min is added at an addition rate min is added at an addition rate of 0.3% by weight of mixof 0.3% by weight of mix
•• 6 pounds of Aspha6 pounds of Aspha--min per tonmin per ton
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Creates a controlled Creates a controlled microscopic foaming effectmicroscopic foaming effect
Creates an increased volume Creates an increased volume of the binder in the mixof the binder in the mix
Creates micro pores in the mix Creates micro pores in the mix making a higher workability of making a higher workability of the mix along with obtaining a the mix along with obtaining a higher higher compactabilitycompactability
Previously only possible at Previously only possible at higher temperatureshigher temperatures
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Type of Mineral Filler Bin usedType of Mineral Filler Bin used
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Calibrating the FeederCalibrating the FeederThe outlet is removedThe outlet is removed
A container is placed under the hopper A container is placed under the hopper and the unit startedand the unit started
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Bags of AsphaBags of Aspha--minmin
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HAD SOME PROBLEMS WITH HAD SOME PROBLEMS WITH FEED SYSTEMFEED SYSTEM
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Drum mix plant Drum mix plant
Aspha-min blown into drum close to binder delivery point.
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TRANSPARENT HOSE TO MONITOR FLOW
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MAIN ENTRANCE TO MAIN ENTRANCE TO PLANT SITEPLANT SITE
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MAIN ENTRANCE TO MAIN ENTRANCE TO PLANT SITEPLANT SITE
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TYPE 2 PG 70-22
TYPE 1 PG 70-22
PAVEMENT DESIGN
Not drawn to scale
TYPE 2 PG 70-22
3”
3”
3”
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Mixes were designed using Marshall Mixes were designed using Marshall Mix Design Procedures per ODOT Mix Design Procedures per ODOT
specificationsspecifications75 blows75 blows
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Production TemperaturesProduction Temperatures
•• EACH OF THE TWO MIXES WERE EACH OF THE TWO MIXES WERE PRODUCED AT:PRODUCED AT:
•• 300 300 °°FF•• 240240--255 255 °°FF•• 230230--235 235 °°FF
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Mix Design IssuesMix Design Issues
•• What temperature should specimens be What temperature should specimens be compacted?compacted?
•• TSR TSR •• Volumetrics at plantVolumetrics at plant•• Superpave vs. MarshallSuperpave vs. Marshall
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Type 2 Zeolite Mix % Air Voids
22.5
33.5
44.5
55.5
66.5
77.5
88.5
9
4.0 4.5 5.0 5.5 6.0
% AC
% A
ir V
oids Original Design
Zeolite 255Zeolite 235
4.74.7 5.35.35.45.4
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WHAT BINDER CONTENT WHAT BINDER CONTENT SHOULD WE USE?SHOULD WE USE?
•• DECIDED TO USE THE ORGINAL DECIDED TO USE THE ORGINAL DESIGN BINDER CONTENTDESIGN BINDER CONTENT
•• WILL COMPACT SPECIMENS AT THE WILL COMPACT SPECIMENS AT THE DESIGN TEMPERATURE NOT THE DESIGN TEMPERATURE NOT THE PLACEMENT TEMPERATURESPLACEMENT TEMPERATURES
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Type 1 Zeolite Mix % Air Voids
11.5
22.5
33.5
44.5
55.5
66.5
77.5
88.5
9
5.5 6.0 6.5 7.0 7.5
% AC
% A
ir V
oids Original Design
Zeolite 255FZeolite 235F
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SAME ISSUE WITH TYPE 1SAME ISSUE WITH TYPE 1
•• DECIDED TO STAY WITH ORIGINAL DECIDED TO STAY WITH ORIGINAL DESIGN TEMPERATURESDESIGN TEMPERATURES
•• WILL USE ORIGINAL MARSHALL MIX WILL USE ORIGINAL MARSHALL MIX DESIGNDESIGN
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APA RUT TESTINGAPA RUT TESTING
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T-2 WARM ASPHALT STUDY LOADED WHEEL TEST COMPARISON
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 1000 2000 3000 5000 7000
# OF CYCLES
DEF
. IN
INC
HES
Original Design255F235F
T-2 WARM ASPHALT STUDY LOADED WHEEL TEST COMPARISON
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 1000 2000 3000 5000 7000
# OF CYCLES
DEF
. IN
INC
HES
Original Design255F235F
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T-1 WARM ASPHALT STUDY LOADED WHEEL TEST COMPARISON
0
0.05
0.1
0.15
0.2
0.25
0.3
0 1000 2000 3000 5000 7000
# OF CYCLES
DEF
. IN
INC
HES
Original Design266F246F
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TSRTSR
•• EXAMINED THE TSR VALUES IN THE EXAMINED THE TSR VALUES IN THE LABORATORY AS RELATED TO LABORATORY AS RELATED TO ORIGINAL DESIGN AND EACH ORIGINAL DESIGN AND EACH TEMPERATURE TEMPERATURE
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TYPE 2 Zeolite Tensile Strength Ratio
40
45
50
55
60
65
70
75
80
85
ORIGINAL DESIGN ZEOLITE 255F ZEOLITE 235F
Mix Type
TSR
Rat
io
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TYPE 1 Zeolite Tensile Strength Ratio
40
45
50
55
60
65
70
75
80
85
90
ORIGINAL DESIGN ZEOLITE 255F ZEOLITE 235F
Mix Type
TSR
Rat
io
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0102030405060708090
Des
ign
803
Lab
Sec.
1
Sec
4
ControlEuro ZeoliteUS Zeolite
SISTER COMPANY PIKE INDUSTRIES FOUND SOME ISSUES WITH TSR
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PRODUCTIONPRODUCTION•• ASTEC DOUBLE BARRELASTEC DOUBLE BARREL•• CALIBRATED THE ASPHACALIBRATED THE ASPHA--MIN TO MIN TO
PLANTPLANT’’S EXPECTED TONS PER HOURS EXPECTED TONS PER HOUR•• EXPECTED TPH EXPECTED TPH -- 200200--250 TPH250 TPH•• SILO STORAGE TIME APPROX 20SILO STORAGE TIME APPROX 20--30 30
MINUTESMINUTES•• WEATHER: COOL LOW MID 40WEATHER: COOL LOW MID 40’’S HIGH 65S HIGH 65
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FIRST MATERIAL PRODUCEDFIRST MATERIAL PRODUCED
•• The material coming The material coming out of the dryerout of the dryer--drum drum discharge chute was discharge chute was uncoateduncoated
•• When the material When the material was loaded into the was loaded into the truck the material truck the material was coated!was coated!
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During production, noticed higher amp draw for the slant conveyor
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Production Production
•• Easier to produce than expectedEasier to produce than expected•• Some concerns about baghouse Some concerns about baghouse
temperaturetemperature•• Did experience decrease in tons per Did experience decrease in tons per
hourhour
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Seeing is Believing!Seeing is Believing!
Hot Mix 314 F Warm Mix 254 F
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LaydownLaydown
•• Did not tell crew Did not tell crew temperatures at firsttemperatures at first
•• Fewer paver fumesFewer paver fumes•• Private crew did the Private crew did the
hand workhand work•• Little to no build up Little to no build up
in trucksin trucks
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Warm Asphalt Mix Warm Asphalt Mix at lower temperature at lower temperature could be handled in could be handled in the same way as the same way as normal HMAnormal HMA
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TYPE 2 PLACEMENTTYPE 2 PLACEMENT
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CompactionCompaction
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CONDUCTED NUCLEAR GAUGE TESTSCONDUCTED NUCLEAR GAUGE TESTS
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Mix cooled quicklyMix cooled quickly
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Loadout with Warm AsphaltLoadout with Warm Asphalt
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LoadoutLoadout
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TEST RESULTS OF TEST RESULTS OF PRODUCED MIXPRODUCED MIX
•• TSR TYPE 2 ONE HOUR CURE= TSR TYPE 2 ONE HOUR CURE= 87%87%•• TSR TYPE 1 ONE HOUR CURE= TSR TYPE 1 ONE HOUR CURE= 80%80%•• BETTER THAN MIX DESIGN RESULTSBETTER THAN MIX DESIGN RESULTS
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Cores yielded good densityCores yielded good density
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TYPE 2 PG 70-22 95.3%(230F)95.3%(230F)
TYPE 1 PG 70-22 94.4%94.4% (230F)(230F)
PAVEMENT DENSITYPAVEMENT DENSITY--AVERAGEAVERAGEBASED ON FIELD MTD 1 HOUR CUREBASED ON FIELD MTD 1 HOUR CURE
TYPE 2 PG 70-22 96.5% (240F)96.5% (240F)
AVERAGE DENSITY STANDARD AVERAGE DENSITY STANDARD TEMPERATURES 93%TEMPERATURES 93%
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Cure Time Cure Time –– Early ConcernEarly Concern
•• In some cases, Europeans allow In some cases, Europeans allow pavement to pavement to ““curecure”” before allowing before allowing traffic on roadway traffic on roadway
•• When does Warm AsphaltWhen does Warm Asphalt’’s workability s workability end?end?
•• Will pavements rut if traffic allowed on Will pavements rut if traffic allowed on an hour or so after placement? an hour or so after placement?
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ConclusionsConclusions--ProPro
•• Mix can be produced and placed at Mix can be produced and placed at lower temperatureslower temperatures
•• Density did not seem to be an issueDensity did not seem to be an issue•• Lower emissions from load out and Lower emissions from load out and
paving spreadpaving spread•• Workability improvedWorkability improved•• Fuel savingsFuel savings
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ConclusionsConclusions--ConCon
•• Expense of the additive offsets fuel savingsExpense of the additive offsets fuel savings•• Concerned about lower temperatures in Concerned about lower temperatures in
BaghouseBaghouse--corrosion, caking of bagscorrosion, caking of bags•• Possible lower Possible lower tphtph, more load on slant , more load on slant
conveyorconveyor•• Low TSR values in design stageLow TSR values in design stage--did not see did not see
stripping in placestripping in place--may be too soonmay be too soon•• Need larger project to gain experienceNeed larger project to gain experience
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A Word About CostA Word About Cost
•• Most additives, warm asphalt or other, Most additives, warm asphalt or other, are expected to increase the price of the are expected to increase the price of the HMAHMA
•• Some processes or additives may Some processes or additives may require plant/production modificationsrequire plant/production modifications
•• It is not anticipated that the fuel savings It is not anticipated that the fuel savings will totally offset these costswill totally offset these costs
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Questions to be answeredQuestions to be answered
•• Are there economic benefits?Are there economic benefits?•• How will compaction be affected?How will compaction be affected?•• What temperature should volumetric What temperature should volumetric
specimens be compacted?specimens be compacted?•• AntistripAntistrip -- Is it needed?Is it needed?•• DOT acceptance?DOT acceptance?•• EPA possible involvement???EPA possible involvement???
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Projected cost savings used oilProjected cost savings used oil
Warm Asphalt Cost of Fuel Savingsbased on Used Oil
$1.20
$1.30
$1.40
$1.50
$1.60
$1.70
$1.80
$1.90
$2.00
325 300 275 250 225
Temperature of Mix
Dol
lar P
er T
on o
f Fue
l
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Economics of warm asphaltEconomics of warm asphalt
•• ZeoliteZeolite--$0.60 per pound (not including $0.60 per pound (not including shipping)shipping)
•• 0.3% per ton of mix0.3% per ton of mix•• 6 # per ton6 # per ton•• $3.60 per ton of mix$3.60 per ton of mix
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