University of Anbar

College of Engineering
Civil Engineering Department

PRODUCING A NOVEL COLD MIX ASPHALT

A Project Report Submitted in partial fulfilment of the requirements for the

Bachelor’s Degree in Civil Engineering

By

Omer Hamoud Manaae

Omer Hussain zuber

Supervisor

Dr.Taher M. Ahmed

Mr.Saif Saad Mansoor

Mr.Thamer Y. Ahmed

"January 2020"
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CHAPTER ONE INTRODUCTION

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 CHAPTER ONE INTRODUCTION

DECLARATION STATEMENT

We, the undersigned students, hereby declare that the project work entitled “Producing novel
cold mix asphalt ” submitted to University of Anbar, is entirely our own work and has not
been copied from any other source. Any material that has been used from other sources has
been properly cited and acknowledged in the report.

We are fully aware that any copying or improper citation of references/sources used in this
report will be considered plagiarism, which is a clear violation of the ethics code of
University of Anbar.

Signature: Signature:
Student Name: Omer Hamoud Student Name: Omer Hussain
Student ID: Student ID:
Date: 14 /1 /2020
Date: 14 /1 /2020

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 CHAPTER ONE INTRODUCTION

CERTIFICATION

Approved by:

Signature: Signature:
Supervisor Name: Co-supervisor Name:
Mr.Saif Saad Mansoor
Dr.Taher M. Ahmed
Department: Department:
Civil Engineering Civil Engineering
Date: 14 /1 /2020 Date: 14 /1 /2020

Signature: Signature:
Co-supervisor Name:
Format Adherence Committee Mr.Thamer Y. Ahmed

Department: Department:
Civil Engineering Civil Engineering
Date: 14 /1 /2020 Date: 14 /1 /2020

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CHAPTER ONE INTRODUCTION

ABSTRACT

Generally, cold emulsified asphalt mixture contents from two parts: a mix made of emulsified
asphalt and aggregate. Emulsified asphalt is produced from base asphalt, emulsifier agent and
water with percentage approxmently of 40% to 75% asphalt, 0.1% to 2.5% emulsifier and
25% to 60% water plus some minor components. Aggregate is the skeleton part of the mix
structure, this aggregate contains on a vital parts is called the filler which is passed sieve No.
200.

The primary aims of this search is the potential of improving cold mix by incorporating
Geopolymer, in this regards a parts of filler will be replaced by fly ash which is one of the
main components of Geopolymer.

The main objectives of this study include evaluation Marshal properties (mechanical and
volumetric properties for hot mix asphalt and cold mix ,i.e. as a reference of mixes, and cold
mixes modified with Geopolymer. Additionally, indirect tensile test will be performance to
evaluate the moisture damage of mixes.

Finally, a conclusion can be drawn based on the output of this study, then it can be
recommended the visibility of using this type of cold asphalt mix.

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CHAPTER ONE INTRODUCTION

ACKNOWLEDGEMENTS

Firstly and finally, I would like to thank Allah the Most Gracious the Most Merciful,
for his blessings and for helping me achieve success in every endeavour of my life.

Our sincere thanks go to the main supervisor, Dr.Taher M. Ahmed, for his guidance, constant
support, inspiration, and wonderful patience during our research. We only have admiration
and respect for him.

We would also like to thank the staff civil engineering laboratories of Anbar University for
their help throughout our research, especially Mr.Thamer Y. Ahmed.

We would like to express our profound thanks and gratitude to Mr.Saif Saad Mansoor for his
guidance, encouragement, and advice

Our warmest thanks to my family and friends for their love, guidance and unconditional
encouragement throughout my personal life and professional life.

finally?

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CHAPTER ONE INTRODUCTION

Table of Contents

List of Figures............................................................................................................................vi

List of Tables............................................................................................................................vii

List of Abbreviations...............................................................................................................viii

Chapter 1 Introduction ...............................................................................................................1

1.1 General …............................................................................................................................1

1.2 Scope of research..................................................................................................................1

1.3 Researchsignificance.............................................................................................................1

1.4 Research layout (research structure) ....................................................................................2

Chapter 2 Literature Review......................................................................................................3

2.1 General .…….…………......................................................................................................3

2.2 Bitumen ...............................................................................................................................4

2.3 Emulsified ………………………………….……………………………………………..5

2.4 Hot mix asphalt ………………………………..………………………………………….6

2.5 Cold mix asphalt ……………………………….…………………………………………7

Chapter 3 experimental work (research methodology)............................................................10

3.1 Introduction…………………………………………….…………………………………10

3.2 The Used Materials…………………………………….…………………………………10

3.2.1 Aggregate………………..................………………………...…………...…….……10

3.2.2 Bitumen…………………………………………………………………………………12

3.2.3 Emulsified……………………………………………………………………...………12

3.2.4 Water………………………………………………………………………….......…….13

3.2.5 Fly Ash.............................................................................................................................13

3.2.6 Alkaline Solution.............................................................................................................13

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CHAPTER ONE INTRODUCTION

3.3 Methodology (Design Mixing, curing)………………………………………….....……..14

3.3.1 Determination of aggregate gradation…………………………………………....……..13

3.3.2 Estimation of emulsified bitumen content ……………………………………......……15

3.3.3 mixing…………………………………………………………………………....……..16

3.3.4 Curing..............................................................................................................................18
CHAPTER 4 High Strength and Fast Curing CRA Mixtures And Conclusions……….…….20
4.1 Introduction…………………………………………………………………………...…..20
4.2 Stiffness modulus…………………………………………………………...…………….21
4.2.1 CMA specimens’ curing……………………..…………………………………………21
4.3 Performance of the optimum CRA mixtures cured at high temperature……..…………..21
4.4 Temperature susceptibility of the optimum CRA mixtures………………………………22
4.5 Performance of outdoor specimens………...……………………………………………..22
4.6 Water loss of CRA mixtures…………...…………………………………………………22
4.7 Conclusions……………………………………………………………………………….23

Refrence……………..…………………………………..........................................................24

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CHAPTER ONE INTRODUCTION

List of Figures

Figure (2-1) Bitumen………………………..............................................................................5

Figure (2-2) Emulsified asphalt ……………………………………………………………….5

Figure (2-3) Hot mix asphalt …………………………..………………………………...….…6

Figure (2-4) show producing bitumen mixtures with different temperatures ……………........9

Figure (3-1) Aggregate gradients……………………………………………………………..10

Figure (3-2) Emulsified ………………………………………………………………………12

Figure (3-3) Drying Aggregates in oven……………………………………………………..15

Figure (3-4) Addition emulsified to aggregates…………………………………………..…..17

Figure (3-5) Start manually mixing…………………………………………………………..17

Figure(3-6) Compaction samples by Marshall hammer…………………………………..….18

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CHAPTER ONE INTRODUCTION

List of Tables

Table(3-1) Physical properties of coarse aggregate…............................................................. 11

Table (3-2) Physical properties of fine aggregate…................................................................ 11

Table (3-3) Physical properties of Doura asphalt ….............................................................. 12

Table (3-4) Chemical Composition For Materials Binders……..……………………………14

Table (3-5) Sieve Analyses……………………………..……………………….……………15

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 CHAPTER ONE INTRODUCTION

List of Abbreviations

SCM supplementary cementations materials

AASHTO American Association of State Highway Officials

HMA Hot mix asphalt

CMA Cold mix asphalt

BEMs Bituminous Emulsion Mixtures

FA Fly Ash

NaOH Sodium Hydroxide

Na2SiO4 Sodium Silicate

OPC Ordinary Portland Cement
ITSM Indirect Tensile Stiffness Modulus
ITS Indirect Tensile Strength
CRA Cold Rolled Asphalt

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CHAPTER ONE INTRODUCTION

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CHAPTER ONE INTRODUCTION

CHAPTER ONE

1. INTRODUCTION
1.1 general
Cold asphalt Mixtures means manufacturing of asphalt at ambient temperature using
bitumen emulsion as the binder. It has been widely utilised in many countries such as the
USA and France.
Decreasing wastes from aggregate production processes, reducing land-filling and reducing
CO2 emissions during hot bituminous mixture production and laying are the main target
schemes for the environmentally friendly processes. Cold asphalt Mixtures is one of the
attractive methods of producing bituminous mixtures to tackle the mentioned
disadvantages when incorporating some waste and/or by-product materials individually or
collectively into these mixtures. Recently, researchers have shown an increased interest in
incorporating supplementary cementations materials in production of cold asphalt
mixtures around the world.
The use and development of cold asphalt mixtures were not brought forward in the Iraq
due to the shortage of experience among engineers and the applicability in the industry
field.

1.2 Aims of Research

This study aims to produce and evaluating cold asphalt mixture and improving their
characteristics by incorporating the Geopolymer technology where the novelty is producing
a new cold mix can be nominated Cold-Geopolymer Asphalt Mixtures (CGAM). On the
other hand, the same aggregate is used for producing hot mix asphalt (HMA) to be a
reference for comparison.

1.3 Research Objectives

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CHAPTER ONE INTRODUCTION

The objectives of this study includes evaluating the mechanical and volumetric properties for
hot , cold and CGAM mixes. Mechanical properties will be evaluating using Marshall stability,
Marshall stiffness and indirect tensile strength; while volumetric properties will be evaluated
using air voids and bulk density.

o 1.4 Research Layout (research structure)

The presented research is organized in five chapters:-

Chapter 1 presents a preface for this study, which mainly contains general background for
cold and hot mixes.

Chapter 2 includes the more relevant and up-to-date literature review to the presented
study. A critical review was carried out whenever is needed and relevant.

Chapter 3 displays the details of the used material in this work and their characterizations,
brief description and the basics of the used techniques in addition to present the detailed
followed methodology of the experimental work.

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CHAPTER ONE INTRODUCTION

CHAPTER TWO

LITERATURE REVIEW
2.1 General

An extensive review related to cold emulsified asphalt mixture and the factors that affected its
performance and development was carried out and presented in this chapter. The materials
and the methods of producing in addition to a historical background were particularly
presented.

Shakir et al. investigated the possibility of using the cold emulsified asphalt mixtures for road
construction and maintenance as an alternative to the hot asphalt mixtures, due to its practical,
economical, and environmental properties. This research focused on evaluates and test the
emulsified asphalt material properties to be used as paving mixture. The properties tested of
emulsified asphalt mixture were air voids, bulk density, wet Marshall stability, dry Marshall
stability, retained Marshall stability, flow tests and compared with the common used
specification. From several trial mixes it is found that the optimal percentages of initial
residual bitumen amount to produced adequate results for coating test, mixing , compaction,
curing and Marshall stability were ranged from (2.5%, 3%,3.5%,4% and 4.5%), and the best
percentage was (3.5%). at the end, it can be said that the emulsified asphalt mixture is a good
alternative mixture to the hot asphalt mixture for road construction and maintenance.[2]

Ahmed et al.[16] studied how to the enhancement of Cold Asphalt Emulsion Mixtures
(CAEMs) using blended fillers, including assessment of the microstructure. The materials
used were fly ash (FA), ground granulated blast furnace slag and Ordinary Portland cement,
and were used for the binary binder while silica fume was added to the binary binder to obtain
ternary binder. The durability and mechanical results indicated that the ternary binder was
more suitable than the binary binder for the manufacturing of Cold Asphalt Emulsion
Mixtures. The microstructural test shows that the effect of a two-part binder on the internal
microstructure of CAEMs was slightly negative and more noticeable in CAEMs containing
FA. It is proposed that the addition of Silica Fume to binary binder mixtures can eliminate the
delay in formation of hydration products caused by the bitumen emulsion. In general, the

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CHAPTER ONE INTRODUCTION

study suggests that the use of binary binder -CAEMs might be appropriate for pavements in
cold climate whereas ternary blended would be effective in road pavements exposed to severe
conditions both in hot and cold climates.

Abbas et al. studied the possibility of producing fast curing, high strength, and sustainable
mixtures by using various waste and by-product materials individually or/and collectively as a
replacement for mineral filler. The materials used were: Poultry Litter Fly Ash (PLFA), Waste
Paper Sludge Ash (WPSA), which has high lime and galenite content, which has high alkali
components, Silica Fume (SF), and Rice Husk Ash (RHA), which is rich silica content and
cost-plus material, collectively instead of mineral filler. This study showed a variation in the
improvement properties of cold mixes, however it was positive in comparing to HMA.[1]

2.2 Asphalt Cement (Bitumen)

It might be noted here that the term ‘bitumen’ is used in UK pavement technical literature to
describe what is termed ‘asphalt cement’ in the USA. Asphalt cement or bitumen is a heavy,
dark brown to black mineral substance, one of several mixtures of hydrocarbons. It may be
found in natural deposits or may be a refined product by distractive distillation for crude oil.
Asphalt cement or bitumen was described as a is viscous and elastic behavior, complex
material, the response of bitumen to stress is dependent on loading time, temperature and the
amount of loading. Bitumen behaves as viscous liquids at high temperatures or long loading
times, while it behaves as elastic (brittle) solids at very low temperatures or short times of
loading. Bitumen modification with additives and/or decrease of the bitumen viscosity in
production and paving temperatures allows reducing the temperature in which bitumen is still
workable. To determine the good production and paving temperature and predict asphalts
behavior for long term in-service life. It is vitally important to have knowledge about bitumen
properties and their influence on the visco-elastic behavior of binder.

2.3 Emulsified Asphalt

It is a very fine atom and pure bitumen It has the ability to dissolved in water by a specific
element called the emulsion. The emulsion is a foaming substance such as soap that makes
bitumen atoms distributed in water in one degree as long as the emulsion is in the form of a
liquid and after using the emulsion the water steam leaving the bitumen covering the surface

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CHAPTER ONE INTRODUCTION

with an equal degree. The emulsion is obtained by segmentation the cement asphalt into small
particles that are carrying a charge positive (cationic) or negative (anionic ) so that they
remain suspended in an aqueous medium and add proven substances to it to keep it in the
suspended state as it is after the stabilizing effect is over, the asphalt particles stick together,

forming a cohesive layer and raises water. Figure (2-1) shows the asphalt emulsion at room
temperature.

(A) Natural picture . (B) Image under the microscope[5].

Figure( 2-1) Emulsified asphalt

2.4 Hot Mix Asphalt (HMA)

The flexible pavement consists of graded minerals held together by a binder. Bitumen is the
more traditional, binder used in the construction of roads, city streets, and highways. In
addition, the term ‘asphalt’ is reserved for materials containing a mixture of bitumen and
graded aggregate. Figure (2-2) shows the pavement process for hot asphalt mixture. HMA is
produced by mixing deferent aggregates sizes to meet the gradation specifications with
bitumen where bitumen’s role is as binder materials while aggregate as a skeleton.

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CHAPTER ONE INTRODUCTION

Figure(2-2) hot mix asphalt[15]

2.4.1 Objectives of HMA

HMA mix design should Be developed with the following objectives in mind:

1. Resistance to Permanent Deformation. the mix should not customer or displace when
subjected to traffic. the resistance to permanent deformacription (or rutting) becomes
critical at elevated temperatures during hot summer months when the viscosity of the
asphalt cement binder is low and the traffic load is primarily carried by the mineral
aggregate structure. resistance to permanent deformation is controlled by selecting
quality aggregates with proper gradation and selecting the asphalt content so that
adequate voids exist in the mix.
2. Fatigue Resistance. the mix should not crack when subjected to repeated loads over
a period of time. complex repeated load either constant stress or constant strain-
controlled.
3. Resistance to Moisture Induced Damage. Some HMA mixes, when subjected to
moisture or water lost adhesion between the aggregate surface and asphalt cement
binder, aggregate properties are primarily responsible for this phenomenon,
although some asphalt cement is more prone to moisture damage (stripping) than
others. If an HMA mix is prone to stripping, then anti-stripping agents should be
used, making the mix impermeable to water also minimizes the problem, moisture
susceptibility of HMA mixes .
4. Durability. The mix must contain sufficient asphalt cement to ensure an adequate
film thickness around the aggregate particles, thus minimizing asphalt cement
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CHAPTER ONE INTRODUCTION

hardening or aging during production and in service. The compacted mix should not
have very high air voids (increased permeability) which accelerate the aging
process.[13]

2.5 Cold Mix Asphalt (CMA)

Cold Bituminous Emulsion Mixtures (CBMA) (one of the cold asphalt technologies) for road
pavements means the manufacturing of asphalt using emulsified bitumen as the binder at
ambient temperature. CMA include a large range of products, preparing procedures and
laying techniques. Normal emulsion or emulsion modified by polymer or solvent. Fiber and
cement can also be used to enhance its properties. Also, CMA may be prepared using an
asphalt plant or on-site using special equipment or by hand mixing. CMA may or may not be
stockpiled before final laying, spreading and laying by:

a) hand (in some cases or road-opening reinstatement)

b) graders or asphalt pavers

CMA might be used as structural layers in heavily trafficked base layers, low trafficked
wearing courses, and non-structural layers in surface treatment layers .

2.5.1 Advantages of Using CMA

Reduction of adverse ecological impact, energy savings, and safety during makings and build
are the main issues encouraging the use of cold mix asphalt ( CMA) instead of Hot Mix
Asphalt (HMA) in the construction of roads and highways.

- The main advantages of adopting CMA are:

➢ Do not command to gaseous emissions, which are potentially harmful to health and
environment, because there is no need to heat mix materials in any steps of the
production process. The CO2 emission from cold mix manufacturing is approximately
14 % compared with hot mix asphalt, Figure (2-3) is a clear comparison in energy
consumption for different production techniques. .

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CHAPTER ONE INTRODUCTION

➢ CMA production is cheaper than conventional hot asphalt mix production. Energy
saving is because of: firstly, CMA production does not require drying and heating of
aggregate mixture, while traditional HMA production requires drying and heating of
aggregate mixtures to more than 140 °C as well as heating of the bitumen to a range of
temperatures between 140 °C and 170 °C. Secondly, transport costs are generally
higher for HMA as both raw materials and finished product have to be carried over
longer distances because cold mix plants are simpler than conventional hot mix
versions and therefore they are normally considered to be portable.
➢ More safety to handle: skin contact is not eliminated by using CMA and in fact, they
are more likely to be handled than hot or warm asphalt.
➢ Have logistical advantages over hot mix, in that they can be stored or transported over
longer distances and it is not necessary to use insulated trucks for shorter journeys
➢ No waste is expected from cold mixtures, as may happen with HMA when the losses
in mixture temperature reach a certain unacceptable value. .[6],[7],[8].
2.5.2 Disadvantages or Problems from CMA

Disadvantages are mainly due to some inherent problems associated with the
performance of the pavement produced by the CMA process which causes them to be
regarded as “inferior” to conventional hot asphalt. Therefore, CMA has been used for
small-scale works such as reinstatement works and for works in far areas with low to
medium traffic conditions.

➢ Stated by the previous studies and applications. The major problems with this type of
application are the long curing time (evaporation of trapped water) required to achieve
the maximum performance and the poor early life strength (because of the existence of
water). They stated that the full curing in the field of these mixtures may occur
between 2‒24 months depending on the mixture’s ingredients and weather conditions.
➢ High air voids for the compacted CMA are reported to be another concern.
➢ There are also other concerns regarding CMA, like insufficient coating percentage
because of the incompatibility between the aggregates and emulsion, binder drainage
during storage because of the low viscosity of the emulsion, and binder stripping from

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CHAPTER ONE INTRODUCTION

the aggregate due to high water sensitivity and weak adhesion. .[6],[9],[10]

Figure (2-4 ) shows three main techniques used to produce bituminous mixtures at different
mixing and applying temperatures, these are hot asphalt, warm asphalt, and cold asphalt
technology.[11].

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CHAPTER ONE INTRODUCTION

CHAPTER THREE
EXPERIMENTAL WORK
(METHOLOGY OF RESEARCH)
3.1 Introduction

This chapter gives a description of the mixing materials and mixing ratios as well as the
method of mixing and the mechanism and instruments of the examination the mechanical
characteristics. Also, it explains the work method of mixing and preparation of asphalt
mixtures in detail.

3.2 Materials

3.2.1 Aggregate

After performing the sieve analysis of fine and coarse aggregate and filler. Aggregate
gradients can be seen in Figure(3-1).

0.3mm 2.36mm 25.5mm

0.075mm 4.75mm 19mm

Filler 9.5mm 12.5mm

Figure(3-1) . Aggregate gradients. [Resource: Researchers]

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CHAPTER ONE INTRODUCTION

3.2.1.1 Coarse Aggregate

The aggregate passing from sieve number 1.5 inch (37.5 mm) and residual on sieve number 4
inch (4.75 mm) from Al-Nebai quarry, which is natural gravel that was used for all mixes. It
satisfied with the State Corporation for Roads and Bridges in Iraq (SCRB) .The physical
properties of used coarse aggregate are shown in Table (3-1).

Table (3-1) Physical properties of coarse aggregate. [Resource: Researchers]

Property Test Method

Specific Gravity 2.5

ASTM C – 127
Density (Kg/m3) 2500
ASTM C – 128
% Water absorption 0.8

3.2.1.2 Fine aggregate

Natural sand was used as a fine aggregate in this study. This fine aggregate passing from sieve
number 4 inch (4.75 mm ) and residual on sieve number 200 inch (0.075 mm), the physical
properties of fine aggregate are shown in Table (3-2). The specific gravity and modulus of
fineness were 2.65 g and 2.5 g, respectively which satisfied the State Corporation for Roads
and Bridges in Iraq (SCRB) .

Table (3-2) Physical properties of fine aggregates. [Resource: Researchers]

Property Test Method

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CHAPTER ONE INTRODUCTION

Specific Gravity 2.67

ASTM C – 127
3
Density (Kg/m ) 2.43
ASTM C – 128
% Water absorption 0.6

3.2.1.3 Filler

In this research, limestone filler was used, it is the stone powder, it does not react with
water. The specific gravity was (Gs = 2.88) according to specifications (ASTM C188).

3.2.2 Bitumen

The asphalt used in this study from the Doura refinery in Baghdad, where one type of asphalt
has a grade (40-50), the physical properties of asphalt is detailed in Table (3-3).

Table (3-3) Physical properties of Doura asphalt.

Property Test condition Unit ASTM Values
Designation
Penetration 100gm, 5 sec , 100gm, 25oC 0.1 mm D-5 44
Specific gravity 25oC --- D-70 1.03
Ductility 5 cm/min, 25oC Cm D-70 +100
Flash point ------- oC D-92 325
Softening point ------- oC D-36 52

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CHAPTER ONE INTRODUCTION

Viscosity (RV) 135 oC Cst D-4402 351

Mass losses TFO 5 hours, 163 oC % D-1754 0.52
Penetration 100gm, 5 sec , 100gm, 25oC 0.1 mm D-70 26
Softening point 5 cm/min, 25oC Cm D-70 56

3.2.3 Emulsified

In this study, emulsified asphalt was supplied from the local market as shown in Figure (3-2).
Unfortunately, the specification of this material are not supplied with the container.

Figure(3-2)Emulsified. [Resource: Researchers]

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CHAPTER ONE INTRODUCTION

3.2.4 Water

In this study, tap water was used in preparing cold mixing asphalt as pre-watering for
aggregate. Water was free of impurities, organic and solids material. The optimum water
content was found by taking four samples with different percentages of water were (1.5%,0
1%, 0.5%, and 0.25%) from the total weight of dry aggregate.

3.2.5 Fly Ash (FA)

It is a by-product waste material produced from coal-fired station plants. It forms as a result
of using coal as a fuel for generating electric energy. FA is removed from the plant as a
sediment waste material before produced gases are released into the atmosphere
throughout the chimney [3]. Fly ash content depends on the dirt in the coal before
combustion, besides the properties of the combustion process. As a result, the chemical
characteristics of fly ash are varied substantially in determining its late chemical activity and
physical properties. It is categorized into two categories based on the lime content present
[4]. Fly ash content depends on the dirt in the coal before combustion, besides the
properties of the combustion process. As a result, the chemical characteristics of fly ash are
varied substantially in determining its late chemical activity and physical properties. It mainly
contains silica and alumina. It is categorized into two categories based on the lime content
present [4]. In this study FA class F which are representing low calcium content, as shown in
the chemical compositions in Table 1 was used.

3.2.6 Alkaline Solution

The alkaline solutions used in this study are sodium hydroxide (NaOH) and sodium silicate
(Na2SiO3). The Sodium hydroxide is in flakes form with 98 % purity that is commercially
available. It was prepared by melting caustic soda flakes in water. Different molar
concentrations can be produced depending on the ratio of caustic soda flakes to water. The
molar concentration used in this study ranged from 6 to 14. The reaction of sodium
hydroxide with water was exothermic; therefore, every care should be taken when
preparing it and the solution should be left at least 1 hour to be safely used in producing

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CHAPTER ONE INTRODUCTION

AAC. Sodium Silicate is in a liquid state that provided by the General Company for Vegetable
Oils Industry in Baghdad- Iraq. Its concentration is depending on the ratio of Na2O to SiO2
and H2O. As noticed that the sodium oxide is 14.75 %, SiO2=30.5%, and H2O=54.75%.

Table 3-4 : Chemical Composition For Materials Binders. [Resource: Researchers]

Cement Kiln Fly Ash (FA) Blast furnace

Oxide Silica fume (SF)
Dust (CKD) slag (BFS)
Composition % Type F (wt%) (wt%)
(wt%) (wt%)

AL2O3 4.19 25.39 12 -

SiO2 18.9 47.69 35 85–97

CaO 58.67 7.93 40 <1

K2O 1.37 1.56 2 -

Na2O 1.1 0.08 2 -

Fe2O3 3.25 11.72 1 -

MgO 1.87 1.27 1.5 -

SO3 4.32 0.37 - -

CL 0.39 - - -

3.3 Methodology (Design Mixing, Curing) :-

Until now, there is no universally accepted specification for cold bitumen emulsion mixtures
test and mix design. This study adopted the Asphalt Institute Method detailed in developing
cold emulsion asphalt mixes[17] . The principle steps included in the design process
generally include aggregate properties tests, aggregates blending, and determination of
optimum amounts of bitumen and pre-mix water and bitumen characterizes tests. Mixture
design and testing procedures vary amongst the various road authorities, research institutions
and asphalt researchers [2, 4, 7, 8]. In general, the design methods cover the following steps:

1. Determination of aggregate gradation was taken as a mid-point between lower and

upper limits of aggregate gradation for Iraqi specification for base coarse as show in
Table (3-5). Where this gradation used is a job mix equation. The weight of
27
CHAPTER ONE INTRODUCTION

sample(aggregate) was (1200 g) and then are dried in the oven at a temperature of
110°C for a period of 24 hours or placed in the oven at a temperature of 163°C for a
period of 3 hour. As shown in figure(3-3).
Table(3-5): Sieve analysis according specification for base coarse.

[Resource: Researchers]

Sieve No. min Max Mid Retained Total Requirement

% weight of weight for each
aggregate sieve
1.5(37.5mm) 100 100 100 --- --- ---
1(25.2mm) 90 100 95 5 1200 60
3/4(19mm) 76 90 83 12 1200 144
0.5(12.5mm) 56 80 68 15 1200 180
3/8(9.5mm) 48 74 61 7 1200 84
4(4.75mm) 29 59 44 17 1200 204
8(2.36mm) 19 45 32 12 1200 144
50(0.3mm) 5 19 12 20 1200 240
200(0.075mm 2 8 5 7 1200 84
)
5 1200 60
∑=1200

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CHAPTER ONE INTRODUCTION

Figure(3-3). Drying Aggregate in oven. [Resource: Researchers]

2. Estimation of Emulsified Bitumen Content

The asphalt emulsion content was determine approximated depending on the weight of the dry
aggregate, according to the following formula:

P = (0.05 A + 0.1B + 0.5C) × 0.7 ……………………………………….. (3-1)

Where
P = % Initial residual bitumen content by mass of total mixture,
A = % of aggregate retained on sieve 4.75 mm,
B = % of aggregate passing sieve 4.75 mm and retained on 0.075 mm,
C = % of aggregate passing 0.075 mm.
The initial emulsion content value can be obtained from Equation (3-2)

IEC=(P/X)×100% ……………………………………………..……….. (3-2)

where IEC is the Initial Emulsion Content by mass of total mixture (%) and X is the
percentage of bitumen content in the emulsion (%).[14]

3. Mixing Design Using Marshall method

Marshall's design is relatively an old, but it is used by many road agencies because it is
economical because it uses simple, inexpensive laboratory equipment. This method has been
used in this study for design both hot and cold asphalt mixtures.

3.1.Hot mix asphalt

➢ After the samples dried, the bitumen put in the oven.

➢ We start the process of mixing with the preservation of temperature 160, where we
add bitumen at different rates for every three samples (4%, 4.5%, 5%, 5.5%, 6%).
➢ Place the mixing container on a thermal source in order to preserve the mixing
temperature. Then, we put the aggregates in the container and add the bitumen to it.
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CHAPTER ONE INTRODUCTION

The mixing process is done manually until the aggregate granules are fully mixed
with the bitumen.
➢ After the mixing process is complete, we put the sample into the mold and then
strokes it with a metal rod 25 blow (15 on the sample perimeter and 10 in the middle).
➢ Then we put the mold with the sample in the Marshall compactor, where the device
hammered the sample hammered 75 blow for each face.
➢ We take the samples out after 24 hours using hydraulic jacks.

3.2.Cold mix asphalt

➢ After the samples are dried, the aggregate placed in a mixing container.
➢ We add water to the aggregate at deferent percentage (0.25, 0.5, 1.0, 1.5)%. .
➢ Then emulsified asphalt added to the aggregate. as shown in Figure(3-4).

Figure(3-4) addition emulsified asphalt to aggregates. [Resource: Researchers]

➢ After that we start mixing and the mixing process is done manually until the aggregate
granules are fully mixed with emulsified asphalt, The mixing process continued for 3
minutes. As show below in Figure(3-5).

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CHAPTER ONE INTRODUCTION

Figure (3-5) start manually mixing. [Resource: Researchers]

➢ The coating test will be started using a slow setting. Sixty seconds of mixing time are
sufficient when mixed even coating is obtained. Aggregate coating in excess of 50
percent shall be considered acceptable. The optimum pre-wetting water contentment
gives the best bitumen coating on the mineral aggregate. This optimum water content
will be mixed in all subsequent mixing
➢ Leave the samples for 15 minutes, then it put into the mold and then strokes it with a
metal rod 25 blow (15 on the sample perimeter and 10 in the middle).
➢ Then we put the mold with the sample in the Marshall compactor, where the device
hammered the sample hammered 50 blow for each face.
For determination of adequate compaction level to satisfy final air-void requirements,
Marshall Hammer compactor were using the compaction of the cold mix samples was
carried out. The following compaction effort setting; hammer of (4.356 kg) sliding
weight, and a free fall of (457.2mm) on the top and bottom of each sample. In this
research, for determined suitable compaction, the compaction was carried out at
Heavy compaction effort: 50 Marshall blows each face. As show in Figure(3-6).

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CHAPTER ONE INTRODUCTION

Figure(3-6) Compaction a sample by Marshall hammer. [Resource: Researchers]

➢ The samples taken out from mold after 24 hours using hydraulic jacks.

4. Curing
Curing of Compacted samples, the curing method adopted at this stage was oven
curing of compacted specimen for dry stability test. This curing procedure consisted of
keeping the newly compacted specimen for 24 hr. in their compaction molds. The
samples then extruded and kept for 24 hr. in an oven at 25°C.[13

32
CHAPTER ONE INTRODUCTION

CHAPTER FOUR
High Strength and Fast Curing CRA Mixtures And Conclusions
4.1 Introduction

As reported by the preceding investigations and applications on BEMs, the long curing time
required to achieve the maximum performance and the poor early life strength are the main
concerns about these mixtures. Chevron Research Company stated that the full curing of
those mixtures may occur between 2 months and 2 years depending on their ingredients
and weather conditions. Tanaya et al. indicated that the stiffness modulus of BEMs
containing PFA instead of conventional mineral filler is very comparable to hot mixtures after
full curing conditions (more than 2 years).

This chapter presents the process technology for the production of CRA mixtures containing
different types of filler: the first mixture represents a control CRA containing conventional
limestone dust which is the traditional mineral filler for HRA mixtures and complies with the
BS EN 13108: Part 4 standards requirements (European Committee for Standardization,
2006). While the second mixture represents a CRA containing OPC instead of mineral filler to
investigate the ability to produce a high-performance gap graded CRA mixture containing
OPC. Due to the economic potential as well as the environmental benefit in terms of carbon
emissions and hazards to health, energy savings, and recycling of waste materials,
supplementary cementitious materials have been used individually or collectively instead of
OPC to produce sustainable CRA mixtures. Therefore, the third mixture was CRA with WPSA
(which is an SCM with high lime and gehlenite content) as a replacement for the
conventional mineral filler.

To improve the activity of the secondary binder (i.e. binder generated from the hydration
process between filler and the trapped water incorporated in CMA ), optimization has been
made to produce a Binary Blended Filler (BBF) which was generated from blending WPSA
with PLFA, which is another SCM with high alkali content. The last two steps were focused
on producing fast curing CRA mixtures with Ternary Blended Filler (TBF) which were
generated from blended WPSA, PLFA, and high silica SCM. The first was produced from
blending WPSA and PLFA with SF (which is a high silica content by-product material). Finally,
as SF is a cost-minus material, the idea of replacing this material with another, cost-plus,
material (with similar activity) has been proven successful by using RHA which is rich in silica
content waste material to produce the second

33
CHAPTER ONE INTRODUCTION

4.2 Stiffness modulus

The behavior of bituminous mixtures is particularly elastic, although these mixtures are
viscoelastic materials (Nunn, 1997). The elastic stiffness modulus (ESM) of bituminous
mixtures is a respectable indicator of its ability for load spreading. Furthermore, high ESM
controls the level of tensile strain created in the underlying courses. Consequently, a mixture
with a high elastic stiffness modulus will have a good load-spreading ability which decreases
the deflection caused by the passing traffic loads and the tensile strains in the underlying
layers.

4.2.1 CMA specimens’ curing

The normal curing process adopted in this investigation consisted of two stages. The first
stage was to maintain the sample in the mold for 24 hours at lab temperature, i.e. 20 ºC.
After that time the sample was extruded and kept at lab temperature until testing took place
at different ages, i.e. 1/6, 1, 3, 7, 14, 28, 90, and 180 days to determine the ITSM. Most of
the previous investigations such as were focused on curing of BEMs at high temperatures
such as 40 ºC due to the weak strength of these mixtures. But in this study, the use of 20 ºC
as the normal curing temperature was adopted to prove the possibility of producing high-
performance cold mixtures at normal lab temperature.

4.3 Performance of the optimum CRA mixtures cured at high temperature

Cold BEMs are very sensitive to conditioning temperature and curing time. Therefore, these
mixtures are more suitable for regions where the ability to evaporate the trapped water is
fast. conducted a detailed study on the performance of cold mixtures with different curing
criteria. He concluded that there is a considerable improvement in terms of strength

34
CHAPTER ONE INTRODUCTION

enhancement when these mixtures are cured at higher temperatures. Also, he stated that 1
day @ 20 ºC plus 1 day @ 40 ºC curing criteria represents 7–14 days in the field. In this
study, the said curing criteria were adopted to identify the evolution of the stiffness modulus
with a higher temperature of the produced CRA mixtures. Also, this temperature is a normal
temperature in different regions around the world and it is the common summer
temperature of the author’s country of origin.

4.4 Temperature susceptibility of the optimum CRA mixtures

To indicate the temperature susceptibility of all the optimized CRA mixtures as well as HRAs,
the ITSM test was conducted at 28 days with different testing temperatures, namely 5, 20,
and 40 °C. The slope of the curve in a semi-logarithmic plane can represent temperature
sensitivity, as mixtures with a higher rate of change have more temperature sensitivity.

As shown in this figure, it was not possible to conduct the test for control CRA mixtures at 40
ºC due to the weak strength of those mixtures at high temperatures. Also, the results
confirmed the thermo-dependence of CRA mixtures, showing a decrease in ITSM with an
increase in temperature. However, The presence of strong bonds due to the cementitious
action of modified CRA mixtures’ filler and the residual internal friction between aggregate
particles guarantees high stiffness properties at high temperatures but these mixtures
preserve the temperature-dependent behavior.

Therefore, it is expected that modified CRA mixtures suffer less distortion and rutting as
compared to 100/150 and 40/60 HRA during hot seasons in addition to the possibility of
lower mixtures’ fracture at low temperatures.

4.5 Performance of outdoor specimens

To ensure a better simulation of the site conditions, all the control and optimized CRA
mixtures were manufactured and cured under the rain and real temperature profile in
outdoor exposure conditions. The samples were kept in their molds for 24 hours @ 20 ºC
prior to extrusion.

35
CHAPTER ONE INTRODUCTION

4.6 Water loss of CRA mixtures

To indicate the water loss of different CRA mixtures, all these mixtures were manufactured
and left in the molds for 24 hours before being extruded, then cured at 20 ºC in the lab
room. Simply, water loss for each specimen was taken as the loss in mass at different ages,
i.e. 1, 3, 7, 14 and 28 days

The following points are worthy of note:

i. The rate of water loss for all mixtures before 7 days is higher than after that age,
ii. In general, it can be concluded that LD mixtures have a high water loss in comparison
with the other mixtures which incorporated hydrated filler,
iii. The period of investigation may be too short to indicate the progress of water loss for
long-term studies.

The behavior of CRA mixtures with cementitious filler consumes some of the trapped
water incorporated in these mixtures, especially in the early days. Also, the evaporation
process and absorption of the filler and aggregate materials to this water increased the
total water loss of these mixtures.

4.7 Conclusions
Environmentally friendly, economic and sustainable Cold Rolled Asphalts (CRAs) have been
satisfactorily produced using different Supplementary Cementitious Materials individually
and/or collectively as a replacement for the conventional mineral filler (limestone dust). The
gradation of these mixtures is the same as those mixtures traditionally used to produce Hot
Rolled Asphalt (HRA), which is suitable for surface course heavily trafficked pavements.

The current study was focused on overcoming the main concerns regarding cold BEMs,
which are the long curing time required to achieve the maximum performance, the inferior
early life strength, and high air voids content.

The main concerns of cold BEMs are the long curing time required to achieve the maximum
performance and inferior early life strength. A number of previous investigations indicated
that the full curing of BEMs may occur after 2 months to 2 years depending on their
36
CHAPTER ONE INTRODUCTION

ingredients and weather conditions.

This chapter has presented the optimization sequence of the novel CRA mixtures in terms of
stiffness modulus results, as a respected fundamental property, when different SCMs were
incorporated individually or collectively instead of the conventional mineral filler.
Accordingly, a number of CRA mixtures have been produced,

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[4] D. Bondar, C. J. Lynsdale, N. B. Milestone, N. Hassani, and A. A.

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[8]Thanaya, I., Zoorob, S. & Forth, P. A laboratory study on cold-mix, cold-lay emulsion
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[9] Needhem, D. 1996. Developments in Bitumen Emulsion Mixtures for Roads. PhD thesis,
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[10] Leech, D. 1994. Cold Bituminous Materials for Use in the Structural Layers of Roads.
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[11] Abbas May 2014 " High strength cold rolled asphalt surface course mixtures".

[12] Thanaya, N. A., 2003," Improving the Performance of Cold Bituminous Emulsion
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[13] Federal Highway Administration, Report No.FHWA-IP-79-1,January 1979 .A basic

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[14] Lexington, KY,USA, 1977. Asphalt Institute. Asphalt Cold-Mix Manual: Manual Series No.
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[15]. https://http2.mlstatic.com/carpeta-asfaltica-bacheo-asfalto-caliente-frio-pavimento-D
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