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A Review on Warm Mix Asphalt

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Proceedings of National Conference: Advanced Structures, Materials And Methodology in Civil Engineering
(ASMMCE – 2018), 03 - 04th November, 2018
PAPER CODE: T-407

A Review on Warm Mix Asphalt

Gandu Srikanth,1 Rajiv Kumar 2
Rohit Vasudeva 3

M.Tech Student1#*, Department of Civil Engineering, Lovely Professional University, 144411, Punjab, India.
gandusreekanth@gmail.com
Assistant Professor 2 Department of Civil Engineering, National Institute of Technology- Jalandhar, 144011, Punjab, India.
kumarr@nitj.ac.in, Corresponding Author
Assistant Professor3 Department of Civil Engineering, Lovely Professional University,144411, Punjab, India.
rohit.22225@lpu.co.in

ABSTRACT
Warm Mix Asphalt (WMA) is a new trend developed in Europe and after successful implementation in Europe USA
also accepted the warm mix technology in all 50 states. Presently in India Central Road Research Institute – Delhi
and some of the other organization working on this trend. To reduce the emission of various hazardous gas fumes,
consumption of fuel, compaction & placing Temperature and haul distance industries have Warm Mix Asphalt
instead of hot mix asphalt (HMA). Here they achieve all the properties similar to HMA meanwhile reducing
demerits of HMA by adding various types of additives like emulsions, wax based, chemical & foam technologies
etc. By the order of Supreme Court of India to shut down HMA plants in metropolitan cities so, WMA is an
alternative mix type in metropolitan cities. This paper is the review about various trends, merits & de-merits,
technical aspects, various temperatures of additives while adding with binders, various live examples where this
technology implemented, mix design, performance tests on WMA
KEYWORDS: Warm; Cold and Hot mixes; Mixing and Compaction Global Warming; Haul Distance.

INTRODUCTION
The hot mix asphalt industries constantly working to develop various technologies to enhance pavement
performance, construction efficiency, conserve resources, material improvement and environmental aspects
(Newcomb 2007). In that case, Hot mix asphalt also has a significant role in fuel consumption for heating aggregates
and binder and release various hazardous air pollutants. So, manufacturers need an alternative mix type that can
reduce these effects with same or better results. In HMA, temperature maintenance of aggregates, binder and mix is
a major issue so, to defeat that, asphalt industries constantly working on various asphalt mixes (Ex: Warm & Half-
Warm, Cold, LEA etc.) by reducing mixing & compaction temperature which will lead to reduce energy
consumption and environment pollutants. Mixing temperature of WMA is 110 to 140 OC compare to HMA of 150 to
180 OC (Behl et al. 2013). To safeguard the fossil fuel utilization, strong environmental acts, economical, haul
distances and global warming researchers are focusing on the warm mix technology (Figure 1).

Figure 1 Sustainable Development (D’Angelo 2008)

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WMA is a generic term for various technologies and products that are incorporated into plant produced HMA to
decrease the plant mixing, roadway paving and compaction temperatures while maintaining workability. It’s a
compaction aid for HMA. Warm mix is produced by decreasing the viscosity of binder or Surface Tension at
Asphalt Aggregate Interface or by increasing workability of mix in less temperature. WMA allow mixing, placing
and transporting process at low temperature. It’s not a mix type it is a technology that can use in any mix type where
to decrease mixing & compaction temperature (MS-2 2014).
The main goal of this paper is to write a review on the aspects associated with WMA involving background, history,
advantages and dis-advantages, various WMA technologies & mechanism’s, mix design, best practices for
producing WMA, lab experiments of warm mix asphalt and Various projects in India.

Background (Button et al. 2007) & (Table-1)

Warm mix technology was developed in Europe (1997) then by US (2002) the first trial took place in Europe
(1999), USA(2004), India (2009). Many countries like USA, Canada, Germany, France, India etc countries adopted
this technology on public roads after successful field tests like the Central Road Research Institute -New Delhi for
India.

Table 1: Various Trend Developments (Button et al. 2007)

Sl.No Year Details/Place Type of Technology Remarks

1 1956 LadisCsanyi, Iowa Foamed Foamed bitumen for use as a soil binder
State University

2 1968 Mobil Oil Australia Foamed Adding cold water rather than steam into
the hot bitumen

3 1970 Chevron * He developed mixing & Thickness

Design

4 1997 Chevron * He published full detailed code

“Bitumen mix manual “.

5 1994 Maccarrone, Foamed (Cold Mix) He introduced Cold Mix Asphalt using
G.Holleran Foamed Technology

6 1995 Shell Bitumen They filed a patient on Warm mix

asphalt

7 1997 Sasol Wax Wax They introduced Sasobit in WMA

International, Europe

8 1999 Jenkins, They introduced Half Warm-Mix

A.A.A.Molenaaretc technology.

9 2000 Koenders He introduced this WMA in open & Gap

Graded and stone mastic asphalt

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Advantages :-(D’Angelo et al 2008),(AmbikaBehl 2016),(EAPA 2010), (Sangiorgi 2018), &(Prowell et al. 2014).
a) General: Significant less mixing & compaction temperature, less energy consumption, reduce hazardous
fumes emission, due to less difference between placing and surrounding ambient temperature we can
have long-haul distances, paving in un-attainable places, reduce thermal segregation, less aging effect,
faster construction i.e, compaction temperature is less (less curing time) so we can open traffic in less
time only , Improved deep lift & thin lift in Asphalt pavement, WMA has good compatibility with
RAP so there is reduction in usage of virgin materials and give good kick start to recycle theme
(Zaumanis 2010)
b) Environment: Mainly it decreasesgreenhouse gases by 25-30%. So, this would earn tradable carbon credits
(IRC:SP:101- 2014). It is quite compactable with reclaimed asphalt pavement technology (RAP) that
saves utilizing virgin materials and reduce the hazardous effect of dumping the damaged pavement
materials. Typically 30-40 % of CO2 & SO2, 50 % of Volatile Organic Compounds, 10-30 % or CO,
60-70 % of NOX and 20-25 % of dust reduced by using WMA(D’Angelo et al 2008)(Table-2).
Decreasing the mixing temperature leads to the energy consumption of 35 % and more based on
process.

Table 2: Various pollutant % in Various Countries (D’Angelo et al 2008)

Emission Norway Italy Netherlands France

Co2 31.5 30-40 15-30 23
SO2 NA 35 NA 18
VOC NA 50 NA 19
CO 28.5 10-30 NA NA
NOX 61.5 60-70 NA 18
Dust 54.0 25-55 NA NA

c) Health Benefits: During mixing PAH fumes contain carcinogenic, mutagenic and teratogenic elements that
cause severe health issue for workers.30-50 % of aerosol/fumes and polycyclic aromatic hydrocarbons
(PAH) that affect the workers and surrounding area peoples also get reduced(Prowell et al 2014).
d) Technical Advantages: Less aging& oxidation of bitumen that delay fatigue cracks of pavement, high
workability, enough compaction time, longer haul distances, allow construction during cold weather
condition also.
e) Economical: Average production temperature of WMA is 27-30oC that results an average 22.1 % decrease
in fuel consumption and rest temperature maintain vehicles, burners etc make the value 35 % energy
consumption so parallelly the cost also reduced. Decrease load on Mixing Plant leads to less
maintenance and extend plant life.
f)
Drawbacks: WMA is susceptibility to moisture damage. Due to less mixing temperature leads to incomplete drying
of aggregates the moisture may get trapped in the pavement and leads to moisture damage. WAM have less aging
(Stiffness) of binder so it faces rutting. The initial production cost of WMA is high (Ex: Production at Iceland per-
ton $0.30 for WAM-Foam, $3.50 for Sasobit, and $4.00 for Aspha-Min).

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Classification of Warm mix technologies &Mechanisms :(Capitão et al. 2012),(D’Angelo et al 2008),(Button et

al. 2007)& (Rubio et al. 2012).
The basic principle of this technology is to add additives to the final mix, in this coating of aggregates with the
binder is highly achieved within less temperature typically (30OC less) than of hot mix temperature. Viscosity plays
an important key role in the coating of aggregates. To achieve this warm mix by a) lowering the viscosity of binder
b) reduction of surface tension at aggregates and bitumen interface.
Many authors have classified this warm mix technologies by many types based on Purpose type of additives etc.
Here in this paper considering the classification according to Indian Standard Code for WMA IRC-SP:101-2014,
CRRI -Delhi authored Papers and (MS-2 2014) (Dinis-almeida 2010)& (IRC:SP:101- 2014).

Their are mainly two classifications of Warm mix technologies.

1) Based on temperature parameter (Figure 2). A) Cold Mix: It is produced in ambient temperature by using foam
and emulsions B) Half -Warm Mix Asphalt have these temperatures ranges from 65 to 100 OC C) Warm Mix
Asphalt: It has the mixing & compaction temperature is 110 to 140 OC just above water boiling point. D) Hot Mix: it
has a production temperature of 150-180 OC.

Figure 2: Classification by temperature range, temperatures, and fuel usage are approx. (D’Angelo et al 2008)

2) Based on the type of additive we have three types a) Foaming (Water containing & Water based) b) Chemical
(polymers & Emulsification agents) c) Organic (synthetic wax, fatty acids, amides).
3) Based on purpose: a) Hybrid b) Rheological Modifiers c) Others

a) Foaming :(Zaumanis 2010) (Hurley et al. 2005) water expand 1600 times when converted into steam at
atmospheric pressure when this steam gets entrapped with viscous bitumen it produces foam then results in an
increase in its volume and decrease in viscosity(AmbikaBehl 2016). When preheated aggregates combine with this
foam (high volume bitumen or high surface area bitumen) enable coating of aggregates at a lower temperature.
Foaming technology is subcategorized into two types a) water-based b) water combined. In the water-based water is
injected with a foam generating machine and on other hand water combined here we use zeolites like
aluminosilicates of alkali metals (have 20% water content) when this type of zeolites gets combined with preheated
binder water get release and the same process continue to produce foam and warm mix. These synthetic zeolites are
added to the binder at the rate of 0.25 % by weight. Due to the presence of water stripping may occur so to
overcome this issue it is recommended to have chemical additives that promote the coating of aggregates and
decrease water sensitivity of mix.
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Foaming technology is also used in Low Emission Asphalt (LEA) process. Here coarse and a portion of fine
aggregates are heated at normal HMA temperature and a coating and adhesion additives approx 0.50 % by weight of
binder after adding them heated, wet, coated and remaining fine aggregates or RAP mix together during this vapors
of 3-4 % is released and turn into foam and process continue up to aggregate coating.
Foam asphalt is also used in two-stage WMA process. It has two binders soft and hard binder. Soft binder ranges
between 20-30 % to total binder content first they make completely coat coarse aggregates and on second hard
binder get a coat to pre-coated aggregates.
Ex: Aspha Min, Advera, Double barrell green, Ultrafoam GX

b) Chemical :(Hurley et al. 2006) Generally this technology doesn’t depend on viscosity or foaming to make
changes in mixing and compaction temperature it uses improves chemical additives as surface agents, improve
aggregate coating, anti-stripping agent’s. It mostly contains polymers and emulsification agents etc. Generally, these
chemicals will get mix with binder directly. At normal temperature, it improves interfacial adhesion.
Ex: Rediset&Cecabase improve wetting of aggregates by bitumen, Evotherm is an American technology which
absorbs less water than emulsions. Evotherm 3G is the latest technology which is a water-free warm technology.
Ex: Evotherm, rediset& Table 3

c) Organic :(Hurley and Prowell 2005)

When this additive’s heated to a temperature above its melting point and increase binder’s stiffness at normal
temperature reduces the viscosity of binder at a lower temperature and maintain the same for a long time that allows
proper compaction. Generally, most of this organic additive has a crystalline structure like sasobit that consist 45-
115 carbon atoms & paraffin waxes have 25-40 carbon atoms(AmbikaBehl 2013). Waxes have long molecular
hydrocarbon chain when they combine with bitumen there is a chance of changing binder carbon chain length that
alters few properties of bitumen in terms of stiffness & viscosity etc. While adding organic additives (Wax type) to
binder firstly heat the additive to its softening point and then add to binder this allows to reduce viscosity of the
binder in lower temperature.
Ex: Sasobit, Asphaltan-B,Cecabase& Table 3

d) Hybrid :( IRC: SP: 101- 2014) It’s a combination of two more technologies to achieve required results.
Ex: Low Energy Asphalt is a combination of Chemical and water based on improving aggregate coating at less
temperature.
e) Rheological Modifiers :( IRC: SP: 101- 2014) Here industries use such an additive to improve the rheological
properties of asphalt mix.
Ex: - Wax based additives modify the viscosity of binder.
f) Others :-( IRC: SP: 101- 2014) These are such products manufactured for other purposes but we incorporating
them to produce warm mix.
Ex:- Sulfur & Trinidad Lake Asphalt

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Table 3: Summary of Warm Mix Additives with Usage & Mixing Temperatures
Foaming Additive
WMA Technology Company Recommended Additive/ Usage Mixing Temperature (OC)
Aspha-min® Eurovia and MHI 0.3% by total mass of the mixture 130-170 based on Binder Stiffness

ADVERA® WMA PQ Corporation 0.25% by total mass of the mixture 130-170 based on Binder Stiffness

No additive. It is a two-component 110 - 120

binder system that introduces a soft and
WAM-Foam® KoloVeidekke Shell Bitumen
hard foamed binder at different stages
during plant production.

LEA® LEA-CO 0.2-0.5% by weight of the binder <100

LEA, also LEACO, Fairco, and 0.2 to 0.5 % by weight of Bitumen <100
EIFFAGETravauxPublics
EBE and EBT

ECOMAC Screg Unknown Quality & Quantity Placed at above 45

LT Asphalt Nynas 0.5–1.0% of a hygroscopic filler 90

LEAB® BAM 0.1% by weight of the binder 90

Organic Additives

WMA Technology Company Recommended Additive/ Usage Mixing Temperature (OC)

Sasobit® Sasol 0.8-3.0% by weight of asphalt 130-170 based on Binder Stiffness

Asphaltan-B® Romonta 2.5% by weight of asphalt 130-170 based on Binder Stiffness

Licomont BS 100® Clariant 3% by weight of asphalt mixture 130-170 based on Binder Stiffness

3E LT or Ecoflex Colas Unknown quantity 30-40 drop from HMA

Chemical Additives

WMA Technology Company Recommended Additive/ Usage Mixing Temperature (OC)

CECABASE RT® Arkema Group 0.2-0.4% by weight of asphalt 90-100

Meadwestvaco Asphalt Improve coating, workability, and 85-115

Evotherm®
Innovations adhesion at lower temperatures.

HyperTherm/QualiTherm Coco Asphalt Engineering 0.2-0.3 % by weight of the binder 120

Rediset WMX® Akzo Nobel 2% by weight of the mixture 120-130

Emerging US technology

WMA Technology Company Recommended Additive/ Usage Mixing Temperature (OC)

Evotherm™ Mead-Westvaco Unknown quantity 85-115

Double- Barrel Green Astec Not necessary; an antistripping agent may 116-135
be added similar to normal HMA

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Mix Design Method:- NCHRP 691 report “Mix Design Practices for Warm Mix Asphalt’ recommended mix design
process for WMA. These recommendations have already drafted in AASHTO R35 under “Special Mixture Design
Consideration and Models for Warm Mix Asphalt “. These are the following conclusions given by NCHRP :
a) HMA volumetric results will applicable to WMA if-and-only-if the binder absorption is less than or equal
to 1 % of HMA.
b) Coating, compatibility, moisture sensitivity, and rutting results are not similar to HMA & WMA.
c) Compatibility was found to be different based technology, Production temperature used particularly when
RAP is used.
d) WMA is more susceptible to moisture damage than HMA so using any anti-stripping additives can
decrease that due to less mixing temperature WMA is less resistance to rutting.
e) Even aggregates & binder content is similar for both WMA & HMA specimen prepared under lab
condition for stiffness test exhibiting different results after short-term aging.
Best Practice for Producing WMA (Prowell et al. 2014)
a) Reduce Stockpile moisture content: On average 1% reduction of the moisture content of aggregates utilize
10% fuel saving for that we have two ways 1) Cover with any temporary/Permanent structure 2) grading of
stockpiles
b) Tune burners to ensure complete combustion: Mostly burners contain modulating actuator motor with the
mechanical link with dampers and fuel valves. The disadvantage is at full firing range the maintenance of
air to fuel ratio. Before starting it go through trail mix for ensuring that ratio if the ratio is not proper ie,
incomplete combustion it can easily detect by brown coloration of coated aggregates.
c) Drying aggregates with maintaining baghouse temperatures: The one most tough challenge in the
production of WMA is stockpile temperature high to avoid condensation that results in corrosion of
baghouse & formation of mud.

Lab tests for Warm Mix Asphalt: (Bonaquist 2011) & (IRC:SP:101- 2014)NCHRP: 691 & WMA IRC-SP:101-
2014 have specified few performance tests for WMA although quality and performance tests are similar for both
WMA & HMA as per IRC:111 guidelines but mixing and compaction temperature of WMA is 30 OC lesser than
HMA.
They are three tests for WMA 1) Coating 2) Compatibility 3) Moisture Sensitivity.
a) Compacting: AASHTO T 195 : Min 95 % of coarse aggregate shall be coated.
b) Compatibility: AASHTO T245 : Ratio shall be such that 0.9 <R<1.1
c) Moisture Susceptibility: AASHTO T245 : Tensile Strength Ratio shall be greater than 80% as per IRC: 111

Indian Scenario :(Behl et al. 2013) & (Kumar 2016) India adopt this Warm Mix Asphalt since 2009 by Central
Road Research Institute -New Delhi its first trail begins with 0.50 KM stretch road using Thiopave additive at
Bavana Industrial area owned by DSIDC.
Basically, we have two WMA suppliers they are Shell and MWV (MeanWestvaco). Shell provide Thiopave and
MWV supply Evotherm. Shell Thiopave get accreditation by IRC because they are improving the mechanical
properties of AshokaBuildcon Ltd under gridlines of Ashoka Highway Research Center working on Thiopave since
2010. Since 2009 they are few projects constructed using WMA they are Bhavana Industrial Area (0.5 KM, 2009),
NH-3 (210 KM, Thiopave, 2010), NH-10 (Evotherm,2011), SH-5 Gujarat (1KM, VG-30,2011).

CONCLUSION:
Based upon the literature review its very clear that it has many advantages and for disadvantages, here have
solutions to reduce its negative effect. It’s an alternative way for HMA in metropolitan cities. WMA exhibiting same
positive results of HMA (Approx). Due to lower mixing temperature, it is reducing the aging of binder that that

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results in resistance towards thermal and fatigue cracks. WMA has good compatibility with waste & recycling
materials like RAP, various plastic polymers, replaceable materials with aggregates and with binders so it’s a user-
friendly technology. As environmental, economic, health benefits of WMA compared with HMA have much better
results that result in US, UK, Germany, Canada, and India etc like giant countries to adopt this technology in their
public transportation infrastructure.
There is no evidence of reduction of CO in case of WMA; there is a reduction of 36% of total organic matter
(Prowell et al. 2014).
In India Organic & chemical additive are better because for using they not required huge modifications of existing
HMA plants (Prowell et al. 2011).

ACKNOWLEDGEMENTS
With the grace of my parent's Srinivas Rao & Annapurna, my supporting faculty Mr.Charanjot Singh and Dr. Rajiv
Kumar, I have been constantly empowering myself, professionally and personally. Mr.RohitVasudeva & Ms.Banita
Sharma sustained and encouraged me in this field and encouraged me to write this paper. So, I would like to extend
my heartfelt gratitude to all of them.

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