Matthew Corrigan, P.E.

Asphalt Pavement Engineer

Warm Mix Asphalt Technologies

National Initiatives
Federal Highway Administration Office of Pavement Technology Washington DC, USA

Moving Ahead for Progress in the 21st Century Act www.fhwa.dot.gov/map21/

Provides an array of provisions designed to increase innovation and improve efficiency, effectiveness, and accountability in the planning, design, engineering, construction and financing of transportation projects. Building on FHWAs Every Day Counts initiative, MAP-21 changes will speed up the project delivery process, saving time and money for individuals and businesses, and yielding broad benefits nationwide.

Research, Technology Deployment, Training & Education

Highway Research & Development - $115.0 million* Technology & Innovation Deployment - $62.5 million* Training & Education - $24.0 million* ITS Program - $100.0 million* University Transportation Centers - $72.5 million* Bureau of Transportation Statistics - $26.0 million* SHRP 2 implementation (funded as set aside of State Planning and Research funds) - $TBD
*Annual $ Funding Levels

Accelerates project delivery and promotes innovation. Technology Innovation and Deployment Program $62.5 M per fiscal year (2013-14)
SHRP2 Implementation Every Day Counts initiatives Demonstrations Pilots and Testing Accelerated Innovation Deployment At least $12 million per year of these funds must be used to accelerate the deployment and implementation of pavement technology.

www.fhwa.dot.gov/map21/tid.cfm

The Every Day Counts Initiative

Accelerating Technology Deployment
Every Day Counts is NOT about inventing the next "big thing". It is about taking effective, proven and marketready technologies and getting them into widespread use. By advancing 21st century solutions, we can improve safety, reduce congestion and keep America moving and competitive.

Every Day Counts

Every Day Counts

The Every Day Counts Initiative

Accelerating Technology Deployment

Warm Mix Asphalt (WMA)

www.fhwa.dot.gov/everydaycounts

Performance Metrics
1. By December 2011, 40 State DOTs and all Federal Lands Highway Divisions will have a specification &/or contractual language that allows WMA on Federal-aid or Federal Lands projects.
40 States + all FLHD (Complete)

2. By December 2012, at least 30 State DOTs will have achieved set targets for WMA usage.
18 Total with set usage goals (as of Fall 2012)

In 2010, use of WMA estimated:

We saved over 30 million gallons of fuel during production We reduced CO2e by 800,000 tons
Equivalent to taking 150,000 vehicles off the road!

If used 100% WMA 10 x

General Technology Categories

Material Processing
Ex. LEA (Hot Coated Coarse Agg + Moist Fine Agg + Additives)

Organic Additives
Waxes, Hydrocarbon Based Products

Chemical Additives
Surfactants

Foaming Processing
Water Injection, Zeolites

Hybrid Systems
example: H20 + Surfactant

Technology Overview**
Many US technologies web-linked at:
http://warmmixasphalt.com/wmatechnologies.aspx

This listing does NOT constitute an endorsement or approval.

**Federal Highway Administration does not endorse or promote any particular proprietary product or technology.

Stakeholder Engagement: WMA Technical Working Group

FHWA NIOSH NAPA

Established in 2005 Adjourned in 2012 Co-Chairs: g Group (TWG) Matthew Corrigan

Labor

Industry

Ron White
AASHTO State DOT

NCAT

State APA

FHWA Commitment to Stakeholder Engagement in the Pavement & Materials Program

Asphalt Pavements Concrete Pavements Sustainability ETG

Mixture ETG

Binder ETG

Models ETG

Executive ETG

Engineer ETG

WMA Task Group

MSCR Task Group Linear Amplitude Sweep TG GTR Task Group

Pavement Preservation ETG

RPUG Surface Characteristics IRI ETG

Roadmap Track Team

RAP/RAS Task Group

Roadmap Track Team

Performance Testers TG

AASHTO Subcommittees

Construction

Maintenance
AASHTO JTP DGIT

Materials

Roadmap Track Team

Construction Task Group

Others as Needed

14

NCHRP Projects funded as a result of WMA TWG efforts:

9-43 --Mix Design Practices for WMA $522,501 Properties, Emissions, and 9-47 --Engineering Field Performance of WMA Technologies $79,000 and Performance of WMA 9-47A --Properties $1,121,000 Technologies of WMA Technologies: 9-49 --Performance $450,000 Stage I--Moisture Susceptibility --Performance of WMA Technologies: 9-49A Stage II--Long-Term Field Performance $900,000 Laboratory Conditioning of 9-52 --Short-Term $800,000 Asphalt Mixtures of Foamed Asphalt for Warm 9-53 --Properties $700,000 Mix Asphalt Applications Aging of Asphalt Mixtures for 9-54 --Long-Term $800,000 Performance Testing and Prediction Asphalt Shingles in Asphalt 9-55 --Recycled $600,000 Mixtures with WMA Technologies of a WMA 20-07 (311) --Development $50,000 Tech. Evaluation Program Total $6,022,501

completed completed Jan 2013 Jun 2013 Jul 2016 Dec 2014 Sept 2014 begin 2013 begin 2013 completed

National Research Initiatives

NCHRP 9-43 Mix Design Practices for Warm Mix Asphalt $500,000

Products:

NCHRP Project 09-43

Appendix to AASHTO R35 with commentary Special Mixture Design Considerations and Methods for Warm Mix Asphalt (WMA) WMA Mix Design Workshop/Training Module
Being converted to web based training thru NHI

Chapter on WMA Mix Design for the NCHRP Project 09-33 Mix Design Manual Standard Practice For Measuring Properties of Warm Mix Asphalt (WMA) for Performance Analysis Using the AASHTO MEPDG (AASHTO DARWin-ME Software)

Resource
www.ct.gov/dot/AASHTO-R35

Course Number: FHWA-NHI-131137

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Appendix to AASHTO R35 with commentary Special Mixture Design Considerations and Methods for Warm Mix Asphalt (WMA)

Approved by AASHTO Subcommittee on Materials and published: Standard Specifications for Transportation Materials and Methods of Sampling and Testing (32nd Edition, 2012)

Mix Design Considerations

WMA 240F

HMA 330F

Commercially Available Laboratory Foaming Devices

Wirtgen, WLB 10 S

PTi THE FOAMER

InstroTek, Inc. AccuFoamer

 NCHRP 20-07/ Task 311, Development of a Warm Mix Asphalt Technology Evaluation Program (complete)
Myers McCarthy Consulting Engineers, LLC http://apps.trb.org/cmsfeed/TRBNetProjectDisplay. asp?ProjectID=3075

AASHTO NTPEP Panel has been established to review findings: www.ntpep.org POC: Tom Baker, Washington State DOT

Warm-Mix Asphalt: Best Practices, 3nd Edition

Stockpile Moisture Management Burner Adjustments and Efficiency Aggregate Drying and Baghouse Temperatures Drum Slope and Flighting Combustion Air RAP usage Placement Changes
Quality Improvement Series 125

State DOT WMA Usage - 2006

AK WA MT OR MN ID SD WI NY ND VT ME

WY
NV UT CA AZ CO KS MO NE IA IL

MI
PA OH CT NJ DE MD DC

NH MA RI

IN
KY

WV VA NC SC

Guam

NM

OK

TN AR
MS AL GA

HI

TX LA FL

VI

PR

Mobile Asphalt Testing Laboratory Program WMA Project Locations

State DOT WMA Usage - 2012

AK WA MT OR MN ID SD WI NY ND VT ME

WY
NV UT CA AZ CO KS MO NE IA IL

MI
PA OH

NH MA RI
CT NJ DE MD DC

495

IN
KY

WV VA NC SC

Guam

NM

OK

TN AR
MS AL GA

HI

TX LA FL

VI

PR

Mobile Asphalt Testing Laboratory Program WMA Project Locations

Interstate Highway WMA Usage

AK WA 90 MT OR ID WY NV NE IA VT ME NH NH MA MA RI RI CT 295 NJ DE MD DC

15

ND
MnROAD MN

SD

94

WI

81 86 87NY
MI IL

90 70 65 55
OK AR

5
CA

UT

IN

CO 70

465
KY TN 81

OH

KS

MO

75
GA

495 WV 66 VA
NC SC

PA

78

495

Guam

AZ

NM

40

10
HI

30
TX
LA

MS

AL

35 820 37

VI

10

295
FL

I-WMA

75

95
PR

WMA Usage in HMA/WMA

Percentage of Total Mix Production in USA
Total HMA/WMA mix: 358.4 (million tons)
25% 20% 15% 10% 5% 0%

359.8

366.0

19%
5% 2009
16.8 million tons

11% 2010
41.1 million tons

2006
WMA trials begin

2011
68.7 million tons

2012
data being collected

Source: draft NAPA annual survey presented during Feb. 2013 NAPA Annual Meeting

WMA Usage by Technology

Percent of market for WMA production in USA
100

80
60 40 20 0 2009 2010 2011 Plant Foaming Chemical Additive Additive Foaming Organic Additive

Source: draft NAPA annual survey presented during Feb. 2013 NAPA Annual Meeting

RAS Usage in HMA/WMA

Total RAS tons used for mix production in USA
Total asphalt mix: 358.4 (million tons)
1,600 1,400 1,200 1,000 800 600 400 200 0

359.8

366.0

2009
701 thousand tons

2010
1,099 thousand tons

2011
1,192 thousand tons

2012
data being collected

Source: draft NAPA annual survey presented during Feb. 2013 NAPA Annual Meeting

RAP Usage in HMA/WMA

Percentage of Total Mix Production in USA
Total HMA/WMA mix: 358.4 (million tons)
25% 20% 15% 10% 5% 0%

359.8

366.0

19%

20%

22%

2009
67.2 million tons

2010
73.5 million tons

2011
79.1 million tons

2012
data being collected

Source: draft NAPA annual survey presented during Feb. 2013 NAPA Annual Meeting

National Research Initiatives

NCHRP 9-54: Long-Term Aging of Asphalt Mixtures for Performance Testing and Prediction
http://apps.trb.org/cmsfeed/TRBNetProjectDisplay.asp ?ProjectID=3400 RFP close date: 10/18/2012

NCHRP 9-55: Recycled Asphalt Shingles in Asphalt Mixtures with WMA Technologies
http://apps.trb.org/cmsfeed/TRBNetProjectDisplay.asp ?ProjectID=3401 RFP close date: 11/14/2012

National Research Initiatives

Research Needs Statement for proposed 2014 NCHRP 09-xx project:

Recycling Agents Used For Asphalt Mixtures Containing High Recycled Asphalt Binder Ratios

Items for continued involvement:

Standardize reheating procedure for WMA mixtures for volumetric and performance tests? Use of RAS, RAP, GTR, alternate binders, and combinations used with WMA technologies?
Low temperature applications w/ high percentages?

Rejuvenating agents marketed as WMA? Use of WMA to remove SMA fiber requirements? Incentives and motivation for improved density?
Increased density requirements on WMA?

Items for continued involvement:

Conditioning for WMA performance testing? Need for WMA specific mix design? (AASHTO R-35)
Incorporate impact of aggregate absorption?
Short term and long term?

Need for laboratory foaming equipment?

Evaluation of asphalt foam characteristics?

Are unique foam properties provided or simply volume expansion & improved coating?

Local agency WMA acceptance and training?

Every Day Counts

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Every Day Counts

37

Every Day Counts

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Thank You!
Matthew Corrigan, P.E.
Asphalt Pavement Engineer FHWA - Washington D.C.