## Matthew Corrigan, P.E. Asphalt Pavement Engineer Mobile Asphalt Testing Trailer Technical Manager U.S. DOT – Federal Highway Administration November 19, 2014 Pavements / Materials Conference 

# Warm Mix Asphalt in the United States: From Evolution to Revolution

# Where have we been? 2004-05 Number of named WMA technologies in the U.S.? 

# 2013 - 14 Number of named WMA technologies in the U.S.?

# Where have we been? 2004-05 No. of WMA Technical Working Groups? 

# 2013 - 14 No. of WMA Technical Working Groups?

# Stakeholder Engagement: WMA Technical Working Group

FHWA NAPA Industry

State DOT State APA NCAT AASHTO Labor NIOSH 

### Co - Chairs: Matthew Corrigan Ron White 

## Established in 2005 Adjourned in 2012

# Where have we been? 2004-05 No. of WMA International Conferences? 

# 2013 - 14 No. of WMA International Conferences?

# International WMA Conferences 1 st 

## Conference on November 11 - 13, 2008 in Nashville, TN Processes, Mix Production & Placement, Energy

consumption, Mix Design, Material Properties 

## 2 nd 

## Conference October 11 - 13, 2011 in St. Louis, MO Lab & Field Properties, Design & Performance, Health & Environment, RAP w/ WMA, Binder & Mix Properties, Moisture Susceptibility, Construction, etc. 6

# Where have we been? 2004-05 Number of WMA NCHRP Research Projects? 

# 2013 - 14 Number of WMA NCHRP Research Projects?

## 9 -43 $522,501 completed 9 -47 $79,000 completed 9 -47A $1,121,000 completed 9 -49 $450,000 completed 9 -49A $900,000 Jul 2016 9 - 52 $800,000 Nov 2014 9 - 53 $700,000 Dec 2014 9 - 54 $800,000 May 2016 9 - 55 $600,000 Sept 2016 9 - 58 $1,500,000 July 2017 est . 

## 20 - 07 (311) $50,000 completed NCHRP Projects funded as a result of WMA TWG efforts:

- Mix Design Practices for WMA

- Engineering Properties, Emissions, and Field Performance of WMA Technologies

- Properties and Performance of WMA Technologies

- Performance of WMA Technologies: Stage I -- Moisture Susceptibility

- Performance of WMA Technologies: Stage II -- Long -Term Field Performance

- Short -Term Laboratory Conditioning of Asphalt Mixtures

- Properties of Foamed Asphalt for Warm Mix Asphalt Applications

- Long -Term Aging of Asphalt Mixtures for Performance Testing and Prediction

- Recycled Asphalt Shingles in Asphalt Mixtures with WMA Technologies

- Effects of Recycling Agents on Asphalt Mixtures w/High RAS & RAP Binder Ratios

- Development of a WMA Tech. Evaluation Program

## 9 -43 $522,501 completed 9 -47 $79,000 completed 9 -47A $1,121,000 completed 9 -49 $450,000 completed 9 -49A $900,000 Jul 2016 9 - 52 $800,000 Nov 2014 9 - 53 $700,000 Dec 2014 9 - 54 $800,000 May 2016 9 - 55 $600,000 Sept 2016 9 - 58 $1,500,000 July 2017 est. 

## 20 - 07 (311) $50,000 completed NCHRP Projects funded as a result of WMA TWG efforts:

- Mix Design Practices for WMA

- Engineering Properties, Emissions, and Field Performance of WMA Technologies

- Properties and Performance of WMA Technologies

- Performance of WMA Technologies: Stage I -- Moisture Susceptibility

- Performance of WMA Technologies: Stage II -- Long -Term Field Performance

- Short -Term Laboratory Conditioning of Asphalt Mixtures

- Properties of Foamed Asphalt for Warm Mix Asphalt Applications

- Long -Term Aging of Asphalt Mixtures for Performance Testing and Prediction

- Recycled Asphalt Shingles in Asphalt Mixtures with WMA Technologies

- Effects of Recycling Agents on Asphalt Mixtures w/High RAS & RAP Binder Ratios

- Development of a WMA Tech. Evaluation Program

## • Products:

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

– WMA Mix Design Workshop/Training Module

– 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 - METM Software) 

# NCHRP Project 09 -43

http://apps.trb.org/cmsfeed/TRBNetProjectDisplay.asp?ProjectID=977

## Course Number: **FHWA -**  **NHI -**  **131137**

11

## • Original Project 9 -43

– Binder Absorption limited to 0.5 - 1.0 % 

## • ETG Work Item: Expansion to Higher Absorption Mixtures ≥ 2.0%

– Includes High Absorption Lab Foamed Mix 

## • Completed by Dr. Ray Bonaquist, AAT • Confirmed impact of WMA on mixture volumetrics and performance during design and AASHTO R 35 WMA Appendix 

# Expansion of NCHRP 9 -43 Mix Design Study to Higher Absorption Mixtures

## • NCHRP 20 - 07/ Task 311, Development of a Warm Mix Asphalt Technology Evaluation Program

– Myers McCarthy Consulting Engineers, LLC

– http://apps.trb.org/cmsfeed/TRBNetProjec tDisplay.asp?ProjectID=3075 

## • AASHTO NTPEP Program for evaluating WMA technologies is in development www.ntpep.org

# Where have we been? 2004-05 Number of WMA Best Practices Publications? 

# 2013 - 14 Number of WMA Best Practices Publications ?

# Quality Improvement Series 125 3 rd 

# Edition

– Stockpile Moisture Management

– Burner Adjustments and Efficiency

– Aggregate Drying and Baghouse Temperatures

– Drum Slope and Flighting

– Combustion Air

– RAP usage

– Placement Changes

# Where have we been? 2004-05 Number of AASHTO Standards on WMA? 

# 2013 - 14 Number of AASHTO Standards on WMA?

## Approved by AASHTO Subcommittee on Materials and published: Standard Specifications for Transportation Materials and Methods of Sampling and Testing (32nd Edition, 2012) Appendix to AASHTO R35 with commentary “Special Mixture Design Considerations and Methods for WMA”

## Published as Appendix within AASHTO TP 79 - 13 

# AMPT F low Number standardization

# Where have we been? 2004-05 Number of WMA tons produced annually? 

# 2013 Number of WMA tons produced annually?

# Information Series 138

www.asphaltpavement.org/recycling 

# 4th Annual Asphalt

Pavement Industry Survey on Recycled Materials and Warm - Mix Asphalt Usage: 2009– 2013 (released Oct 2014) Product of FHWA & NAPA Cooperative Agreement Contract

# WMA Usage in HMA/WMA Percentage of Total Mix Production in USA

0% 5% 10% 15% 20% 25% 30% 35%



### 2009 2010 2011 2012 2013 5% 11% 30%

16.8 million

tons 41.1 million

tons 

### 19%
68.7 million

tons 86.7 million

tons 

### 2006 WMA trials begin Total asphalt mix : (million tons)


### 24% 358.4 359.8 366.0 360.3 350.7

106.4 million

tons

# StateDOT WMA Usage in HMA/WMA

0% 5% 10% 15% 20% 25% 30% 35% 40%



### 2009 2010 2011 2012 2013 5% 12% 20% 

# Percentage of State Mix Production in USA

26% Total asphalt mix : (million tons) 169.2 172.5 175.3 179.1 160.1

8.6 million

tons 20.0 million

tons 34.6 million

tons 46.4 million

tons 

### 2006 WMA trials begin 55.7 million

tons 

### 35%

# WMA Usage by Technology Percent of market for WMA production in USA

Organic Additive Additive Foaming Chemical Additive Plant Foaming 0 20 40 60 80 100

2009 2010 2011 2012 2013

# Where have we been? 2004-05 Number of WMA projects evaluated by FHWA? 

# 2013 - 14 Number of WMA projects evaluated by FHWA?

## • Mobile Asphalt Pavement Materials Lab

– Site Visit

– Field Data/Testing

– Use/Demo Emerging Test Devices

– POC: Matthew Corrigan, P.E. 

# FHWA Field Support Mobile Asphalt Testing Trailer (MATT)

# WMA Project Locations

VI VT
RI MA NH CT NJ DE MD DC 495 CA AZ CO NM TX OK ARLA MO KY
AL GA
FL VA OH MI AK MT

NV
Guam ME WA OR

UT KS ID WY ND SD MN NE WI IA IL IN

MS TN SC NC WV PA NY

PR HI Mobile Asphalt Testing Trailer ProgramCT NJ DE MD DC 78 495 CA AZ CO NM TX OK AR LA MO KY
AL GA
FL VA OH MI VT AK

VI MT

NV ME WA OR

UT KS ID WY ND SD MN NE WI IA IL IN

MS TN SC NC WV PA NY MA NH

PR RI 90
70
35 10 37 30 40 820 75 5

75 55 94 MnROAD 495 70

65 465 15 90 87 81 86

95 10 295 VT

VI MA NH RI 295 

# Interstate Highway WMA Usage

HI Guam

This image cannot currently be displayed.

**I -**  **WMA** ... circa 2011Every Day Counts 28Every Day Counts 29Every Day Counts 30“The collective efforts from highway agencies and industry partners to advance warm mix asphalt technologies as a standard practice has been tremendous.”

- U.S. DOT Federal Highway Administration “[We] support the development and implementation of warm mix asphalt ... this will inevitably become the standard practice for asphalt mixture production.”

- Global Asphalt Pavement Alliance “WMA technology provides an important tool to the pavement engineer ... designers and contractors alike now have a great opportunity to learn more about this promising practice which is revolutionizing the paving industry in North America.”

- Pete Grass, President, Asphalt Institute “WMA is the future of flexible pavements in the U.S. ... lowering our production and paving temperatures promises improved energy consumption, operations, and quality.”

- Mike Acott, President, NAPA

# Th 232.03806 90 2 - 8 - 18 - 32 - 18 - 10 - 2 

# Y 88.90585 39 2 - 8 - 18 - 9 - 2 

# ou ank Discussion / Comments / Questions

FHWA’s Mobile Asphalt Testing Trailer Office of Asset Management, Pavement, and Construction