NEW GREATER OPPORTUNITIES FOR BITUMEN INNOVATIVE BITUMEN FOR WARM MIX ASPHALT TECHNOLOGIES

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1 NEW GREATER OPPORTUNITIES FOR BITUMEN INNOVATIVE BITUMEN FOR WARM MIX ASPHALT TECHNOLOGIES

2 WMA paving grade bitumen is an innovative product on the Polish road construction market. The search for optimum solutions, numerous studies carried out and the involvement of employees has resulted in the development of a product with special characteristics and unique properties, which as a result, sets a new quality in the production and use of bitumen. The use of recycled material Extending the construction season Energy saving PROVEN TECHNOLOGY USED AROUND THE WORLD ONE OF THE MOST POPULAR TECHNOLOGICAL TRENDS IN THE WORLD IS REDUCING THE NEGATIVE IMPACT OF PRO- DUCTION ON THE ENVIRONMENT AND THE REDUCTION OF ENERGY CONSUMPTION. The production of mineral-asphalt mixtures using Warm Mix Asphalt (WMA) technology is perfectly in line with the trend that is compatible with the idea of sustainable development. WMA paving grade bitumen is obtained by a mixture of required workability without having to heat the asphalt mixture above 160 C. In addition, at every stage of the manufacturing process the temperature is C less, which in effect significantly reduces energy consumption and reduces the emissions of greenhouse gases, odours and dust. The global leader of WMA technology is the United States. It is used successfully in Europe, and permanently entered into to the canon of best practice in road construction. GOOD PRACTICE THE UNITED STATES In 2012 the production volume of WMA mixture constituted 24% of the total mixture production in this country. THE CZECH REPUBLIC The asphalt pavement of one of the largest tunnels in Prague was fully made from WMA technology. THE CZECH REPUBLIC Ongoing research into the development of WMA mixture technology using 50% recycled asphalt pavement. NORWAY The road administration established a premium for the use of WMA for asphalt pavement contractors. The decision was dictated by the necessity to limit the negative impact on the health of road construction employees. FRANCE In 2012, the production of asphalt mixture constituted 7.5% of total asphalt mixture production. The technology and application of warm asphalt mixture is recommended by the Union of French Road Associations (USIFR) with special recommendation to use reclaimed asphalt during production.

3 THE APPLICATION OF WMA PAVING GRADE BITUMEN The above-standard properties of WMA asphalt allow the production of mineral-asphalt mixtures, requiring improved workability in regards to the production method, climatic conditions or composition. Mineral-asphalt mixtures with WMA are particularly recommended for application during work in places with difficult access, such as tunnels and underground car parks. THE USE WMA PAVING GRADE BITUMEN IS RECOM- MENDED FOR THE PRODUCTION OF THE FOLLOWING MINERAL-ASPHALT MIXTURES: warm produced and incorporated mixtures, hot produced mixtures and incorporated in severe weather conditions, mixture with asphalt granulates from recycled asphalt pavement transported over a long distance. ENERGY CONSUMPTION PER MMA TONNE HEATING AND DRY HEATING HEATING 0 C 50 C 100 C 150 C COLD TECHNOLOGY SEMI-WARM TECHNOLOGY WARM TECHNOLOGY HOT TECHNOLOGY TREND = LOWER TEMPERATURE Source: EAPA - The use of Warm Mix Asphalt (v )

4 BENEFITS FROM USING WMA PAVING GRADE BITUMEN THE ENVIRONMENT PARAMETERS OF USABLE SURFACE The use of recycled materials from asphalt pavement. The reduction of energy consumption by up to 30%. The reduction greenhouse gases and dusts. Provides the required technical parameters of the pavement. Limits the technological ageing of bitumen and mineral-asphalt mixtures. Increases the asphalt s resistance to cracks and thermal fatigue. Increases the durability of the pavement. Increases adhesion to the aggregates. AN EXPERT EXPLAINS PAWEŁ CZAJKOWSKI HEAD OF DEPARTMENT OF TECHNOLOGY AND ENVIRONMENTAL PROTECTION

5 SAFETY SAVINGS Stability of production parameters. Lower technology temperature. Improves the working conditions of persons laying asphalt pavements. More workability and better density of the mineral-asphalt mixture. Extends the construction work season - the possibility of building in layers during adverse weather conditions, even at temperatures below 0 C. Transport of the mixture over longer distances - the transport time of asphalt mixture can be three times longer. The repaired road can be commissioned faster. IN CASE OF PAVINGS OF TRADITIONAL MIXTURES THERE IS AN INHERENT RISK FOR RAPID COOLING OF THE LAYER BEING PLACED, WHICH HINDERS PROPER COMPACTION. THE FINAL COMPACTION TEMPERATURE OF THE WMA MIXTURE MAY BE LOWER, THEREFORE THE PERIOD FOR COMPACTION OF A NEW LAYER IS PROLONGED. LOWERING THE APPLICATION TEMPERATURE OF ASPHALT MIXTURE REDUCES THE AMOUNT OF HARMFUL FUMES UP TO 75%. THE REDUCTION OF PRODUCTION TEMPERATURE BY 40 C CAUSES ENERGY SAVINGS OF AROUND 15%. THE PERIOD OF TIME REQUIRED FOR COOLING A LAYER PAVED WITH WMA MIXTURE TO THE TEMPERATURE ALLOWING VEHICLE TRAFFIC ON THE NEW PAVEMENT IS MUCH SHORTER COMPARED TO A LAYER PAVED IN ON HOT TECHNOLOGY. THE APPLICATION WMA GIVES A POTENTIAL INCREASE IN PRODUCTIVITY OF ABOUT 10-15% (LOWER TEMPERA- TURE = AGGREGATE POTENTIAL INCREASES FLOW). THE STANDARDS OF SERIES EN TO EN DO NOT CONSTITUTE A BARRIER FOR THE APPLICATION OF THE TECHNOLOGY OR FOR WMA ASPHALT.

6 PRODUCT HANDLING THE PRODUCTION OF BITUMINOUS MINERAL MIXTURES WITH A REDUCED TEMPERATURE MAY BE CARRIED OUT IN A STANDARD BITUMEN PRODUCTION PLANT. The condition for stable production is the efficient and proper insulation of the waste gas discharge system. Due to the reduced temperature of the aggregates in the drum dryers, the proper temperature of waste gases above the dew point needs to be maintained. The required temperature of aggregates at the bitumen production plant can be obtained by adjusting the rotational speed of the dryers together with correct selection of the burner capacity and the proper specified flow. RECOMMENDED REDUCTION OF TEMPERATURE DURING THE PRODUCTION OF ASPHALT MIX USING WARM MIX TECHNOLOGY, IN A DELIVERY TIME OF ASPHALT MIX OF CA 30 MIN. AT AMBIENT TEMPERATURE REDUCTION OF THE ASPHALT MIX TEMPERATURE above 20 C 10 to 20 C below 10 C* 20 to 40 C 15 to 25 C to 15 C * Attention! If the ambient temperature is below 10 C and there are strong winds, the temperature of asphalt mix should not be reduced.

7 RECOMMENDED TECHNOLOGY TEMPERATURES ROAD BITUMEN 20/30 WMA 35/50 WMA 50/70 WMA PREPARATION OF TEST SAMPLES The procedure of samples handling (heating time and temperature) is defined by EN standard. Samples heated in containers must then be homogenized by stirring. Avoid repeated heating of samples. Temperature of compaction of the asphalt mix samples (warm mix) C* C* C* Temperature of compaction of the asphalt mix samples (hot mix) C C C PRODUCTION OF ASPHALT MIX USING WARM MIX ASPHALT TECHNOLOGY RECOMMENDED TEMPERATURES AT ASPHALT MIXING PLANTS Pumping temperature of the binder Temperature during the production of asphalt mix C C C C** C** C** RECOMMENDED TEMPERATURES OF WARM MIX ASPHALT PAVING Recommended temperature at the start of compaction min. 140 C** min. 130 C** min. 120 C** INDUSTRIAL PRODUCTION OF HOT MIX ASPHALT MIX ASPHALT PLACED IN DIFFICULT CLIMATIC CONDITIONS OR TRANSPORTED OVER LONG DISTANCES APPLICATION OF RAP MATERIAL RECOMMENDED TEMPERATURE AT THE ASPHALT PLANT Pumping temperature of the binder Temperature during the production of asphalt mix C C C C C C RECOMMENDED TEMPERATURE OF PLACING ASPHALT MIX ON HOT Recommended temperature at the start of compaction C*** C*** C*** * depending on the expected temperature of compaction on site ** size of the temperature reduction should be adjusted according to weather conditions (see below - recommendations for process temperature reduction while applying on warm technology) *** depending on the type of mix, layer thickness and the climatic conditions

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