USE OF PAVEMENT WASTES (RECLAIMED

ASPHALT PAVEMENT) IN BASE AND SUB-BASE

LAYERS OF ROAD CONSTRUCTION
Penumala Roja Rani1, Bharthavarapu Srikanth2.
1* M.Tech Student, MVR College of Engineering & Technology, Kanchikacherla, India.
2* Assistant Professor, MVR College of Engineering & Technology, Kanchikacherla, India.
ABSTRACT
Recycled asphalt pavement (RAP) has increasingly been used as a base material for highway
construction as a sustainable solution. Due to the existence of asphalt, 100 % RAP typically has low strength
and high potential of creep and permanent deformations. RAP can be blended with virgin aggregate, stabilized
by cement and fly ash, or confined by geocell to increase its strength and reduce its creep and permanent
deformations. A good road network is a key for rapid growth of economy of a country. It provides
connectivity to remote areas for various transport activities. There is about 4.2 millions kilometre road network
in India, which ranks second in the world only after United States. Most of the roads are bituminous surfaced
pavements. These roads are periodically resurfaced as maintenance action. It is due to this periodic
maintenance the roads have attained a higher raised level as compared to adjoining properties in urban
locality. These roads can be lowered down up to required and feasible depth by milling process and can be
resurfaced with suitable layer of bituminous mixes replacing all or part of the bituminous pavement. Reclaimed
asphalt pavement (RAP) materials are resulted from milling process. In this study samples of Reclaimed
asphalt pavement (RAP) materials were collected and analysed for suitability of their usage in flexible
pavements. Their characteristics including gradation, California Bearing Ratio(C.B.R).Aggregate Impact value,
Aggregate Crushing value, Specific gravity, Flakiness & Elongation Index, Loss Angles Abrasion value,
Water absorption and soundness were determined and compared to the MORTH specifications. Form the study
it was found that the RAP materials can be effectively used in the soil sub-grade, sub-base and base of the
flexible pavements resulting in reduction of the construction cost.

I.INTRODUCTION
In current pavement engineering practice, the shortage of natural aggregate supplies along with the increase
in processing cost has encouraged the use of various reclaimed materials from old structures as a source of
construction material. This technology reduces both the cost of highway construction and protects
the environment by reducing construction waste. Reclaimed Asphalt Concrete Pavement (RAP) had been used
as aggregate for pavement construction for some time. In EI Cajon-California, considerable saving was
made using RAP as a base course for the construction of a thoroughfare(Munzenmaier, 1994).
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RAP is also widely used in many highway construction projects in Ontario.In most engineering
applications, when used as unbound granular material(UGM), RAP is usually milled or crushed down to
37.5 mm or less, with a maximum allowable top size of approximately 50 mm. RAP has
performed satisfactorily in many cases when it is blended with conventional aggregates as granular
base/sub base. Some of the benefits of RAP aggregates that have been properly incorporated into
granular base/sub base applications include: dequate bearing capacity, acceptable resilient modulus, good
drainage characteristics and durability.
Research objectives
The objective of this research is to carry out performance-related tests on selected RAP and natural
aggregates to explore the feasibility of producing high-performance granular base/sub base layers that
contain up to 100% RAP. The main objective of the study is to find out suitability of Reclaimed asphalt
pavement (RAP) materials to be used in construction of flexible pavements. To perform experimental
investigations to assess the values of related parameters
and their technical viability.
 To use untreated RAP materials as a stabilizing material to treat weak soil sub-grade to
enhance CBR value and thereby reduction in the crust thickness and construction cost as well.
 To use RAP materials after blending in sub-base and base courses of flexible pavements.

II.EXPERIMENTAL PROGRAM
Physical Properties
The properties of RAP are largely dependent on the properties of the constituent materials and the type
of asphalt concrete mix (wearing surface, binder course, etc.). There can be substantial differences between
asphalt concrete mixes in aggregate quality, size, and consistency. Since the aggregates in surface course
(wearing course) asphalt concrete must have high resistance to wear/abrasion (polishing) to contribute to
acceptable friction resistance properties, these aggregates may be of higher quality than the aggregates in binder
course applications, where polishing resistance is not of concern.
Both milling and crushing can cause some aggregate degradation. The gradation of milled RAP is
generally finer and more dense than that of the virgin aggregates. Crushing does not cause as much degradation
as milling; consequently, the gradation of crushed RAP is generally not as fine as milled RAP, but finer than
virgin aggregates crushed with the same type of equipment.
The particle size distribution of milled or crushed RAP may vary to some extent, depending on the type
of equipment used to produce the RAP, the type of aggregate in the pavement, and whether any underlying base
or sub base aggregate has been mixed in with the reclaimed asphalt pavement material during the pavement
removal.

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Table1. Typical range of particle size distribution for reclaimed asphalt pavement (RAP)
IS Sieve(mm) Percentage passing by weight Requirement for GSB grading II (table 400-2) of
MORTH revision 4
53 100 100
26.5 92 50-80
19 80 -
10 66 -
4.75 38 15-35
2.36 22 -
0.6 11 -
0.075 2 <10
Table 2 . Physical and mechanical properties of reclaimed asphalt pavement (RAP).
Type of Property RAP Property Typical Range of Values
Unit Weight 1940 - 2300 kg/m3 (120-140 lb/ft3)
Moisture Content Normal: up to 5%
Maximum: 7-8%
Physical Properties Asphalt Penetration Normal: 10-80 at 25°C (77°F)
Asphalt Content Normal: 4.5-6% Maximum Range: 3-7%

Absolute Viscosity or Recovered Asphalt Normal: 4,000 - 25,000 poises at 60°C

Cement (140°F)
Mechanical Compacted Unit Weight 1600 - 2000 kg/m3 (100-125 lb/ft3)
Properties California Bearing Ratio (CBR) 100% RAP: 20-25% 40% RAP and 60%
Natural Aggregate: 150% or higher

Table 3 . Tests for Aggregates with IS codes

Property of Aggregate Type of Test Test Method
Crushing strength Crushing test IS : 2386 (part 4)
Hardness Los Angeles abrasion test IS : 2386 (Part 5)
Toughness Aggregate impact test IS : 2386 (Part 4)
Shape factors Shape test IS : 2386 (Part 1)

Specific gravity and porosity Specific gravity test and water IS : 2386 (Part 3)
absorption test

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III.TEST RESULTS AND ANALYSIS
MORTH Gradation
This chapter summarizes the laboratory test results of all tests and materials (both natural
aggregates and blends with different RAP contents). 3.1. Collection of Samples:
The particle size distribution (PSD) of collected sample of RAP material and corresponding
requirement of code to use it as granular sub-base (GSB) is shown in table no 1.
From table 1 it is clear that certain sieve size material was missing in RAP to use as GSB material. To match the
required grading the following modifications were done.
 60% of 40mm down and 10% of stone dust as filler to satisfy the requirement as per MORTH 4 th
revision.
 The RAP material was used up to 30% to get the desired grading of GSB (coarse grade) as per
MORTH 2013.

Table: Details of composite GSB with use of RAP

IS Material Percent Requirement for GSB grading II
Sieve 40 RAP Stone 60% 30% 10% Total (table 400-2) of MORTH revision 4
size mm dust 40 mm RAP Stone
(mm) down down dust
53 100 100 100 60 30 10 100 100
26.5 60 90 100 36 27.6 10 73.6 50-80
4.75 11 36 97 6.6 11.4 9.7 27.7 15-35
0.075 0 2 8 0 0.6 0.8 1.4 <10

The table below shows the composition of mixed materials to get the desired grading of GSB material.
Table: Details of composite WMM with use of RAP
IS Material Percent Requirement for
Sieve 45 RAP 11.2 Stone 32% 35% 13% 20% Total WMM grading
size mm mm dust 45mm RAP 11.2 mm Stone (table 400-II) of
(mm) down down down down dust MORTH
revision 4
53 100 100 100 100 32 35 13 20 100 100
45 100 100 100 100 32 35 13 20 100 95-100
20 28 92 100 100 8.96 32.2 13 20 74.6 60-80
12.5 0 70 98 100 0 24.5 12.74 20 57.2 40-60
4.75 0 38 8 97 0 13.3 1.04 19.4 33.7 25-40

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2.36 0 22 0 75 0 7.7 0 15 22.7 15-30
0.6 0 11 0 40 0 3.85 0 18 11.8 8-22
0.75 0 2 0 8 0 0.7 0 1.6 2.3 <10
Sample Composition:
Both natural and RAP samples were brought to required size and suitable grading required for sub-
base, base and surface course as per MORTH specifications. Samples of different compositions were
prepared by adding different percentage of RAP materials (0% RAP, 10%RAP,20%RAP, 30%RAP,
40%RAP and 100% RAP) as shown below
Table: Samples of different compositions
Sample no Details of Composition
R1 RAP 0% + 100% Natural Aggregate
R2 RAP 10% + 90% Natural Aggregate
R3 RAP 20% + 80% Natural Aggregate
R4 RAP 30% + 70% Natural Aggregate
R5 RAP 40% + 60% Natural Aggregate
R6 RAP 100% + 0% Natural Aggregate

Table: Results on Samples of 100% RAP and 100% Natural Aggregates

Characteristics 100% RAP 100% Natural MORTH Remarks
Aggregates Aggregates Limits (Max.)
Aggregate Crushing Value 21.5% 19.7% 30% Satisfactory
Aggregate Impact Value 20.6% 18.3% 30% Satisfactory
Flakiness & Elongation Index 22.7% 17.6% 35% Satisfactory
Loss Angeles Abrasion Test Value 18.3% 16.7% 30% Satisfactory
Specific Gravity 2.7 2.8 2.6-3.0 Satisfactory
Water Absorption 1.8% 1.4% 2% Satisfactory
Soundness Test (with Na2SO4) 7.5 5.3 12 Satisfactory
From the test results as shown in table no above, it was observed that the RAP material can be easily
used in granular sub base as it satisfies the norms as prescribed by MORTH. All the parameters are with in the
prescribed specifications by MORTH

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 Test Results
Table: Results on Samples of different compositions of RAP and Natural Aggregates combinations
Sample Aggregate Aggregate Flakiness & Loss Specific Water Soundn
Composition Crushing Impact Elongation Angeles Gravity Absorption ess
Value Value Index Abrasion Test
(Combined) Test
Value
RAP 10% +
90% Natural 22.8% 21.7% 20.8% 21.1% 2.65 1.32% 7.2%
Aggregate
RAP 20%+
80% Natural 22.7% 20.9% 20.5% 20.1% 2.66 1.10% 7.1%
Aggregate
RAP30% +
70% Natural 20.3% 19.4% 20.4% 19.8% 2.72 0.98% 6.5%
Aggregate
RAP40% +
60% Natural 20.2% 19.6% 20.3% 19.8% 2.73 1.12% 5.2%
Aggregate

Figure.Variation of Aggregate Crushing Value for different Samples

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 Figure.Variation of Aggregate Impact Value for different Samples

Figure.Variation of Los angeles abrasion Value for different Samples

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Figure.Variation of Flakiness & Elongation Index for different Samples

Figure. Variation of Water Absorption for different Samples

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Figure.Variation of Soundness for different Samples

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IV.RESULT ANALYSIS
The test results of various combinations of proportions of RAP and natural aggregates are shown in
table above. The various parameters like Aggregate Crushing Value, Aggregate Impact Value,
Flakiness & Elongation Index (Combined), Loss Angeles Abrasion Test Value, Specific Gravity, Water
Absorption, Soundness Test value and
California Bearing Ratio (CBR) values are within the norms prescribed by MORTH and it can also be
used in base of in flexible pavements. The best result was obtained on combination of30% RAP along with 70%
Natural Aggregates.
The aggregate crushing, Los Angeles abrasion and Impact values are represented in figure
above. The low values shows that the fraction of aggregate crushed is low and hence stronger and more
tougher the aggregate is and it can capable of withstanding on higher wheel loads. The best result was
observed on combination of 30% RAP along with 70% Natural Aggregates.
Water Absorption & Soundness Values of different compositions of RAP & Natural Aggregates The
Water Absorption & Soundness Values of different compositions are Plotted in figure above. The water
absorption value and soundness value for 30% RAP along with 70% Natural Aggregates combination was
found to be 0.98% and 6.56% respectively.

V.CONCLUSIONS
On the basis of study and experimental investigations following conclusions were drawn
1. It was observed that the RAP materials can be successfully used in granular sub base layer of flexible
pavements after blending to match the required grading as per MORTH specifications for sub base material.
2. It was also observed that the RAP materials in combination to natural aggregate in various proportions can be
easily used after blending to match the required grading as per MORTH specifications in the base courses of
flexible pavements
3. It is clear from the above investigation results that 30% replacement of natural aggregate can be successfully
done in base course of flexible pavements, resulting in a savings of around 25-30% in construction cost.
4. It was observed that RAP has a higher content of fines as a result of degradation of material during milling
and crushing operations it can be easily used for soil stabilization purpose to increase the CBR value of sub-
grade and hence the crust thickness of road will be reduced resulting in reduction of cost of construction.
5. Above all the problem of disposal of RAP wastes can be easily solved and adverse effect on environment may
be avoided by using the RAP materials in flexible pavement construction
REFERENCES
[1]SP 20-2002 IRC Rural Road Manual.
[2] Specification of Road &Bridge Work, Ministry of Shipping, Road Transport & Highway, Revision 4.
[3] IS Codes: 2386, 2720.

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[4] IRC-37:2012, Tentative Guidelines for The Design of Flexible Pavement , Indian Road Congress, New
Delhi .
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Bituminous Mixes with Reclaimed Asphalt Pavement Material, International Journal of Research in Engineering
and Technology, Volume 3, 2004.
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Rehabilitation Methods, 2005, 7-11, IIT Kanpur
[7] S.K. Khanna and C.E.G. Justo, highway material testing manual
[8]Schroeder, R. L. "Current Research on the Utilization of Recycled Materials in Highway Construction,"
Federal Highway Administration, Washington, DC, Presented at the International Road Federation Conference,
Calgary, Alberta, Canada, 1994.
[9]Miller, R. H. and R. J. Collins. Waste Materials as Potential Replacements for Highway Aggregates, National
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[10]Collins, R. J. and S. K. Ciesielski. Recycling and Use of Waste Materials and By-Products in Highway
Construction. National Cooperative Highway Research Program Synthesis of Highway Practice 199,
Transportation Research Board, Washington, DC, 1994.
[11]Ahmed, Imtiaz. Use of Waste Materials in Highway Construction. Federal Highway Administration, Report
No. FHWA/IN/JHRP-91/3, Washington, DC, January, 1991.
[12]Saeed, A., W. R. Hudson, and P. Anaejionu. Location and Availability of Waste and Recycled Materials in
Texas and Evaluation of their Utilization Potential in Roadbase. University of Texas, Center for Transportation
Research, Report No. 1348-1, Austin, Texas, October, 1995.
[13]Senior, S. A., S. I. Szoke, and C. A. Rogers, "Ontario's Experience With Reclaimed Materials for Use in
Aggregates." Presented at the International Road Federation Conference, Calgary, Alberta, 1994.
[14]American Association of State Highway and Transportation Officials. "Standard Specification for
Aggregate and Soil-Aggregate Subbase, Base and Surface Courses," AASHTO Designation M147-70, Part I
Specifications, 16th Edition, 1993.

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