Appendix D Tollway Reclaimed Asphalt Materials Special Provisions.pdf

RECLAIMED ASPHALT MATERIALS (RAM) (Illinois Tollway)

Effective: July 25, 2019 Revised: August 30, 2023

Table of Contents:

1. Description

2. References

3. Requirements

4. Materials

4.1. RAP and FRAP Description.

4.2. RAP and FRAP Stockpiles

4.3. RAS Description

4.4. RAS Stockpile

5. Testing

5.1. RAP and FRAP

5.2. RAS

6. Evaluation of Tests

6.1. RAP and FRAP

6.2. RAS

7. Quality Designation of FRAP/RAP

8. Aggregate Applications

1. Description. This work shall consist of the quality and production requirements for Reclaimed Asphalt Materials (RAM) used in Tollway asphalt mixes, subgrade aggregate, and aggregate shoulders. This Special Provision shall replace Articles Section 1031 Reclaimed Asphalt Pavement and Reclaimed Asphalt Shingles of the Illinois Department of Transportation (IDOT) Standard Specifications.

2. References. The following documents are referenced in the Illinois Tollway Reclaimed Asphalt Material (RAM) Special Provision.

2.1. Illinois Department of Transportation – Current Standard Specifications

2.2. Illinois Department of Transportation – Manual of Test Procedures

2.3. Illinois Tollway – Illinois Tollway Manual of Test Procedures

2.4. Illinois Tollway – Asphalt Mixtures Special Provision

2.5. Illinois Tollway - Subgrade Aggregate Special Provision

2.6. Illinois Tollway – Aggregate Shoulders Special Provision

3. Requirements. Laboratories performing the tasks set forth in this special provision shall either be AASHTO re:source accredited or meet the minimum requirements specified in the current IDOT policy memorandum 6-08 “Minimum Private Laboratory Requirements for Construction Materials Testing or Mix Design.”

APPENDIX D

4. Materials. The Contractor shall construct individual, sealed stockpiles meeting one of the definitions for Reclaimed Asphalt Pavement (RAP), Fractionated Reclaimed Asphalt Pavement (FRAP), or Reclaimed Asphalt Shingles (RAS) described in the following subsections.

4.1. RAP and FRAP Description.

Reclaimed Asphalt Pavement (RAP) is the material resulting from cold milling or crushing of an existing asphalt pavement. The Contractor shall supply written documentation that RAP and/or FRAP originated from routes or airfields under federal, state, or local agency jurisdiction.

4.2. RAP and FRAP Stockpiles.

Prior to milling, the Contractor shall request IDOT or the Illinois Tollway to provide verification of the quality of the RAP to clarify the appropriate RAP and FRAP stockpile type. RAP/FRAP taken from an Illinois Tollway Class I, Superpave mainline (high ESAL) surface or binder mixtures is designated as containing Class B quality coarse aggregate. For RAP/FRAP taken from an Illinois Tollway location or other routes or airfields under federal, state or local agency jurisdiction, if Tollway Materials has documentation of the quality of the aggregate, the Contractor shall use the assigned quality provided by Tollway Materials. For pre-existing stockpiles, documentation must be provided that guarantees the following requirements are met.

RAP/FRAP containing contaminants, such as earth, brick, sand, concrete, sheet asphalt, bituminous surface treatment (i.e. chip seal), pavement fabric, joint sealants, etc., will be unacceptable unless the contaminants are removed to the satisfaction of the Engineer. Sheet asphalt shall be stockpiled separately.

Tollway Table 1 - Allowable sources and minimum quality for RAP and FRAP Stockpiles

1/ If Category I Coarse FRAP is used as Friction Category I Coarse FRAP, the surface and binder lifts must be Milled separately.

2/ See Tollway Asphalt Mixtures Special Provision, Section 5.4 for specific requirements 3/ See Tollway Table 9 for Micro-Deval requirements 4/ See Tollway Table 9 for Fractured Faces requirements

All RAP/FRAP stockpiles shall be sufficiently separated to prevent intermingling at the base. Stockpiles shall be identified by signs indicating the type of material. No additional material shall be added to the pile after the pile has been sealed.

4.2.1. RAP Stockpiles

(a) Homogeneous. Homogeneous RAP stockpiles shall consist of sources that represent all of the following:

• The same aggregate quality but shall be at least C quality

• The same type of crushed aggregate (either crushed natural aggregate, ACBF slag, or steel slag)

• Equivalent design gradation requirements

• Design asphalt binder content within 2%

If approved by the Engineer, combined single pass surface/binder millings may be considered “homogenous” with a quality rating dictated by the lowest coarse aggregate quality present in the mixture.

(b) Conglomerate. Conglomerate RAP stockpiles may represent more than one aggregate type and/or quality. This RAP may have an inconsistent gradation and/or asphalt binder content prior to processing. Conglomerate RAP stockpiles shall not contain steel slag or other expansive material as determined by the Tollway Materials.

1) Conglomerate 5/8 – The coarse aggregate in this RAP shall be crushed aggregate of at least C quality and be processed by crushing to where all RAP shall pass the 5/8 in. or smaller screen.

2) Conglomerate 3/8 – The coarse aggregate in this RAP shall be crushed aggregate of at least B quality, and be processed by crushing to where all RAP shall pass the 3/8 in. or smaller screen.

(c) Non-Quality. RAP stockpiles that do not meet the requirements of the stockpile categories listed above, or have no documentation of quality, shall be classified as “Non-Quality”. Non-Quality RAP may be used for Capping Aggregate.

4.2.2. FRAP Stockpiles

FRAP shall require mechanical separation of RAP materials into appropriate sizes using an approved separation device. The Contractor is required to have a QC plan approved by Tollway Materials, a fractionation device approved the Tollway Materials, and sufficient cold feed bins. Fractionated RAP shall be separated by source (Category I and II), size (fine and coarse portions), and presence of steel slag and/or expansive materials, and shall be stockpiled separately. Separate calibrated cold feed bins are required for each size of

FRAP.

(a) FRAP Category

1) Category I: The aggregate type shall be crushed/manufactured and may represent more than one aggregate type. Category 1 coarse portion shall be at least B quality. Stockpiles designated as “with steel slag/expansive materials” shall be milled from surface friction course pavements that include steel slag and/or expansive materials. Category I coarse portion FRAP containing steel slag may be blended with friction aggregate to obtain the specified properties in asphalt surface friction course mixes.

2) Category II: Aggregates present may represent more than one aggregate type and/or quality. The fine aggregate in this RAP shall be manufactured or natural sand. The coarse aggregate in this RAP may be crushed aggregate shall be at least C quality. Category 2 coarse portion RAP stockpiles shall not contain steel slag or other expansive material and shall not contain uncrushed gravel as determined by the Illinois Tollway.

(b) FRAP Size

1) Fine Portion: The fine portion of FRAP is the portion of the processed material that meets the gradation in the table below.

Tollway Table 2 - Fine FRAP Gradation Requirements

Sieve Size Percent Passing

3/8 in. (9.5mm) 100

No. 4 (4.75mm) 95-100

2) Coarse Portion: The coarse portion of FRAP is one or more of the coarse portions of the processed material larger than the No. 4 sieve.

The maximum top size of the coarse portion of FRAP may not exceed Tollway Table 3, and the gradation must be within Table 3’s limits.

Tollway Table 3 – Coarse FRAP Size Requirements for Mix Designs

Asphalt Mix Design Designation

Maximum FRAP Screen Size 100%

Passing

No. 4 Sieve (Percent Passing)

19.0 mm 5/8 inch

≤45% 12.5 mm 5/8 inch

9.5 mm ½ inch

4.3. RAS Description.

RAS shall be salvaged asphalt shingles from the processing and grinding of pre-consumer or post-consumer shingles.

The RAS producer must be certified under the current version of IDOT’s “Qualified Producer List of Certified Sources for Reclaimed Asphalt Shingles.”

4.4. RAS Stockpile.

RAS stockpiles shall be sufficiently separated to prevent intermingling at the base. Stockpiles shall be identified by signs indicating the type of material. No additional material shall be added to the pile after the pile has been sealed.

4.4.1 RAS Type

1) Type 1. Type 1 RAS shall be processed, pre-consumer asphalt shingles salvaged from the manufacturer of asphalt roof shingles.

2) Type 2. Type 2 RAS shall be processed post-consumer shingles only, salvaged from residential dwellings of four units or less, that are not subject to the National Emission Standards for Hazardous Air Pollutants

(NESHAP).

RAS shall meet either Type 1 or Type 2 requirements as specified herein. Type 1 and Type 2 RAS shall not be blended in any asphalt mixture. Processed RAS materials from Type 1 or Type 2 RAS sources shall be stockpiled separately from other recycled materials. Blending of RAS materials in a stockpile with other recycled materials from other sources is prohibited.

The RAS producer may mechanically blend sand (FM 01, FM 02, FM 20 or FM

22) or fine, processed reclaimed asphalt pavement (RAP) up to an equal weight of processed RAS will be permitted. The process and procedures to incorporate sand or RAP shall be included in the producer’s QC Plan. The sand shall be “B Quality” or better from an approved Aggregate Gradation Control System source.

Processed Type 1 or Type 2 RAS materials shall not contain more than 0.5% deleterious materials. Deleterious materials including, but not limited to, asbestos, metals, glass, rubber, nails, soil, brick, tars, paper, wood, and plastics, shall not exceed 0.5% by weight as determined on material retained on the 4.75 mm (No. 4) sieve.

4.4.2 RAS Size

RAS Requirements: All RAS materials shall be processed by certified producers such that the following gradation requirements in Tollway Table 4 are met:

Tollway Table 4 - RAS Gradation Requirements

Sieve Size Percent Passing

3/8 in. (9.5 mm) 100

No. 4 (4.75 mm) 93 - 100

5. Testing.

Reclaimed asphalt materials to be used on Illinois Tollway projects shall be tested by the contractor according to the following requirements. The Engineer or Tollway Materials reserves the right to witness and test any sample (split or agency-taken) to verify the Contractor/processors’ test results. All RAP/FRAP/RAS gradation and asphalt production test results shall be uploaded into I-MIRS when testing is complete.

5.1. RAP and FRAP

When used in asphalt mixtures, the RAP/FRAP shall be sampled and tested as follows for mix design and production.

Extract RAP/FRAP samples using a chemical extraction according to Illinois Modified AASHTO T164 or Illinois Tollway Modified ASTM D8159 Automatic Extraction Procedure. Report both gradation and asphalt content at the frequencies in Tollway Table 5.

Tollway Table 5 - RAP/FRAP Stockpile Testing Frequencies

Testing Type Number of tests Tonnage

Mix Design Gradation Average of 5 tests 200 - 2500 ton

Start-up Production 1 test per 500 ton Up to 2000 ton

RAP/FRAP Production 1 test per 2000 ton Throughout production

The above frequencies shall be used for establishing a RAP/FRAP gradation target for mix design and production of new RAP/FRAP for use in existing an asphalt mix design.

In addition, each type and size of RAP/FRAP shall be sampled from the stockpile loadout face at a minimum frequency of once per week per plant location when WMA is being produced. These samples shall be tested using chemical extraction according to Illinois Modified AASHTO T164 or Illinois Tollway Modified ASTM D8159 Automatic Extraction Procedure. The results shall be uploaded to I-MIRS.

A record of test results, including a 4 test running average, shall be maintained by the Contractor and be available to the Engineer for review on request.

Daily WMA plant reports shall reflect the most current four test running average for each type and size RAP/FRAP used during its production.

For use of an existing un-tested RAP/FRAP stockpile, the Contractor shall submit a plan for approval to the Illinois Tollway proposing a satisfactory method of sampling and testing the RAP/FRAP pile either in-situ or by re-stockpiling. The sampling plan shall meet the minimum frequency required above and detail the procedure used to obtain representative samples throughout the pile for testing.

Additionally, each field sample shall be split to obtain two samples of test sample size. One of the two test samples from the final split shall be labeled and stored for Tollway Materials use.

5.2. RAS

When used in asphalt mixtures, the RAS shall be sampled and tested as follows for mix design and production.

Extract RAS samples using a chemical extraction according to Illinois Modified AASHTO T164 or Illinois Tollway Modified ASTM D8159 Automatic Extraction Procedure. Report both gradation and asphalt content at the frequencies in Tollway Table 6.

Tollway Table 6 - RAS Stockpile Testing Frequencies

Testing Type Number of tests Tonnage

Mix Design Gradation Average of 5 tests 200 - 1000 ton

Start-up Stockpile 1 test per 200 ton Up to 1000 ton

Continued Stockpile 1 test per 500 ton Throughout stockpiling

The above frequencies shall be used for establishing a RAS gradation target for mix design and stockpiling of RAS for use in existing an asphalt mix design.

Dry Gradation and Deleterious Content shall be tested at the same frequency as extractions. A sample of 500 to 700 grams of the RAS shall be air dried and dry sieved on the 3/8 and No. 4 sieve and any deleterious material larger than the No.

4 sieve shall be removed and weighed. Dry gradations shall meet the gradation specified in Tollway Table 4, and deleterious content shall meet the requirements set forth in Section 4.4.1 of this document.

6. Evaluation of Tests

6.1. RAP and FRAP

Once the Mix Design RAP/FRAP target is established for a stockpile, that gradation and asphalt content will be the target for future stockpile testing. When adding to an existing approved stockpile, production of RAP/FRAP shall follow the “start-up” frequencies in Tollway Table 5. If the average of the first 4 tests fall within the targets of Tollway Table 7, production can continue and testing frequencies shall follow “production” frequencies in Tollway Table 5.

Tollway Table 7 – RAP/FRAP Extraction Requirements Compared to Mix Design

Parameter

Homogeneous / Conglomerate

5/8 and 3/8

RAP

Conglomerate “D” Quality

Fine FRAP Coarse FRAP

1 in. (25 mm) ± 5 %

1/2 in. (12.5 mm) ± 8 % ± 15 % ± 8 %

No. 4 (4.75 mm) ± 6 % ± 13 % ± 6 %

No. 8 (2.36 mm) ± 5 % ± 5 %

No. 16 (1.18 mm) ± 15 %

No. 30 (600 μm) ± 5 % ± 5 %

No. 200 (75 μm) ± 2.0 % ± 4.0 % ± 2.0 %

Asphalt Binder ± 0.4 % 1/ ± 0.5 % ± 0.3 % ± 0.3 %

1/ The tolerance for conglomerate 3/8 shall be ± 0.3%.

If the running average of four, for any property, falls outside the tolerances set forth in Tollway Table 7, the RAP/FRAP shall be diverted into another stockpile. The RAP/FRAP can be placed on the approved stockpile after two consecutive tests, tested at a frequency of one sample per 500 tons, each pass the requirements of Tollway Table 7.

6.2. RAS

Once the Mix Design RAS target is established for a stockpile, that gradation and asphalt content will be the target for future stockpile testing. When adding to an existing approved stockpile, RAS testing shall follow the “start-up” frequencies in Tollway Table 6. If the average of the first 4 tests fall within the targets of Tollway Table 8, production can continue and testing frequencies shall follow “stockpile” frequencies in Tollway Table 6.

Tollway Table 8 – RAS Testing Requirements Compared to Mix Design

Parameter RAS Sample

No. 8 (2.36 mm) ±5%

No. 16 (1.18 mm) ±5%

No. 30 (600 µm) ±4%

No. 200 (75 µm) ±2.0%

Asphalt Binder ±1.5%

If the running average of four, for any property, falls outside the tolerances set forth in Tollway Table 8, the RAS shall be stockpiled separately. At that time, the

Contractor shall contact the RAS producer and stop shipment until the producer can assure compliance. When new RAS is shipped, test at the start up frequency for the running average of 4 passes the requirements of Tollway Table 8.

7. Quality Designation of RAP/FRAP

See Tollway Table 1 for Tollway quality designation of RAP/FRAP. If the quality is not known, the quality shall be determined as follows.

The Contractor shall obtain a representative sample witnessed by Tollway Materials.

The sample shall be a minimum of 50 lb. (25 kg). The sample shall be extracted according to Illinois Modified AASHTO T164 or Illinois Tollway Modified ASTM D8159 Automatic Extraction Procedure by a consultant laboratory prequalified by IDOT for the specified testing. The consultant laboratory shall submit the test results along with the recovered aggregate to Tollway Materials. The cost for this testing shall be paid by the Contractor. The aggregate portion of the RAP/FRAP must meet the requirements in Tollway Table 9:

Tollway Table 9 – RAP/FRAP Aggregate Quality Testing Requirements

Quality Test Test Procedure Minimum Requirement

Micro Deval ASTM D6928 or

AASHTO T327

≤15.0%

Coarse Aggregate Angularity

ITP 5821

≥85.0% 2 or more crushed faces

≥97.0% 1 or more crushed faces

8. RAP in Aggregate Applications

RAP in Aggregate Shoulders. The use of RAP in aggregate shoulders shall be as follows.

Stockpiles and Testing. RAP stockpiles may be any of those listed herein, except Non-Quality and FRAP.

Gradation.

1) The material shall have 100% passing the 1.5-inch sieve and be well graded down through fines.

2) The material shall be determined as well graded by calculating the Coefficient of Uniformity (Cu) and Coefficient of Curvature (Cc) per ASTM D2487, with required Cu ≥ 4.0, and Cc ≥ 1.0 and ≤ 3.0.